Toyota - Highlander - Workshop Manual - 2005 - 2005

01-1 INTRODUCTION - HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL 010QH-01 GENERAL INFORMATION 1. (a) (b) (c) (d) 2. (a) 3. (a) 4. (a) (b) GENERAL DESCRIPTION This manual is written in accordance with SAE J2008. Repair operations can be separated into 3 main processes: 1. Diagnosis 2. Removing/Installing, Replacing, Disassembling/Reassembling, Checking and Adjusting 3. Final Inspection This manual explains the ”Diagnosis” (found in the ”Diagnostics” section) and ”Removing and Installing, Replacing, Disassembling, Installing and Checking, and Adjusting”. ”Final Inspection” is omitted. The following essential operations are not written in this manual. However, these operations must be performed in actual situations. (1) Operations with a jack or lift (2) Cleaning of a removed part when necessary (3) Visual check INDEX An alphabetical INDEX section is provided at the end of the book as a reference to help you find the item to be repaired. PREPARATION Use of Special Service Tools (SST) and Special Service Materials (SSM) may be required, depending on the repair situation. Be sure to use SST and SSM when they are required and follow the working procedure properly. A list of SST and SSM is in the Preparation section of this manual. REPAIR PROCEDURES A component illustration is placed under the title where necessary. Non-reusable parts, grease application areas, precoated parts and torque specifications are noted in the component illustrations. Example: Filler Cap Float Clevis Pin
Gasket Reservoir Tank Boot
Grommet Slotted Spring Pin Clip 12 (120, 9) Clevis 15 (155, 11) Snap Ring Washer Lock Nut Push Rod Piston Cylinder N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part N17080 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1 01-2 INTRODUCTION - HOW TO USE THIS MANUAL (c) Torque specifications, grease application areas, and non-reusable parts are emphasized in the procedures. NOTICE: There are cases where such information can only be explained by using an illustration. In these cases, all the information such as torque, oil, etc. are described in the illustration. (d) The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. (e) Only items with key points are described in the text. What to do and other details are placed in illustrations next to the text. Both the text and illustrations are accompanied by standard values and notices. (f) Illustrations of similar vehicle models are sometimes used. In those cases, specific details may be different from the actual vehicle. (g) Procedures are presented in a step-by-step format: (1) The illustration shows what to do and where to do it. (2) The task heading tells what to do. (3) The explanation text tells how to perform the task. It also has information such as specifications and warnings. Example: Illustration: D31332 what to do and where Task heading: what you will be doing INSTALL FRONT AXLE HUB BEARING Detailed text: how to perform task Set part No. Component part No. B80366 HINT: This format provides an experienced technician with a FAST TRACK to the necessary information. The task headings are easy to read and the text below the task heading provides detailed information. Important specifications and warnings are always written in bold type. 5. (a) SERVICE SPECIFICATIONS SPECIFICATIONS are presented in bold-faced text throughout the manual. The specifications are also found in the Service Specifications section for quick reference. 6. TERMS DEFINITION CAUTION NOTICE HINT Possibility of injury to you or other people. Possibility of damage to the components being repaired. Provides additional information to help you perform repairs. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2 01-3 INTRODUCTION 7. (a) - HOW TO USE THIS MANUAL SI UNIT The units used in this manual comply with the SI UNIT (International System of Units) standard. Units from the metric system and the English system are also provided. Example: Torque: 30 N⋅m (310 kgf⋅cm, 22 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3 01-4 INTRODUCTION - IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION 010QI-01 VEHICLE IDENTIFICATION AND SERIAL NUMBERS 1. (a) VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the vehicle identification number plate and certification label, as shown in the illustration. A: Vehicle Identification Number Plate B: Certification Label 2. ENGINE SERIAL NUMBER AND TRANSAXLE SERIAL NUMBER The engine serial number is stamped on the cylinder block of the engine and the transmission serial number is stamped on the housing as shown in the illustration. A: 3MZ-FE B: 2AZ-FE C: U140E, U151E, U151F, U241E A B D25521 (a) A B C D25520 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 4 01-21 INTRODUCTION - REPAIR INSTRUCTION 010QK-02 VEHICLE LIFT AND SUPPORT LOCATIONS 1. (a) (b) 2. (a) (b) (c) 3. (a) NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP THE VEHICLE The vehicle must be unloaded before jacking up the vehicle. Never jack up/lift up a heavily loaded vehicle. When removing heavy equipment such as the engine and transmission, the center of gravity of the vehicle may shift. To stabilize the vehicle: place a balance weight in a location where it will not roll or shift; or use a mission jack to hold the jacking support. NOTICE FOR USING 4 POST LIFTS Follow the safety procedures outlined in its instruction manual. Use precautionary measures to prevent the free wheel beam from damaging tires or wheels. Use wheel chocks to secure the vehicle. NOTICE FOR USING JACK AND SAFETY STAND Work in a flat area using wheel chocks at all times. (b) Rubber Attachment (c) (d) D25523 (f) (g) (e) Use a safety stand with a rubber attachment, as shown in the illustration. Apply the jack and rigid rack to the specified location on the vehicle. When jacking up the front wheels, release the parking brake and place wheel chocks only behind the rear wheels. When jacking up the rear wheels, place wheel chocks only in front of the front wheels. The jack should not be used without the rigid rack. When jacking up only the front wheels or only the rear wheels, place wheel chocks on both sides of the wheels touching the ground. When lowering the vehicle with its front wheels jacked up, release the parking brake and place wheel chocks only in front of the rear wheels. When lowering a vehicle with its rear wheels jacked up, place wheel chocks only behind the front wheels. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 21 01-22 INTRODUCTION - REPAIR INSTRUCTION 2WD Center of Wheel 1,080 mm (42.52 in.) 4WD 1,110 mm Center of Wheel (43.70 in.) : JACK POSITION : SUPPORT POSITION, PANTOGRAPH JACK POSITION : CENTER OF VEHICLE GRAVITY (unload condition) D27508 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 22 01-23 INTRODUCTION 4. (a) (b) (c) (d) (e) (f) - REPAIR INSTRUCTION NOTICE FOR USING SWING ARM TYPE LIFT Follow safety procedures outlined in its instruction manual. Use a swing arm equipped with a rubber attachment, as shown in the illustration. When using the lift, its center should be as close to the vehicle’s center of gravity as possible. Set the vehicle on the lift as level as possible. Then match the groove of the cradle to the rigid rack support location. Be sure to lock the swing arms before lifting and during work (if equipped with arm locks). Lift the vehicle up off the ground. Stand at a safe distance and shake the vehicle to check its stability. Rubber Attachment Center of Lift Center of Wheel * L * ... 2WD: 1,080 mm (42.52 in.) 4WD: 1,110 mm (43.70 in.) : CENTER OF VEHICLE GRAVITY (unload condition) D25518 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 23 01-24 INTRODUCTION 5. (a) (b) (c) - REPAIR INSTRUCTION NOTICE FOR USING PLATE TYPE LIFT Follow safety procedures outlined in its instruction manual. Use plate lift attachments (rubber lifting blocks) on top of the plate surface. Refer to the table below to determine how to properly set the vehicle. Right and left set position Place the vehicle over the center of the lift. Front and rear set position Place the attachments at the ends of the rubber plate surface, under the vehicle lift pad (A and C in the illustration). Raise the plate slightly and reposition the vehicle so the top of the attachment (B in the illustration) is aligned with the front side notch in the vehicle rocker flange. (d) Lift the vehicle up off the ground, and shake it to make sure that it is stable. B C A Attachment Dimensions 85 mm (3.35 in.) 70 mm (2.76 in.) 100 mm (3.94 in.) 200 mm (7.87 in.) D25522 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 24 01-5 INTRODUCTION - REPAIR INSTRUCTION REPAIR INSTRUCTION 010QJ-02 PRECAUTION (b) HINTS ON OPERATIONS 2 1 3 6 5 4 D25016 1 Looks
Always wear a clean uniform.
Hat and safety shoes must be worn. 2 Vehicle protection
Prepare a grille cover, fender cover, seat cover and floor mat before starting the operation. 3 Safe operation
When working with 2 or more persons, be sure to check safety for one another.
When working with the engine running, pay attention to providing ventilation for exhaust fumes in the workshop.
If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety equipment and take extra care not to injure yourself or others.
When jacking up the vehicle, be sure to support the specified location with a safety stand.
When lifting up the vehicle, use appropriate safety equipment. 4 Preparation of tools and measuring gauge
Before starting operation, prepare a tool stand, SST, gauge, oil, shop rag and parts for replacement. Removal and installation, disassembly and assembly operations
Diagnose with a thorough understanding of proper procedures and of the reported problem.
Before removing the parts, check the general condition of the assembly and for deformation and damage.
When the assembly is complicated, take notes. For example, note the total number of electrical connections, bolts, or hoses removed. Add matchmarks to insure re-assembly of components in the original positions. Temporarily mark hoses and their fittings, if needed.
Clean and wash the removed parts if necessary and assemble them after a thorough check. Removed parts
Place the removed parts in a separate box to avoid mixing them up with the new parts or contaminating the new parts.
As for non-reusable parts such as a gasket, an O-ring, and a self-locking nut, replace them with new ones following the instructions in this manual.
Retain the removed parts for customer inspection, if requested. 5 6 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 5 01-6 INTRODUCTION (c) - REPAIR INSTRUCTION JACKING UP AND SUPPORTING VEHICLE (1) Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations (see page 01-21 ). (d) Seal Lock Adhesive Z11554 PRECOATED PARTS (1) Precoated parts are bolts and nuts, that are coated with a seal lock adhesive at the factory. (2) If a precoated part is retightened, loosened or moved in anyway, it must be recoated with the specified adhesive. (3) When reusing precoated parts, clean off the old adhesive and dry the part with compressed air. Then apply new seal lock adhesive appropriate to the bolts and nut. NOTICE: Perform the torque with the lower limit value of the torque tolerance. (4) Some seal lock agents harden slowly. You may have to wait for the seal lock agent to harden. (e) GASKETS (1) When necessary, use a sealer on gaskets to prevent leaks. (f) BOLTS, NUTS AND SCREWS (1) Carefully follow all the specifications for tightening torques. Always use a torque wrench. (g) FUSES Medium Current Fuse and High Current (1) When replacing fuses, be sure that the new fuse Fuse Equal Amperage Rating has the correct amperage rating. DO NOT exceed the rating or use one with a lower rating. BE1367 Illustration Symbol Abbreviation Part Name FUSE FUSE MEDIUM CURRENT FUSE M-FUSE HIGH CURRENT FUSE H-FUSE D27353 V35002 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 6 01-7 INTRODUCTION (h) - REPAIR INSTRUCTION CLIPS (1) The removal and installation methods of typical clips used in body parts are shown in the table below. HINT: If clips are damaged during a procedure, always replace the damaged clip with a new clip. Shape (Example) Removal/Installation Clip Pliers Clip Remover Remove clips from front or rear using clip remover or pliers. Protective Tape Screwdriver Remove fasteners with a clip remover or screwdriver. Protective Tape Scraper Remove clips with a wide scraper to prevent panel damage. D25786 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 7 01-8 INTRODUCTION - REPAIR INSTRUCTION Removal/Installation Shape (Example) Removal Installation Screwdriver Push Clip Remover Remove rivet by pushing the center pin through and prying out the rivet shell. Removal Installation Screwdriver Push Clip Remover Remove rivet by unscrewing the center pin and prying out the rivet shell. Removal Installation Push Screwdriver Clip Remover Small Clip Remover Remove rivet by prying out the pin and then prying out the rivet shell. V35006 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 8 01-9 INTRODUCTION (i) REPAIR INSTRUCTION REMOVAL AND INSTALLATION OF VACUUM HOSES (1) To disconnect vacuum hoses, pull and twist from the end of the hose. Do not pull from the middle of the hose as this may cause damage. CORRECT INCORRECT - D31750 (2) (3) (4) D25064 (j) L1 TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL (1) If SST or an extension tool is combined with the torque wrench to extend its length, do not tighten the torque wrench to the specified torque values in this manual. The resulting torque will be excessive. (2) Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with the torque wrench. (3) Formula: T’ = T x L2/(L1 + L2) L2 D02612 L1 L2 When disconnecting vacuum hoses, use tags to identify where they should be reconnected. After completing the job, double check that the vacuum hoses are properly connected. The label under the hood shows the proper layout. When using a vacuum gauge, never force the hose onto a connector that is too large. Use a step-down adapter for adjustment. Once the hose has been stretched, it may leak air. T’ Reading of torque wrench {N⋅m (kgf⋅cm, ft⋅lbf)} T Torque {N⋅m (kgf⋅cm, ft⋅lbf)} L1 Length of SST or extension tool (cm) L2 Length of torque wrench (cm) D01201 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 9 01-10 INTRODUCTION - REPAIR INSTRUCTION 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 disconnecting the negative (-) terminal cable from the battery, the SRS may deploy.) Disconnecting the negative (-) terminal cable will erase the memory of all vehicle systems. Initialize 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 assembly or the seat belt pretensioner to hot air or flames. (9) Use a voltmeter/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting electrical 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 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 10 01-1 1 INTRODUCTION (b) Mark - REPAIR INSTRUCTION SPIRAL CABLE (in Combination Switch) (1) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, otherwise cable disconnection and other problems may occur. Refer to page 60-26 for information about correct installation of the steering wheel. D30401 (c) HORN BUTTON ASSEMBLY (with Airbag) (1) When removing the horn button assembly or handling a new horn button, it should be placed with the pad surface facing up. See illustration below. Placing the horn button with the pad surface facing down may lead to a serious accident if the airbag accidently inflates. Also, do not place anything on top of the horn button. (2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury. (3) Grease or detergents of any kind should not be applied to the steering wheel pad. (4) Store the horn button assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and electrical noise is not nearby. (5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (4 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag or seat belt pretensioner deploying due to currents entering the squib wiring. (6) When disposing of the vehicle or the horn button assembly by itself, the airbag should be inflated using an SST before disposal (see page 60-19 ). Perform the operation in a safe place away from electrical noise. Example: CORRECT INCORRECT D25096 Example: NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER Z13950 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 11 01-12 INTRODUCTION (d) - REPAIR INSTRUCTION INSTRUMENT PANEL PASSENGER AIRBAG ASSY (1) Always place a removed or new instrument panel passenger airbag assembly with the airbag inflation direction facing up. Placing the airbag assembly with the airbag inflation direction facing down could cause a serious accident if the airbag inflates. (2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which could cause serious injury. (3) Grease or detergents of any kinds should not be applied to the instrument panel passenger airbag assembly. (4) Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and electrical noise is not nearby. (5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (4 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring. (6) When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal (see page 60-31 ). Activate in a safe place away from electrical noise. Example: CORRECT INCORRECT D27522 Example: NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER Z13951 (e) CURTAIN SHIELD AIRBAG ASSEMBLY (1) Always place the removed or new curtain shield airbag assembly in a clear plastic bag, and keep it in a safe place. NOTICE: Plastic bag is not re-useable. CAUTION: Never disassemble the curtain shield airbag assembly. (2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which is very dangerous. (3) Grease should not be attached to the curtain shield airbag assembly, and the surface should not be cleared with detergents of any kind. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 12 01-13 INTRODUCTION (4) (5) (6) - REPAIR INSTRUCTION Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and electrical noise is not nearby. When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (2 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring. When disposing of a vehicle or the curtain shield airbag assembly unit, the airbag should be deployed using SST before disposal (see page 60-40 ). Activate in a safe place away from electrical noise. Example: CORRECT INCORRECT Clear Plastic Bag D31641 NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER (f) D30931 FRONT SEAT AIRBAG ASSEMBLY (1) Always place a removed or new front seat airbag assembly with the airbag inflation direction facing up. Placing the airbag assembly with the airbag inflation direction facing downward could cause a serious accident if the airbag deploys. (2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which is very dangerous. (3) Grease should not be applied to the front seat airbag assembly, and the airbag door should not be cleaned with detergents of any kind. (4) Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and electrical noise is not nearby. (5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (2 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring. (6) When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal (see page 60-46 ). Activate in a safe place away from electrical noise. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 13 01-14 INTRODUCTION - REPAIR INSTRUCTION Example: NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER (g) D30924 SEAT BELT PRETENSIONER (1) Never measure the resistance of the seat belt pretensioner. This may cause the seat belt pretensioner to activate, which is very dangerous. (2) Never disassemble the seat belt pretensioner. (3) Never install the seat belt pretensioner on another vehicle. (4) Store the seat belt pretensioner in area where the ambient temperature is below 80°C (176°F), the humidity is not high and electrical noise is not nearby. (5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (2 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to currents entering the squib wiring. (6) When disposing of a vehicle or the seat belt pretensioner unit by itself, the seat belt pretensioner should be activated before disposal (see page 61-8 ). Activate in a safe place away from electrical noise. (7) The seat belt pretensioner is hot after being activated, so allow some time for it to cool down sufficiently before disposal. Never apply water to cool down the seat belt pretensioner. (8) Oil or water should not be put on the front seat outer belt, and the front seat outer belt should not be cleaned with detergents of any kind. Example: NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER (h) D30370 AIRBAG SENSOR ASSEMBLY (1) Never reuse an airbag sensor assembly that has been involved in a collision where the SRS has deployed. (2) The connectors to the airbag sensor assembly should be connected or disconnected with the sensor mounted on the floor. If the connectors are connected or disconnected while the airbag sensor assembly is not mounted to the floor, it could cause accidental deployment of the SRS. (3) Work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and the negative (-) terminal cable is disconnected from the battery, even if only loosening the set bolts of the airbag sensor assembly. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 14 01-15 INTRODUCTION (i) - REPAIR INSTRUCTION WIRE HARNESS AND CONNECTOR (1) The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes broken, repair or replace it. Negative (-) Terminal 2. (a) ELECTRONIC CONTROL REMOVAL AND INSTALLATION OF BATTERY TERMINAL (1) Before performing electronic work, disconnect the battery negative (-) terminal cable beforehand to prevent component and wire damage caused by accidental short circuits. (2) When disconnecting and installing the terminal cable, turn the ignition switch and lighting switch OFF and loosen the terminal nut completely. Perform these operations without twisting or prying the terminal. Remove the battery cable from battery post. (3) Clock settings, radio settings, DTCs and other data are erased when the battery cable is removed. Before removing the battery cable, record any necessary data. (4) When disconnecting the battery’s negative (-) terminal cable, re-initialize the following systems after the completion of the operation. (b) HANDLING OF ELECTRONIC PARTS (1) Do not open the cover or case of the ECU unless absolutely necessary. If the IC terminals are touched, the IC may be rendered inoperative by static electricity. (2) To disconnect electronic connectors, pull the connector itself, not the wires. (3) Be careful not to drop electronic components, such as sensors or relays. If they are dropped on a hard floor, they should be replaced. (4) When cleaning the engine with steam, protect the electronic components, air filter and emission-related components from water. (5) Never use an impact wrench to remove or install temperature switches or temperature sensors. (6) When checking the continuity at the wire connector, insert the tester probe carefully to prevent terminals from bending. D25080 INCORRECT D31751 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 15 01-16 INTRODUCTION 3. (a) (b) - REPAIR INSTRUCTION REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS PLACE FOR REMOVING AND INSTALLING OF FUEL SYSTEM PARTS (1) Work in a place with good air ventilation and without any ignition sources, such as a welder, grinder, drill, electric motor or stove. (2) Never work in a place such as a pit or near a pit because vaporized fuel will collect in those places. REMOVING AND INSTALLING OF FUEL SYSTEM PARTS (1) Prepare a fire extinguisher before starting operation. (2) To prevent static electricity, install a ground on the fuel changer, vehicle and fuel tank, and do not spray the area with water. The work surface will become slippery. Do not clean up spills with water as this will spread and gasoline and create a fire hazard. (3) Never use any electric equipment like an electric motor or a working light, as they may create sparks or high temperatures. (4) Never use an iron hammer, as it may create sparks. (5) Dispose of fuel-contaminated shop rags separately using a fire resistant container. 4. (a) (b) D01563 (c) Spring Type Clamp 5. (a) (b) (c) (d) Clamp Track D25081 6. (a) (b) D20025 (c) (d) (e) REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS If any metal particle enters the inlet pass, this may damage the engine. When removing and installing the inlet system parts, cover the openings of the removed parts and engine openings. Use clean shop rags, gummed tape, or other suitable materials. When installing the inlet system parts, check that no metal particles have entered the engine or the installed part. HANDLING OF HOSE CLAMPS Before removing the hose, check the clamp position so that you can restore it in the same way. Replace deformed or dented clamps with new ones. When reusing a hose, attach the clamp on the clamp track portion of the hose. For a spring type clamp, to spread the tabs slightly after installation by pushing in the direction of the arrow marks as shown in the illustration. FOR VEHICLES EQUIPPED WITH MOBILE COMMUNICATION SYSTEMS Install the antenna as far away from the ECU and sensors of the vehicle electronic systems as possible. Install an antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle electronic systems. For details of the ECU and sensors locations, refer to the section on applicable components. Keep the antenna and feeder separate from other wirings as much as possible. This will prevent signals from the communication equipment from affecting vehicle equipment and vice-versa. Check that the antenna and feeder are correctly adjusted. Do not install any high-powered mobile communication system. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 16 01-17 INTRODUCTION - REPAIR INSTRUCTION 7. (a) FOR VEHICLES EQUIPPED WITH TRACTION CONTROL (TRAC) SYSTEM When testing with a 2-wheel drum tester such as a speedometer tester, a combination tester of the speedometer and brake, a chassis dynamometer, or when jacking up the front wheels and driving the wheels, always turn the TRAC system OFF beforehand via the TRAC OFF switch before testing. NOTICE: TRAC system OFF condition can be confirmed by the ”TRAC OFF” warning indicator light in the combination meter. 8. DLC3 CG 1 2 3 4 5 6 7 8 9 10 11 12 1314 1516 TS A82779 FOR VEHICLES EQUIPPED WITH VEHICLE SKID CONTROL (VSC) SYSTEM (a) NOTICES WHEN USING DRUM TESTER (1) Before beginning testing, disable the Vehicle Skid Control system (VSC). To disable the VSC, turn the ignition switch OFF and connect SST to terminals TS and CG of DLC3. SST 09843-18040 NOTICE:
Confirm that the VSC warning light blinks.
VSC system will be reset when the engine is restarted.
For safety, secure the vehicle with restraint chains while using a wheel dynamometer. (b) NOTICES OF RELATED OPERATIONS TO VSC (1) Do not carry out unnecessary installation and removal as it might affect the adjustment of VSC related parts. (2) Be sure to follow the instructions for work preparation and final confirmation of proper operation of the VSC system. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 17 01-18 INTRODUCTION - REPAIR INSTRUCTION 9. WHEN SERVICING FULL-TIME 4WD VEHICLES (a) MEASURING POINTS FOR SPEEDOMETER TESTER NOTICE:
Tester with a function of load setting cannot be used.
Inspection should be done in the front wheels.
Do not start, accelerate nor decelerate the vehicle suddenly.
Maximum vehicle speed must be below 60 km/h (when using free roller, it must be below 50 km/h).
Driving time should be within 1 minute. (1) (2) (3) (4) (5) D25530 Place the front wheels onto the rollers. Set the rear wheels free by free rollers or rigid racks. Fasten the vehicle with the lock chain. Start the engine, and then measure the vehicle speed by increasing the speed gradually in the D range. After the measurement completion, decrease the vehicle speed by brake gradually, and then stop the vehicle. D25531 (b) MEASURING POINTS FOR BRAKE TESTER NOTICE:
Tester with a function of load measurement cannot be used
High-speed type brake cannot be used. (1) Place the wheels to be measured (front or rear) onto the rollers. (2) Shift the shift lever into neutral. (3) Perform the measurement by driving the tester rollers. HINT: In case that the dragging force is over 10% of the load put on the axis, inspection of the wheel’s rotating condition should be done with both of the left and right axes jacked up. If no abnormality is found in the rotating condition, adhesive torque of the viscous coupling causes the excessive dragging fore and therefore it means no problem exists in the vehicle. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 18 01-19 INTRODUCTION - REPAIR INSTRUCTION (c) MEASURING POINTS FOR ON-VEHICLE BALANCER (1) Jack up all 4 wheels with 2 post lifts. (2) Fasten the vehicle by setting 2 pick-up stands in the bottom of suspension arm’s tip of the front wheels or rear wheels to be measured. (3) Support the vehicle with rigid racks so that vehicle will not lean in the vehicle’s front/rear direction. (4) Release the parking brake. (5) Check that no dragging force exists by turning each D25532 wheel by hand. (6) Set the wheel balancers. (7) Measurement should be done by using both of engine drive and wheel balancer roller drive. NOTICE:
Start the engine, and then increase the vehicle speed gradually in the D range.
Do not accelerate nor decelerate suddenly.
Deceleration should be done by brake gradually.
Take special care that the vehicle does not move.
Measurement should be done quickly. 10. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER CAUTION: If a large amount of unburned gasoline or gasoline vapors flow into the converter, it may cause oveheating and create a fire hazard. To prevent this, observe the following precautions. (a) Use only unleaded gasoline. (b) Avoid prolonged idling. Avoid idling the engine for more than 20 minutes. (c) Avoid a spark jump test. (1) Perform a spark jump test only when absolutely necessary. Perform this test as rapidly as possible. (2) While testing, never race the engine. (d) Avoid a prolonged engine compression measurement. Engine compression measurements must be performed as rapidly as possible. (e) Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 19 01-20 INTRODUCTION - REPAIR INSTRUCTION 11. (a) INCORRECT D25533 INCORRECT WHEN TOWING FULL-TIME 4WD VEHICLES Tow the vehicles with the 4 wheels touching the ground or the 4 wheels held up. In case that an abnormality exists in the chassis and drive train, tow the vehicle with the 4 wheels held up. (b) Never tow the vehicle with either condition of the front wheels only or the rear only held up. NOTICE: Towing with either condition of the front wheels only the rear wheels only held up might cause the drive train burned-out or the wheels flying off the dolly. D25534 (c) Flat Bed Truck (d) Towing the vehicle should be done by one of the towing methods as shown in the illustration. If the vehicle has a trouble in the chassis or drive train, use the wheel lift type truck. Parking Brake Transaxle Shift Lever Position Flat Bed Truck Applied Any Position Wheel Lift Type Truck Applied Any Position Towing Method Wheel Lift Type Truck NOTICE: Do not use any towing method other those shown above. D25529 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 20 01-36 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 010QN-01 ELECTRONIC CIRCUIT INSPECTION PROCEDURE 1. (a) BASIC INSPECTION RESISTANCE MEASURING CONDITION OF ELECTRONIC PARTS (1) Unless stated, all resistance is measured at an ambient temperature of 20C (68F). Resistances measured may be outside the specifications if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. (b) INCORRECT INCORRECT CORRECT D32092 Looseness of Crimping Core Wire Terminal Deformation Pull Lightly D25087 HANDLING CONNECTORS (1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, then press the lock claw and separate the connector. (2) When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. (3) Before connecting the connector, check that there are no deformed, damaged, loose or missing terminals. (4) When connecting a connector, press firmly until you hear the lock close with a ”click” sound. (5) If checking the connector with a TOYOTA electrical tester, check it from the backside (harness side) of the connector using a mini test lead. NOTICE:
As a waterproof connector cannot be checked from the backside, check by connecting a sub-harness.
Do not damage the terminals by moving the inserted tester needle. (c) CHECKING CONNECTORS (1) Checking when the connector is connected: Squeeze the connector together to confirm that it is fully inserted and locked. (2) Checking when the connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign objects and water; and bent, rusted, overheated, contaminated, and deformed terminals. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 36 INTRODUCTION - (3) Same terminal as a male terminal INCORRECT INCORRECT REPAIR METHOD OF CONNECTOR TERMINAL (1) If there is any dirt on the terminal, clean the contact point using an air gun or shop rag. Never polish the contact point using sandpaper as the platings may come off. (2) If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. (3) Damaged, deformed, or corroded terminals should be replaced. If the terminal will not lock into the housing, the housing may have to be replaced. (e) HANDLING OF WIRE HARNESS (1) If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. (2) Never twist, pull or slacken the wire harness more than necessary. (3) Never make the wire harness come into contact with a high temperature part, rotating, moving, vibrating or sharp-edged parts. Avoid panel edges, screw tips and similar sharp items. (4) When installing parts, never pinch the wire harness. (5) Never cut or break the cover of the wire harness. If it is cut or broken, replace it or securely repair it with vinyl tape. 2. (a) CHECK OPEN CIRCUIT For an open circuit in the wire harness in Fig. 1, perform a resistance check (step b) or a voltage check (step c). D32094 Fig. 1 ECU C Sensor OPEN 1 1 2 2 Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for good tension when inserting and after full engagement. (d) D32093 INCORRECT 01-37 D25088 INCORRECT CORRECT HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS B A 1 2 1 2 Z17004 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 37 01-38 INTRODUCTION (b) Fig. 2 ECU Sensor 1 2 C HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Check the resistance. (1) Disconnect connectors A and C and measure the resistance between them. Resistance: Below 1 Ω HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. Fig. 2: 1 2 A 1 2 B - Tester Connection Specified Condition Connector A terminal 1 Connector C terminal 1 10 kΩ or higher Connector A terminal 2 Connector C terminal 2 Below 1 kΩ Z17005 If your results match the examples above, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. (2) Fig. 3 ECU Tester Connection Specified Condition Connector A terminal 1 Connector B1 terminal 1 Below 1 kΩ Connector B2 terminal 1 Connector C terminal 1 10 kΩ or higher Sensor 1 2 B2 1 2 C 1 1 2 2 A B1 B04722 If your results match the examples above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. (c) Fig. 4 5V Sensor 0V 1 5V 1 2 C 1 2 B 2 A Z17007 Disconnect connector B and measure the resistance between the connectors. Fig. 3: Check the voltage. (1) In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. Fig. 4: With each connector still connected, measure the voltage between the body ground these terminals (in this order): 1) terminal 1 of connector A at the ECU 5V output terminal, 2) terminal 1 of connector B, and 3) terminal 1 of connector C. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 38 INTRODUCTION - (2) HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 01-39 Example results: Tester Connection Specified Condition Connector A terminal 1 - 5V Body ground Connector B terminal 1 - 5V Body ground Connector C terminal 1 - 0V Body ground If your results match the examples above, an open circuit exists in the wire harness between terminal 1 of B and terminal 1 of C. Fig. 5 C SHORT 1 2 B 1 2 3. (a) CHECK SHORT CIRCUIT If the wire harness is ground shorted (Fig. 5), locate the section by conducting a resistance check with the body ground (below). (b) Check the resistance with the body ground. (1) Disconnect connectors A and C and measure the resistance between terminals 1 and 2 of connector A and the body ground. Resistance: 10 kΩ or higher A 1 2 Z17008 Fig. 6 ECU Sensor 1 2 C 1 2 B 1 2 A Z17009 HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. Fig. 6: Tester Connection Connector A terminal 1 Body ground Connector A terminal 2 Connector C terminal 2 Specified Condition Below 1 kΩ 10 kΩ or higher If your results match the examples above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 39 01-40 INTRODUCTION (2) Fig. 7 ECU Sensor 1 2 C 1 2 B2 1 2 B1 1 2 - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Disconnect connector B and measure the resistance between terminal 1 of connector A and the body ground, and terminal 1 of connector B2 and the body ground. Fig. 7: Tester Connection Connector A terminal 1 - A Body ground Z17808 Connector B2 terminal 1 Body ground Specified Condition 10 kΩ or higher Below 1 kΩ If your results match the examples above, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. 4. CHECK AND REPLACE ECU NOTICE:
The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side.
When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch ON.
Check that the connectors are fully seated. Check for loose, corroded or broken wires. (a) First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Replace the ECU with a normal functioning one and check if the symptoms occur. If the trouble symptoms stop, replace the ECU. (1) Measure the resistance between the ECU ground terminal and body ground. Resistance: Below 1 Ω Example Ground IN0383 (2) ECU Side Ground W/H Side Disconnect the ECU connector. Check the ground terminals (on the ECU side and wire harness side) for evidence of bending, corrosion or foreign material. Lastly check the contact pressure of the female terminals. Ground IN0384 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 40 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 01-25 HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 010QL-02 GENERAL INFORMATION A large number of ECU controlled systems are used in the HIGHLANDER. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system’s circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs. Detailed information and troubleshooting procedures on major ECU controlled systems in this vehicle are outlined below: System See Page 1. SFI System (2AZ-FE) 05-1 2. SFI System (3MZ-FE) 05-362 3. Tire Pressure Warning System 05-729 4. ABS with EBD & BA & TRAC & VSC System 05-761 5. Electronic Controlled Automatic Transaxle [ECT] (U241E/U140F) 05-876 6. Electronic Controlled Automatic Transaxle [ECT] (U151E/U151F) 05-986 7. Air Conditioning System 05-1114 8. Supplement Restraint System 05-1194 9. Lighting System 05-1526 10. Audio System 05-1611 11. Rear Seat Entertaiment System 05-1690 12. Navigation System 05-1749 13. Combination Meter 05-1868 14. Power Window Control System 05-1901 15. Power Door Lock Control System 05-1934 16. Wireless Door Lock Control System 05-1960 17. Sliding Roof System 05-1974 18. Engine Immobiliser System 05-1985 19. Theft Deterrent System 05-2012 20. Multiplex Communication System 05-2040 21. CAN Communication System 05-2090 22. Cruise Control System 05-2136 FOR USING OBD II SCAN TOOL OR HAND-HELD TESTER
Before using the scan tool or tester, the scan tool’s instruction book or tester’s operator manual should be read thoroughly.
If the scan tool or tester cannot communicate with the ECU controlled systems when you have connected the cable of the tester to the DLC3 with the ignition switch and tester turned ON, there is a problem on the vehicle side or tester side. (1) If communication is normal when the tester is connected to another vehicle, inspect the diagnosis data link line (Bus
line) or ECU power circuit of the vehicle. (2) If communication is still impossible when the tester is connected to another vehicle, the problem is probably in the tester itself. So perform the Self Test procedures outlined in the Tester Operator’s Manual. Author
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: 25 01-26 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 010QM-01 HOW TO PROCEED WITH TROUBLESHOOTING HINT: Carry out troubleshooting in accordance with the procedures below. Only a basic procedure is shown. Details in the Diagnostic Section show the most effective methods for each circuit. Confirm the troubleshooting procedures for the relevant circuit before beginning troubleshooting. 1 VEHICLE BROUGHT TO WORKSHOP 2 CUSTOMER PROBLEM ANALYSIS (a) Ask the customer about the conditions and environment when the problem occurred. 3 (a) SYMPTOM CONFIRMATION AND DTC (AND FREEZE FRAME DATA) CHECK Check the battery positive voltage. Standard: 11 to 14 V (Engine stopped) Visually check the wire harness, connectors and fuses for open and short, etc. Warm up the engine to the normal operating temperature. Confirm the problem symptoms and conditions, and check for DTCs according to the related chart. (b) (c) (d) OK Go to step 5 NG 4 (a) DTC CHART Check the results obtained in step 3, then confirm the inspection procedures for the system or part using the DTC chart. Go to step 6 5 (a) Check the results obtained in step 3. Confirm the inspection procedures for the system or part using the problem symptoms table. 6 (a) PROBLEM SYMPTOMS CHART CIRCUIT INSPECTION OR PARTS INSPECTION Confirm the circuit in the system or the part that should be checked using the problem symptoms table or the results obtained in step 4. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 26 INTRODUCTION 7 (a) HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 01-27 REPAIR Repair the affected system or part according to the instructions in step 6. 8 (a) - CONFIRMATION TEST After completing repairs, confirm that the problem has been solved. If the problem does not recur, perform a confirmation test under the same conditions and in the same environment as when it occurred the first time. END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 27 01-28 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CUSTOMER PROBLEM ANALYSIS HINT:    In troubleshooting, the problem symptoms must be confirmed accurately. Preconceptions should be discarded in order to give an accurate judgement. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time it occurred. As much information as possible should be gathered for reference. Past problems that seem unrelated may also help in some cases. In the Diagnostic section, a customer problem analysis table is provided for each system. 5 items are important points in the problem analysis: Important Points with Customer Problem Analysis




What ----- Vehicle model, system name When ----- Date, time, occurrence frequency Where ----- Road conditions Under what conditions? ----- Running conditions, driving conditions, weather conditions How did it happen? ----- Problem symptoms (Sample) Supplemental Restraint System check sheet. CUSTOMER PROBLEM ANALYSIS CHECK Inspector’s Name Supplemental Restraint System Check Sheet VIN Production Date Customer’s Name / / Licence Plate No. Date Vehicle Brought In / km miles Odometer Reading / Date Problem First Occurred Weather Temperature Vehicle Operation / Fine Cloudy Rainy Snowy / Other Approx. Starting Driving [ Idling Constant speed Other Acceleration Deceleration ] 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 28 INTRODUCTION - 01-29 HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT: The diagnostic system in the HIGHLANDER has various functions.  The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction’s DTC can be checked by a technician during troubleshooting.  Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. By using these functions, the problem areas can be narrowed down and troubleshooting is more effective. Diagnostic functions are incorporated in the following systems in the HIGHLANDER: System SFI System Diagnostic Trouble Code Check Input Signal Check (Sensor Check) Diagnotis Test Mode (Active Test)  (with Check Mode)       (with Check Mode)   ABS with EBD & BA & TRAC & VSC System Electronic Controlled Automatic Transaxle [ECT] Air Conditioning System  Supplement Restraint System  Power Window Control System  Power Door Lock Control System  Wireless Door Lock Control System  Engine Immobiliser System  Multiplex Communication System  Cruise Control System      In the DTC check, it is very important to determine whether the problem indicated by the DTC is: 1 still occurring, or 2 occurred in the past but has since returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current conditions, as shown in the table below. Never skip the DTC check. Failure to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not pertinent to the problem. Follow the procedures listed above in the correct order. A flow chart showing how to proceed with troubleshooting using the DTC check is shown below. Directions from the flow chart will indicate should be performed DTC troubleshooting or to the troubleshooting of each problem symptom.  1 DTC CHECK 2 MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR THE MEMORY 3 SYMPTOM CONFIRMATION a a Symptoms exist b No symptoms exist Go to step 5 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 29 01-30 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS b 4 SIMULATION TEST USING THE SYMPTOM SIMULATION METHODS 5 DTC CHECK a a DTC displayed b No DTC displayed Troubleshooting of problem indicated by DTC b 6 SYMPTOM CONFIRMATION a No symptoms exist b Symptoms exist If a DTC was displayed in the initial DTC check, it indicates that the trouble may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors (see page 01-36 ). a SYSTEM NORMAL b TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 30 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 01-31 SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no problem symptoms occur. In such cases, a thorough customer problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer’s vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or occurs as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied on a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. 1. VIBRATION METHOD: When vibration seems to be Vibrate Slightly the major cause. (a) PART AND SENSOR (1) Apply slight vibration with a finger to the part of the sensor considered to be the cause of the problem and check whether or not the malfunction occurs. HINT: Applying strong vibration to relays may open relays. (b) CONNECTORS (1) Slightly shake the connector vertically and horizontally. (c) WIRE HARNESS Shake Slightly (1) Slightly shake the wire harness vertically and horizontally. The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. Vibrate Slightly B71602 2. Malfunction D25084 HEAT METHOD: If the problem seems to occur when the area in question is heated. (a) Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTICE:  Do not heat to more than 60C (140F). Exceeding this temperature may damage components.  Do not apply heat directly to the parts in the ECU. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 31 01-32 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 3. D25085 WATER SPRINKLING METHOD: When the malfunction seems to occur on a rainy day or in highhumidity. (a) Sprinkle water onto the vehicle and check if the malfunction occurs. NOTICE:  Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by applying water spray onto the front of the radiator.  Never apply water directly onto electronic components. HINT: If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or shorts. Proceed with caution during water tests. 4. ON (a) HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when electrical load is excessive. Turn on all the electrical loads including the heater blower, headlights, rear window defogger, etc., and check if the malfunction occurs. B02389 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 32 INTRODUCTION - 01-33 HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS DIAGNOSTIC TROUBLE CODE CHART Use Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the table below to determine the trouble area and proper inspection procedure. The Supplemental Restraint System (SRS) diagnostic trouble code chart is shown below as an example.
DTC No. Indicates the diagnostic trouble code.
Page or Instructions Indicates the page where the inspection procedures for each circuit is to be found, or gives instructions for checking and repairs.
Trouble Area Indicates the suspect areas of the problem.
Detection Item Indicates the system or details of the problem. DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the DTC check, check the circuit for that code listed in the table below (Proceed to the page given for that circuit). DTC No. (See page) Detection Item
Short in D squib circuit B0100/13 (05-119)
Open in D squib circuit B0101/14 (05-124)
Short in D squib circuit (to ground) B0102/11 (05-128)
Short in D squib circuit (to B+) B0103/12 (05-132) B0105/53 (05-136)
Short in P squib circuit B0106/54
Open in P squib circuit SRS Warning Light Trouble Area
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness ON
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness ON
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness ON
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness ON
Front passenger airbag assembly (squib)
Airbag sensor assembly
Wire harness
Front passenger airbag assembly (squib) ON ON
Airbag sensor assembly
Wire harness
Short in P squib circuit (to Ground)
Front passenger airbag assembly (squib)
Airbag sensor assembly
Wire harness ON 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 33 01-34 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS PROBLEM SYMPTOMS TABLE The suspected circuits or parts for each problem symptom are shown in the table below. Use this table to troubleshoot when, during a DTC check, a ”Normal” code is displayed but the problem is still occurring. Numbers in the table show the inspection order in which the circuits or parts should be checked. HINT: In some cases, the problem is not detected by the diagnostic system even though a problem symptom is present. It is possible that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a completely different system.
Page Indicates the page where the flow chart for each circuit is located.
Circuit Inspection, Inspection Order Indicates the circuit which needs to be checked for each problem symptom. Check in the order indicated by the numbers.
Problem Symptom
Circuit or Part Name Indicates the circuit or part which needs to be checked. PROBLEM SYMPTOMS TABLE HINT: Inspect the ”Fuse” and ”Relay” before confirming the suspected area in the charts below (See page 68-1). Symptom See Page Suspected Area Black screen 1. Power source circuit (multi-display assy) 2. Multi-display 05-1267 67-7 Screen cannot be dimmer in night time 1. SRS warning light circuit (multi-display assy) 2. Multi-display assy 05-1277 67-7 A navigation system cannot be operated 1. Steering pad switch circuit 05-1183 2. AVC-LAN circuit (radio receiver assy-multidisplay assy) 05-1303 3. Radio receiver assy 67-5 4. Multi-display assy 67-7 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 34 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 01-35 CIRCUIT INSPECTION How to read and use each page is shown below.
Circuit Description The major role, operation of the circuit and its component parts are explained.
Diagnostic Trouble Code No. and Detection Item
Indicates the diagnostic trouble codes, diagnostic trouble code settings and suspect areas for a problem.
Inspection Procedures Use the inspection procedures to determine if the circuit is normal or abnormal. If it is abnormal, use it to determine whether the problem is located in the sensors, actuators, wire harness or ECU. SFI SFI
Indicates the condition of the connector of the ECU during the check.
Wiring Diagram This shows a wiring diagram of the circuit. Use this diagram together with ELECTRICAL WIRING DIAGRAM to thoroughly understand the circuit. Wire colors are indicated by an alphabetical code. B = Black, L = Blue, R = Red, BR = Brown, LG = Light Green, V = Violet, G = Green, O = Orange, W = White, GR = Gray, P = Pink, Y = Yellow, SB = Sky Blue The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Connector being checked is connected. Connector being checked is disconnected. Connections of tester are indicated by (+), (-) after terminals name. For inspection of connector with body ground, there is nothing about the body ground written down. D25842 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 35 01-41 INTRODUCTION - TERMS TERMS 010QO-02 ABBREVIATIONS USED IN MANUAL Abbreviations Meaning ABS Anti-Lock Brake System A/C Air Conditioner AC Alternating Current ACC Accessory ACIS Acoustic Control Induction System ACSD Automatic Cold Start Device A.D.D. Automatic Disconnecting Differential A/F Air-Fuel Ratio AHC Active Height Control Suspension ALR Automatic Locking Retractor ALT Alternator AMP Amplifier ANT Antenna Approx. Approximately ASSY Assembly A/T, ATM Automatic Transmission ATF Automatic Transmission Fluid AUTO Automatic AUX Auxiliary AVG Average AVS Adaptive Variable Suspension B+ Battery Voltage BA Brake Assist BACS Boost Altitude Compensation System BAT Battery BDC Bottom Dead Center B/L Bi-Level B/S Bore-Stroke Ratio BTDC Before Top Dead Center BVSV Bimetallic Vacuum Switching Valve CAN Controller Area Network CB Circuit Breaker CCo Catalytic Converter For Oxidation CD Compact Disc CF Cornering Force CG Center Of Gravity CH Channel CKD Complete Knock Down COMB. Combination CPE Coupe CPS Combustion Pressure Sensor CPU Central Processing Unit CRS Child Restraint System CTR Center C/V Check Valve CV Control Valve CW Curb Weight DC Direct Current 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 41 01-42 INTRODUCTION - TERMS Abbreviations Meaning DEF Defogger DFL Deflector DIFF. Differential DIFF. LOCK Differential Lock D/INJ Direct Injection DLC Data Link Connector DLI Distributorless Ignition DOHC Double Overhead Camshaft DP Dash Pot DS Dead Soak DSP Digital Signal Processor DTC Diagnostic Trouble Code DVD Digital Versatile Disc EBD Electric Brake Force Distribution ECAM Engine Control And Measurement System ECD Electronic Controlled Diesel ECDY Eddy Current Dynamometer ECT Electronic Control Transmission ECU Electronic Control Unit ED Electro-Deposited Coating EDU Electronic Driving Unit EDIC Electric Diesel Injection Control EFI Electronic Fuel Injection E/G Engine EGR Exhaust Gas Recirculation EGR-VM EGR-V acuum Modulator ELR Emergency Locking Retractor EMPS Electric Motor Power Steering ENG Engine ESA Electronic Spark Advance ETCS-i Electronic Throttle Control System-intelligent EVAP Evaporative Emission Control EVP Evaporator E-VR V Electric Vacuum Regulating Valve EX Exhaust FE Fuel Economy FF Front-Engine Front-Wheel-Drive F/G Fuel Gauge FIPG Formed In Place Gasket FL Fusible Link F/P Fuel Pump FPU Fuel Pressure Up Fr Front F/W Flywheel FW/D Flywheel Damper FWD Front-Wheel-Drive GAS Gasoline GND Ground GPS Global Positioning System HAC High Altitude Compensator H/B Hatchback 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 42 01-43 INTRODUCTION - TERMS Abbreviations Meaning H-FUSE High Current Fuse HI High HID High Intensity Discharge (Head Lamp) HSG Housing HT Hard Top HWS Heated Windshield System IC Integrated Circuit IDI Indirect Diesel Injection IFS Independent Front Suspension IG Ignition IIA Integrated Ignition Assembly IN Intake (Manifold, Valve) INT Intermittent I/P Instrument Panel IRS Independent Rear Suspension ISC Idle Speed Control J/B Junction Block J/C Junction Connector KD Kick-Down LAN Local Area Network LB Liftback LCD Liquid Crystal Display LED Light Emitting Diode LH Left-Hand LHD Left-Hand Drive L/H/W Length, Height, Width LLC Long-Life Coolant LNG Liquified Natural Gas LO Low LPG Liquified Petroleum Gas LSD Limited Slip Differential LSP & PV Load Sensing Proportioning And Bypass Valve LSPV Load Sensing Proportioning Valve MAP Manifold Absolute Pressure MAX. Maximum MIC Microphone MIL Malfunction Indicator Lamp MIN. Minimum MG1 Motor Generator No.1 MG2 Motor Generator No.2 MP Multipurpose MPI Multipoint Electronic Injection MPX Multiplex Communication System M/T, MTM Manual Transmission (Transaxle) MT Mount MTG Mounting N Neutral NA Natural Aspiration No. Number O2S Oxygen Sensor O/D Overdrive 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 43 01-44 INTRODUCTION - TERMS Abbreviations Meaning OEM Original Equipment Manufacturing OHC Overhead Camshaft OHV Overhead Valve OPT Option ORVR On-board Refilling Vapor Recovery O/S Oversize P & BV Proportioning And Bypass Valve PCS Power Control System PCV Positive Crankcase Ventilation PKB Parking Brake PPS Progressive Power Steering PTC Positive Temperature Coefficient PS Power Steering PTO Power Take-Of f P/W Power Window R&P Rack And Pinion RAM Random Access Memory R/B Relay Block RBS Recirculating Ball Type Steering R/F Reinforcement RFS Rigid Front Suspension RH Right-Hand RHD Right-Hand Drive RLY Relay ROM Read Only Memory Rr Rear RRS Rigid Rear Suspension RWD Rear-Wheel Drive SDN Sedan SEN Sensor SICS Starting Injection Control System SOC State Of Charge SOHC Single Overhead Camshaft SPEC Specification SPI Single Point Injection SRS Supplemental Restraint System SSM Special Service Materials SST Special Service Tools STD Standard STJ Cold-Start Fuel Injection SW Switch SYS System T/A Transaxle TACH Tachometer TBI Throttle Body Electronic Fuel Injection TC Turbocharger TCCS TOYOTA Computer-Controlled System TCV Timing Control Valve TDC Top Dead Center TEMP. Temperature TEMS TOYOTA Electronic Modulated Suspension 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 44 01-45 INTRODUCTION - TERMS Abbreviations Meaning TFT TOYOTA Free-Tronic TIS Total Information System For Vehicle Development T/M Transmission TMC TOYOTA Motor Corporation TMMK TOYOTA Motor Manufacturing Kentucky, Inc. TRAC Traction Control System TURBO Turbocharge TWC Three-W ay Catalyst U/D Underdrive U/S Undersize VCV Vacuum Control Valve VENT Ventilator VIN Vehicle Identification Number VPS Variable Power Steering VSC Vehicle Stability Control VSV Vacuum Switching Valve VTV Vacuum Transmitting Valve VVT-i Variable Valve Timing-intelligent w/ With WGN Wagon W/H Wire Harness w/o Without WU-TWC Warm Up Three-way Catalytic Converter WU-OC Warm Up Oxidation Catalytic Converter 1st First 2nd Second 2WD Two Wheel Drive Vehicle (4 x 2) 3rd Third 4th Fourth 4WD Four Wheel Drive Vehicle (4 x 4) 4WS Four Wheel Steering System 5th Fifth 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 45 01-46 INTRODUCTION - TERMS 010QP-01 GLOSSARY OF SAE AND TOYOTA TERMS This glossary lists all SAE-J1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their TOYOTA equivalents. SAE ABBREVIATIONS TOYOTA TERMS ( )--ABBREVIATIONS SAE TERMS A/C Air Conditioning Air Conditioner ACL Air Cleaner Air Cleaner, A/CL AIR Secondary Air Injection Air Injection (AI) AP Accelerator Pedal B+ Battery Positive Voltage +B, Battery Voltage BARO Barometric Pressure HAC CAC Charge Air Cooler Intercooler CARB Carburetor Carburetor CFI Continuous Fuel Injection CKP Crankshaft Position Crank Angle CL Closed Loop Closed Loop CMP Camshaft Position Cam Angle CPP Clutch Pedal Position - CTOX Continuous Trap Oxidizer - CTP Closed Throttle Position LL ON, Idle ON DFI Direct Fuel Injection Direct Injection (DI/INJ) DI Distributor Ignition DLC1 DLC2 DLC3 Data Link Connector 1 Data Link Connector 2 Data Link Connector 3 1: Check Connector 2: Total Diagnosis Communication Link (TDCL) 3: OBD II Diagnostic Connector DTC Diagnostic Trouble Code Diagnostic Trouble Code DTM Diagnostic Test Mode - ECL Engine Coolant Level - ECM Engine Control Module Engine ECU (Electronic Control Unit) ECT Engine Coolant Temperature Coolant Temperature, Water Temperature (THW) EEPROM Electrically Erasable Programmable Read Only Memory Electrically Erasable Programmable Read Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM) EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV) EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR) EI Electronic Ignition Distributorless Ignition (DLI) EM Engine Modification Engine Modification (EM) EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM) EVAP Evaporative Emission Evaporative Emission Control (EVAP) FC Fan Control - FEEPROM Flash Electrically Erasable Programmable Read Only Memory - FEPROM Flash Erasable Programmable Read Only Memory - FF Flexible Fuel - FP Fuel Pump Fuel Pump GEN Generator Alternator GND Ground Ground (GND) - - - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 46 01-47 INTRODUCTION - TERMS HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S) IAC Idle Air Control Idle Speed Control (ISC) IAT Intake Air Temperature Intake or Inlet Air Temperature ICM Ignition Control Module IFI Indirect Fuel Injection IFS Inertia Fuel-Shutoff - ISC Idle Speed Control - KS Knock Sensor Knock Sensor MAF Mass Airflow Air Flow Meter MAP Manifold Absolute Pressure Manifold Pressure Intake Vacuum MC Mixture Control Electric Bleed Air Control Valve (EBCV) Mixture Control Valve (MCV) Electric Air Control Valve (EACV) MDP Manifold Differential Pressure MFI Multiport Fuel Injection Electronic Fuel Injection (EFI) MIL Malfunction Indicator Lamp Check Engine Lamp MST Manifold Surface Temperature - MVZ Manifold Vacuum Zone - NVRAM Non-V olatile Random Access Memory - O2S Oxygen Sensor Oxygen Sensor, O2 Sensor (O2S) OBD On-Board Diagnostic On-Board Diagnostic System (OBD) OC Oxidation Catalytic Converter Oxidation Catalyst Convert (OC), CCo OL Open Loop Open Loop PAIR Pulsed Secondary Air Injection Air Suction (AS) PCM Powertrain Control Module - PNP Park/Neutral Position - PROM Programmable Read Only Memory - PSP Power Steering Pressure - PTOX Periodic Trap Oxidizer Diesel Particulate Filter (DPF) Diesel Particulate Trap (DPT) RAM Random Access Memory Random Access Memory (RAM) RM Relay Module ROM Read Only Memory Read Only Memory (ROM) RPM Engine Speed Engine Speed SC Supercharger Supercharger SCB Supercharger Bypass E-ABV SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection SPL Smoke Puff Limiter - SRI Service Reminder Indicator - SRT System Readiness Test - ST Scan Tool - TB Throttle Body Throttle Body TBI Throttle Body Fuel Injection Single Point Injection Central Fuel Injection (Ci) TC Turbocharger Turbocharger TCC Torque Converter Clutch Torque Converter Indirect Injection (IDL) - - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 47 01-48 INTRODUCTION - TERMS TCM Transmission Control Module Transmission ECU, ECT ECU TP Throttle Position Throttle Position TR Transmission Range TVV Thermal Vacuum Valve Bimetallic Vacuum Switching Valve (BVSV) Thermostatic Vacuum Switching Valve (TVSV) TWC Three-W ay Catalytic Converter Three-W ay Catalytic (TWC) Manifold Converter CCRO TWC+OC Three-W ay + Oxidation Catalytic Converter CCR + CCo VAF Volume Airflow Air Flow Meter VR Voltage Regulator Voltage Regulator VSS Vehicle Speed Sensor Vehicle Speed Sensor WOT Wide Open Throttle Full Throttle WU-OC Warm Up Oxidation Catalytic Converter - WU-TWC Warm Up Three-Way Catalytic Converter - 3GR Third Gear - 4GR Fourth Gear - - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 48 02-60 PREPARATION - SEAT BELT SEAT BELT 020XO-03 PREPARATION SST 09082-00700 SRS Airbag Deployment Tool FRONT SEAT BELT 09082-00770 Airbag Deployment Wire Sub-harness No.5 FRONT SEAT BELT Equipment Torque wrench 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 108 02-67 PREPARATION - SEAT SEAT 023H3-02 PREPARATION Recomended Tools 09042-00010 Torx Socket T30 FRONT SEAT ASSY LH (POWER SEAT TYPE) FRONT SEAT ASSY LH (MANUAL SEAT TYPE) 09042-00020 Torx Socket T40 REAR NO.1 SEAT ASSY LH(W/O REAR NO.2 SEAT) REAR NO.1 SEAT ASSY RH(W/O REAR NO.2 SEAT) REAR NO.1 SEAT ASSY LH(W/REAR NO.2 SEAT) REAR NO.1 SEAT ASSY RH(W/REAR NO.2 SEAT) 09042-00050 Torx Socket T45 REAR NO.1 SEAT ASSY RH(W/O REAR NO.2 SEAT) REAR NO.1 SEAT ASSY LH(W/REAR NO.2 SEAT) REAR NO.1 SEAT ASSY RH(W/REAR NO.2 SEAT) 09082-00040 TOYOTA Electrical Tester FRONT POWER SEAT CONTROL SYSTEM SEAT HEATER SYSTEM 09200-00010 Engine Adjust Kit FRONT SEAT ASSY LH (POWER SEAT TYPE) FRONT SEAT ASSY LH (MANUAL SEAT TYPE) Torx is a registered trademark of Textron Inc. Equipment Hog ring Hog ring pliers Tape To avoid surface damage Torque wrench Torx socket wrench (T55) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 115 02-7 PREPARATION - ENGINE MECHANICAL ENGINE MECHANICAL 023HH-01 PREPARATION SST 09011-38121 12 mm Socket Wrench for 12 Pointed Head CYLINDER BLOCK ASSY(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) CYLINDER HEAD GASKET(3MZ-FE) CYLINDER HEAD GASKET NO.2(3MZ-FE) CYLINDER BLOCK ASSY(3MZ-FE) 09032-00100 Oil Pan Seal Cutter PARTIAL ENGINE ASSY(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) 09201-01055 Valve Guide Bushing Remover & Replacer 5.5 CYLINDER HEAD ASSY(3MZ-FE) 09201-10000 Valve Guide Bushing Remover & Replacer Set CYLINDER HEAD ASSY(2AZ-FE) CYLINDER HEAD ASSY(3MZ-FE) (09201-01050) Valve Guide Bushing Remover & Replacer 5 CYLINDER HEAD ASSY(2AZ-FE) 09201-41020 Valve Stem Oil Seal Replacer CYLINDER HEAD ASSY(2AZ-FE) CYLINDER HEAD ASSY(3MZ-FE) 09202-70020 Valve Spring Compressor CYLINDER HEAD ASSY(2AZ-FE) CYLINDER HEAD ASSY(3MZ-FE) Attachment CYLINDER HEAD ASSY(2AZ-FE) CYLINDER HEAD ASSY(3MZ-FE) Crankshaft Pulley Holding Tool PARTIAL ENGINE ASSY(2AZ-FE) ENGINE REAR OIL SEAL(2AZ-FE) CHAIN(2AZ-FE) (09202-00010) 09213-54015 PARTIAL ENGINE ASSY(3MZ-FE) TIMING BELT(3MZ-FE) CAMSHAFT (RH BANK)(3MZ-FE) CAMSHAFT (LH BANK)(3MZ-FE) CYLINDER HEAD GASKET(3MZ-FE) CYLINDER HEAD GASKET NO.2(3MZ-FE) OIL PUMP SEAL(3MZ-FE) ENGINE REAR OIL SEAL(3MZ-FE) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 55 02-8 PREPARATION (91651-60855) - ENGINE MECHANICAL Bolt PARTIAL ENGINE ASSY(2AZ-FE) ENGINE REAR OIL SEAL(2AZ-FE) CHAIN(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) TIMING BELT(3MZ-FE) CAMSHAFT (RH BANK)(3MZ-FE) CAMSHAFT (LH BANK)(3MZ-FE) CYLINDER HEAD GASKET(3MZ-FE) CYLINDER HEAD GASKET NO.2(3MZ-FE) OIL PUMP SEAL(3MZ-FE) ENGINE REAR OIL SEAL(3MZ-FE) 09222-30010 Connecting Rod Bushing Remover & Replacer CYLINDER BLOCK ASSY(3MZ-FE) 09223-00010 Cover & Seal Replacer PARTIAL ENGINE ASSY(3MZ-FE) OIL PUMP SEAL(3MZ-FE) 09223-15030 Oil Seal & Bearing Replacer PARTIAL ENGINE ASSY(2AZ-FE) ENGINE REAR OIL SEAL(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) ENGINE REAR OIL SEAL(3MZ-FE) 09223-22010 Crankshaft Front Oil Seal Replacer PARTIAL ENGINE ASSY(2AZ-FE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(2AZ-FE) 09228-06501 Oil Filter Wrench PARTIAL ENGINE ASSY(2AZ-FE) 09228-07501 Oil Filter Wrench PARTIAL ENGINE ASSY(3MZ-FE) 09248-55040 Valve Clearance Adjust Tool Set VALVE CLEARANCE(3MZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) CAMSHAFT (RH BANK)(3MZ-FE) CAMSHAFT (LH BANK)(3MZ-FE) (09248-05410) Valve Lifter Press VALVE CLEARANCE(3MZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) CAMSHAFT (RH BANK)(3MZ-FE) CAMSHAFT (LH BANK)(3MZ-FE) (09248-05420) Valve Lifter Stopper VALVE CLEARANCE(3MZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) CAMSHAFT (RH BANK)(3MZ-FE) CAMSHAFT (LH BANK)(3MZ-FE) 09249-63010 Torque Wrench Adaptor FAN AND GENERATOR V BELT(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) CAMSHAFT (RH BANK)(3MZ-FE) CAMSHAFT (LH BANK)(3MZ-FE) CYLINDER HEAD GASKET(3MZ-FE) CYLINDER HEAD NO.2(3MZ-FE) GASKET 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 56 02-9 PREPARATION - ENGINE MECHANICAL 09308-10010 Oil Seal Puller TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(2AZ-FE) 09309-37010 Transmission Bearing Replacer PARTIAL ENGINE ASSY(2AZ-FE) CHAIN(2AZ-FE) 09325-20010 Transmission Oil Plug PARTIAL ENGINE ASSY(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) CYLINDER HEAD GASKET(3MZ-FE) ENGINE REAR OIL SEAL(3MZ-FE) 09330-00021 Companion Flange Holding Tool PARTIAL ENGINE ASSY(2AZ-FE) ENGINE REAR OIL SEAL(2AZ-FE) CHAIN(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) TIMING BELT(3MZ-FE) CAMSHAFT (RH BANK)(3MZ-FE) CAMSHAFT (LH BANK)(3MZ-FE) CYLINDER HEAD GASKET(3MZ-FE) CYLINDER HEAD GASKET NO.2(3MZ-FE) OIL PUMP SEAL(3MZ-FE) ENGINE REAR OIL SEAL(3MZ-FE) 09520-01010 Drive Shaft Remover Attachment PARTIAL ENGINE ASSY(3MZ-FE) ENGINE REAR OIL SEAL(3MZ-FE) 09520-24010 Differential Side Gear Shaft Puller PARTIAL ENGINE ASSY(3MZ-FE) ENGINE REAR OIL SEAL(3MZ-FE) Shocker Set PARTIAL ENGINE ASSY(3MZ-FE) ENGINE REAR OIL SEAL(3MZ-FE) 09628-6201 1 Boll Joint Puller PARTIAL ENGINE ASSY(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) ENGINE REAR OIL SEAL(3MZ-FE) 09843-18020 Diagnosis Check Wire ENGINE(2AZ-FE) 09843-18030 Tacho-pulse Pickup Wire No.2 ENGINE(2AZ-FE) FAN AND GENERATOR BELT(2AZ-FE) (09520-32040) V ENGINE(3MZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) CYLINDER HEAD GASKET(3MZ-FE) CYLINDER HEAD GASKET NO.2(3MZ-FE) ENGINE REAR OIL SEAL(3MZ-FE) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 57 02-10 PREPARATION 09843-18040 - ENGINE MECHANICAL Diagnosis Check Wire No.2 ENGINE(2AZ-FE) ENGINE(3MZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) CYLINDER HEAD GASKET(3MZ-FE) CYLINDER HEAD GASKET NO.2(3MZ-FE) ENGINE REAR OIL SEAL(3MZ-FE) 09930-00010 Drive Shaft Nut Chisel PARTIAL ENGINE ASSY(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) ENGINE REAR OIL SEAL(3MZ-FE) 09950-50013 Puller C Set PARTIAL ENGINE ASSY(2AZ-FE) CHAIN(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) TIMING BELT(3MZ-FE) CAMSHAFT (RH BANK)(3MZ-FE) CAMSHAFT (LH BANK)(3MZ-FE) CYLINDER HEAD GASKET(3MZ-FE) CYLINDER HEAD GASKET NO.2(3MZ-FE) OIL PUMP SEAL(3MZ-FE) (09951-05010) Hanger 150 PARTIAL ENGINE ASSY(2AZ-FE) CHAIN(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) TIMING BELT(3MZ-FE) CAMSHAFT (RH BANK)(3MZ-FE) CAMSHAFT (LH BANK)(3MZ-FE) CYLINDER HEAD GASKET(3MZ-FE) CYLINDER HEAD GASKET NO.2(3MZ-FE) OIL PUMP SEAL(3MZ-FE) (09952-05010) Slide Arm PARTIAL ENGINE ASSY(2AZ-FE) CHAIN(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) TIMING BELT(3MZ-FE) CAMSHAFT (RH BANK)(3MZ-FE) CAMSHAFT (LH BANK)(3MZ-FE) CYLINDER HEAD GASKET(3MZ-FE) CYLINDER HEAD GASKET NO.2(3MZ-FE) OIL PUMP SEAL(3MZ-FE) (09953-05020) Center Bolt 150 PARTIAL ENGINE ASSY(2AZ-FE) CHAIN(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) TIMING BELT(3MZ-FE) CAMSHAFT (RH BANK)(3MZ-FE) CAMSHAFT (LH BANK)(3MZ-FE) CYLINDER HEAD GASKET(3MZ-FE) CYLINDER HEAD GASKET NO.2(3MZ-FE) OIL PUMP SEAL(3MZ-FE) (09954-0501 1) Claw No.1 PARTIAL ENGINE ASSY(3MZ-FE) OIL PUMP SEAL(3MZ-FE) (09954-05021) Claw No.2 PARTIAL ENGINE ASSY(2AZ-FE) CHAIN(2AZ-FE) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 58 02-1 1 PREPARATION (09954-05031) - ENGINE MECHANICAL Claw No.3 PARTIAL ENGINE ASSY(3MZ-FE) TIMING BELT(3MZ-FE) CAMSHAFT (RH BANK)(3MZ-FE) CAMSHAFT (LH BANK)(3MZ-FE) CYLINDER HEAD GASKET(3MZ-FE) CYLINDER HEAD GASKET NO.2(3MZ-FE) OIL PUMP SEAL(3MZ-FE) 09950-60010 Replacer Set CYLINDER BLOCK ASSY(2AZ-FE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) (09951-00200) Replacer 20 CYLINDER BLOCK ASSY(2AZ-FE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(2AZ-FE) (09951-00430) Replacer 43 PARTIAL ENGINE ASSY(3MZ-FE) 09950-70010 Handle Set PARTIAL ENGINE ASSY(2AZ-FE) CYLINDER HEAD ASSY(2AZ-FE) CYLINDER BLOCK ASSY(2AZ-FE) ENGINE REAR OIL SEAL(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) ENGINE REAR OIL SEAL(3MZ-FE) CYLINDER HEAD ASSY(3MZ-FE) (09951-07100) Handle 100 PARTIAL ENGINE ASSY(2AZ-FE) CYLINDER HEAD ASSY(2AZ-FE) CYLINDER BLOCK ASSY(2AZ-FE) ENGINE REAR OIL SEAL(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) ENGINE REAR OIL SEAL(3MZ-FE) CYLINDER HEAD ASSY(3MZ-FE) 09960-10010 Variable Pin Wrench Set PARTIAL ENGINE ASSY(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) TIMING BELT(3MZ-FE) CAMSHAFT (RH BANK)(3MZ-FE) CAMSHAFT (LH BANK)(3MZ-FE) CYLINDER HEAD GASKET(3MZ-FE) CYLINDER HEAD GASKET NO.2(3MZ-FE) OIL PUMP SEAL(3MZ-FE) (09962-01000) Variable Pin Wrench Arm Assy PARTIAL ENGINE ASSY(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) TIMING BELT(3MZ-FE) CAMSHAFT (RH BANK)(3MZ-FE) CAMSHAFT (LH BANK)(3MZ-FE) CYLINDER HEAD GASKET(3MZ-FE) CYLINDER HEAD GASKET NO.2(3MZ-FE) OIL PUMP SEAL(3MZ-FE) (09963-00500) Pin 5 PARTIAL ENGINE ASSY(3MZ-FE) CAMSHAFT (RH BANK)(3MZ-FE) CAMSHAFT (LH BANK)(3MZ-FE) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 59 02-12 PREPARATION - ENGINE MECHANICAL (09963-00700) Pin 7 PARTIAL ENGINE ASSY(2AZ-FE) (09963-01000) Pin 10 PARTIAL ENGINE ASSY(3MZ-FE) TIMING BELT(3MZ-FE) CAMSHAFT (RH BANK)(3MZ-FE) CAMSHAFT (LH BANK)(3MZ-FE) CYLINDER HEAD GASKET(3MZ-FE) CYLINDER HEAD GASKET NO.2(3MZ-FE) OIL PUMP SEAL(3MZ-FE) 09992-00500 Compression Gauge Attachment ENGINE(3MZ-FE) 09011-12301 Socket Wrench 30 mm PARTIAL ENGINE ASSY(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) ENGINE REAR OIL SEAL(3MZ-FE) 09031-00040 Pin Punch . CYLINDER HEAD ASSY(2AZ-FE) 09040-0001 1 Hexagon Wrench Set PARTIAL ENGINE ASSY(2AZ-FE) VALVE CLEARANCE(3MZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) Recomended Tools CAMSHAFT (RH BANK)(3MZ-FE) CAMSHAFT (LH BANK)(3MZ-FE) CYLINDER HEAD GASKET(3MZ-FE) CYLINDER HEAD GASKET NO.2(3MZ-FE) ENGINE REAR OIL SEAL(3MZ-FE) CYLINDER HEAD ASSY(3MZ-FE) CYLINDER BLOCK ASSY(3MZ-FE) (09043-20050) Socket Hexagon Wrench 5 VALVE CLEARANCE(3MZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) CAMSHAFT (RH BANK)(3MZ-FE) CAMSHAFT (LH BANK)(3MZ-FE) CYLINDER HEAD GASKET(3MZ-FE) CYLINDER HEAD GASKET NO.2(3MZ-FE) ENGINE REAR OIL SEAL(3MZ-FE) (09043-20060) Socket Hexagon Wrench 6 PARTIAL ENGINE ASSY(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) ENGINE REAR OIL SEAL(3MZ-FE) (09043-20080) Socket Hexagon Wrench 8 VALVE CLEARANCE(3MZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) CAMSHAFT (RH BANK)(3MZ-FE) CYLINDER HEAD GASKET(3MZ-FE) CYLINDER HEAD GASKET NO.2(3MZ-FE) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 60 02-13 PREPARATION (09043-20100) - ENGINE MECHANICAL Socket Hexagon Wrench 10 PARTIAL ENGINE ASSY(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) ENGINE REAR OIL SEAL(3MZ-FE) CYLINDER BLOCK ASSY(3MZ-FE) (09043-20120) Socket Hexagon Wrench 12 PARTIAL ENGINE ASSY(3MZ-FE) (09043-30140) Straight Hexagon Wrench 14 CYLINDER HEAD ASSY(3MZ-FE) (09043-20060) Socket Hexagon Wrench 6 PARTIAL ENGINE ASSY(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) ENGINE REAR OIL SEAL(3MZ-FE) (09043-20080) Socket Hexagon Wrench 8 VALVE CLEARANCE(3MZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) CAMSHAFT (RH BANK)(3MZ-FE) CYLINDER HEAD GASKET(3MZ-FE) CYLINDER HEAD GASKET NO.2(3MZ-FE) (09043-20100) Socket Hexagon Wrench 10 PARTIAL ENGINE ASSY(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) ENGINE REAR OIL SEAL(3MZ-FE) CYLINDER BLOCK ASSY(3MZ-FE) 09043-50100 Bi-hexagon Wrench 10 mm PARTIAL ENGINE ASSY(2AZ-FE) CYLINDER HEAD GASKET(2AZ-FE) 09090-04020 Engine Sling Device CHAIN(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) ENGINE REAR OIL SEAL(3MZ-FE) 09200-00010 Engine Adjust Kit VALVE CLEARANCE(3MZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) 09216-00021 Belt Tension Gauge ENGINE(3MZ-FE) DRIVE BELT(3MZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) TIMING BELT(3MZ-FE) CAMSHAFT (RH BANK)(3MZ-FE) CAMSHAFT (LH BANK)(3MZ-FE) CYLINDER HEAD GASKET(3MZ-FE) CYLINDER HEAD GASKET NO.2(3MZ-FE) OIL PUMP SEAL(3MZ-FE) ENGINE REAR OIL SEAL(3MZ-FE) 09904-00010 (09904-00040) Expander Set PARTIAL ENGINE ASSY(3MZ-FE) CAMSHAFT (RH BANK)(3MZ-FE) CAMSHAFT (LH BANK)(3MZ-FE) No. 3 Claw PARTIAL ENGINE ASSY(3MZ-FE) CAMSHAFT (RH BANK)(3MZ-FE) CAMSHAFT (LH BANK)(3MZ-FE) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 61 02-14 PREPARATION - ENGINE MECHANICAL Equipment Abrasive compound Valve Brush Piston Caliper gauge Carbide cutter CO/HC meter Compression gauge Connecting rod aligner Cylinder gauge Dial indicator Dye penetrant Engine tune-up tester Groove cleaning tool Piston ring groove Heater Hexagon wrench (1.5 mm) Timing belt tensioner Micrometer Pin hole grinder Connecting rod bushing Piston ring compressor Piston ring expander Plastigage Precision straight edge Press Reamer Cylinder Ridge reamer Cylinder Soft brush Cylinder head Cylinder block Solvent Spring tester Valve spring Steel square Valve spring Thermometer Torque wrench Valve seat cutter Valve guide bushing brush V-block Vernier calipers Wire brush Valve Cylinder head 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 62 02-15 PREPARATION - ENGINE MECHANICAL SSM 08826-00080 Seal Packing Black or equivalent (FIPG) VALVE CLEARANCE(2AZ-FE) PARTIAL ENGINE ASSY(2AZ-FE) CYLINDER HEAD GASKET(2AZ-FE) CAMSHAFT(2AZ-FE) CHAIN(2AZ-FE) VALVE CLEARANCE(3MZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) CAMSHAFT (RH BANK)(3MZ-FE) CAMSHAFT (LH BANK)(3MZ-FE) CYLINDER HEAD GASKET(3MZ-FE) CYLINDER HEAD GASKET NO.2(3MZ-FE) CYLINDER HEAD ASSY(3MZ-FE) 08826-00100 ”Seal Packing 1282B,” THREE BOND 1282B or equivalent (FIPG) PARTIAL ENGINE ASSY(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) CYLINDER BLOCK ASSY(3MZ-FE) 08833-00070 ”Adhesive 1324,” THREE BOND 1324 or equivalent PARTIAL ENGINE ASSY(2AZ-FE) CYLINDER BLOCK ASSY(2AZ-FE) PARTIAL ENGINE ASSY(3MZ-FE) ENGINE REAR OIL SEAL(3MZ-FE) CYLINDER HEAD ASSY(3MZ-FE) CYLINDER BLOCK ASSY(3MZ-FE) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 63 02-3 PREPARATION - FUEL FUEL 023HA-01 PREPARATION SST Injection Measuring Tool Set FUEL SYSTEM(2AZ-FE) FUEL SYSTEM(3MZ-FE) (09268-41 110) Adaptor FUEL SYSTEM(2AZ-FE) FUEL SYSTEM(3MZ-FE) (09268-41300) Clamp FUEL SYSTEM(2AZ-FE) FUEL SYSTEM(3MZ-FE) (95336-08070) Hose FUEL SYSTEM(2AZ-FE) FUEL SYSTEM(3MZ-FE) Retainer Tool,Fuel Pump FUEL PUMP ASSY(2AZ-FE) FUEL TANK ASSY(2AZ-FE) FUEL PUMP ASSY(3MZ-FE) 09268-41047 09808-14020 FUEL TANK ASSY(3MZ-FE) (09808-01410) Holder FUEL PUMP ASSY(2AZ-FE) FUEL TANK ASSY(2AZ-FE) FUEL PUMP ASSY(3MZ-FE) FUEL TANK ASSY(3MZ-FE) (09808-01420) Claw FUEL PUMP ASSY(2AZ-FE) FUEL TANK ASSY(2AZ-FE) FUEL PUMP ASSY(3MZ-FE) FUEL TANK ASSY(3MZ-FE) (09808-01430) Bolt FUEL PUMP ASSY(2AZ-FE) FUEL TANK ASSY(2AZ-FE) FUEL PUMP ASSY(3MZ-FE) FUEL TANK ASSY(3MZ-FE) 09842-30070 Wire ”F” EFI Inspection FUEL SYSTEM(3MZ-FE) 09842-30080 Wire ”H” EFI Inspection FUEL SYSTEM(2AZ-FE) 09082-00040 TOYOTA Electrical Tester FUEL SYSTEM(3MZ-FE) Test Lead Set FUEL SYSTEM(2AZ-FE) FUEL SYSTEM(3MZ-FE) Recomended Tools (09083-00150) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 51 02-4 PREPARATION - FUEL Equipment Clip Measuring Flask Radiator cap tester Stopwatch Torque wrench Vernier calipers 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 52 02-55 PREPARATION - HEATER & AIR CONDITIONER HEATER & AIR CONDITIONER 023HI-01 PREPARATION SST 07110-58060 Air Conditioner Service Tool Set REFRIGERANT AIR CONDITIONING ASSY RADIATOR COOLER CONDENSER ASSY COOLER COMPRESSOR ASSY(2AZ-FE) COOLER ASSY(3MZ-FE) (07117-58060) Refrigerant Drain Service Valve COMPRESSOR REFRIGERANT AIR CONDITIONING ASSY RADIATOR COOLER CONDENSER ASSY COOLER COMPRESSOR ASSY(2AZ-FE) COOLER ASSY(3MZ-FE) (07117-58070) T-Joint COMPRESSOR REFRIGERANT AIR CONDITIONING ASSY RADIATOR COOLER CONDENSER ASSY COOLER COMPRESSOR ASSY(2AZ-FE) COOLER ASSY(3MZ-FE) (07117-58080) Quick Disconnect Adapter COMPRESSOR REFRIGERANT AIR CONDITIONING ASSY RADIATOR COOLER CONDENSER ASSY COOLER COMPRESSOR ASSY(2AZ-FE) COOLER ASSY(3MZ-FE) (07117-58090) Quick Disconnect Adapter COMPRESSOR REFRIGERANT AIR CONDITIONING ASSY RADIATOR COOLER CONDENSER ASSY COOLER COMPRESSOR ASSY(2AZ-FE) COOLER ASSY(3MZ-FE) (07117-78050) Refrigerant Charging Gauge COMPRESSOR REFRIGERANT AIR CONDITIONING ASSY RADIATOR COOLER CONDENSER ASSY COOLER COMPRESSOR ASSY(2AZ-FE) COOLER ASSY(3MZ-FE) COMPRESSOR 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 103 02-56 PREPARATION (07117-88060) - HEATER & AIR CONDITIONER Refrigerant Charging Hose REFRIGERANT AIR CONDITIONING ASSY RADIATOR COOLER CONDENSER ASSY COOLER COMPRESSOR ASSY(2AZ-FE) COOLER ASSY(3MZ-FE) (07117-88070) Refrigerant Charging Hose COMPRESSOR REFRIGERANT AIR CONDITIONING ASSY RADIATOR COOLER CONDENSER ASSY COOLER COMPRESSOR ASSY(2AZ-FE) COOLER ASSY(3MZ-FE) (07117-88080) Refrigerant Charging Hose COMPRESSOR REFRIGERANT AIR CONDITIONING ASSY RADIATOR COOLER CONDENSER ASSY COOLER COMPRESSOR ASSY(2AZ-FE) COOLER ASSY(3MZ-FE) 07117-48130 Vacuum Pump (220 V) REFRIGERANT COOLER ASSY(2AZ-FE) COOLER ASSY(3MZ-FE) 07117-48140 Vacuum Pump (240 V) REFRIGERANT COOLER ASSY(2AZ-FE) COOLER ASSY(3MZ-FE) COMPRESSOR COMPRESSOR COMPRESSOR COMPRESSOR COMPRESSOR 09870-00015 A/C Quick Joint Puller No.1 AIR CONDITIONING ASSY RADIATOR 09870-00025 A/C Quick Joint Puller No.2 AIR CONDITIONING ASSY RADIATOR 95047-10400 Magnet Clutch Stopper (DENSO part No.) COOLER ASSY(2AZ-FE) COOLER COMPRESSOR COMPRESSOR ASSY(3MZ-FE) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 104 02-57 PREPARATION - HEATER & AIR CONDITIONER Recomended Tools 09070-20010 Moulding Remover AIRCONDITIONER ASSY 09904-00010 Expander Set COOLER ASSY(2AZ-FE) COOLER AMPLIFIER COMPRESSOR COMPRESSOR ASSY(3MZ-FE) (09904-00050) No. 4 Claw COOLER ASSY(2AZ-FE) COOLER COMPRESSOR COMPRESSOR ASSY(3MZ-FE) EQUIPMENT Voltmeter Anmeter Ohmmeter Vinyl tape Belt tension gauge Hexagon wrench 10 mm (0.39 in.) Hexagon wrench 4 mm (0.16 in.) Torque socket wrench (E 8) Gas leak detector Dial indicator Torque wrench 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 105 02-5 PREPARATION - EMISSION CONTROL EMISSION CONTROL 023H6-01 PREPARATION Recomended Tools 09082-00040 TOYOTA Electrical Tester EMISSION TEM(2AZ-FE) EMISSION CONTROL SYS- CONTROL SYS- CONTROL SYS- CONTROL SYS- VALVE SUB- VALVE SUB- TEM(3MZ-FE) (09083-00150) Test Lead Set EMISSION TEM(2AZ-FE) EMISSION TEM(3MZ-FE) Equipment Hand-held vacuum pump Ohmmeter Service Wire Harness Torque wrench Vacuum gauge Pressure gauge Vernier caliper SSM 08833-00070 ”Adhesive 1324,” THREE BOND 1324 or equivalent VENTILATION ASSY(2AZ-FE) VENTILATION ASSY(3MZ-FE) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 53 02-22 PREPARATION - STARTING & CHARGING STARTING & CHARGING 023HC-01 PREPARATION SST 09820-00021 Alternator Rear Bearing Puller GENERATOR ASSY(2AZ-FE) GENERATOR ASSY(3MZ-FE) 09820-00031 Alternator Rotor Rear Bearing Replacer GENERATOR ASSY(2AZ-FE) GENERATOR ASSY(3MZ-FE) 09820-63010 Alternator Pulley Set Nut Wrench Set GENERATOR ASSY(2AZ-FE) GENERATOR ASSY(3MZ-FE) (09820-06010) Alternator Rotor Shaft Wrench GENERATOR ASSY(2AZ-FE) GENERATOR ASSY(3MZ-FE) (09820-06020) Alternator Pulley Set Nut 22 mm Wrench GENERATOR ASSY(2AZ-FE) GENERATOR ASSY(3MZ-FE) 09950-4001 1 Puller B Set GENERATOR ASSY(2AZ-FE) GENERATOR ASSY(3MZ-FE) (09951-04020) Hanger 200 GENERATOR ASSY(2AZ-FE) GENERATOR ASSY(3MZ-FE) (09952-04010) Slide Arm GENERATOR ASSY(2AZ-FE) GENERATOR ASSY(3MZ-FE) (09953-04020) Center Bolt 150 GENERATOR ASSY(2AZ-FE) GENERATOR ASSY(3MZ-FE) (09954-04010) Arm 25 GENERATOR ASSY(2AZ-FE) GENERATOR ASSY(3MZ-FE) (09955-04071) Claw No.7 GENERATOR ASSY(2AZ-FE) GENERATOR ASSY(3MZ-FE) (09957-04010) Attachment GENERATOR ASSY(2AZ-FE) GENERATOR ASSY(3MZ-FE) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 70 02-23 PREPARATION - STARTING & CHARGING Holder GENERATOR ASSY(2AZ-FE) GENERATOR ASSY(3MZ-FE) 09950-60010 Replacer Set GENERATOR ASSY(2AZ-FE) GENERATOR ASSY(3MZ-FE) (09951-00250) Replacer 25 GENERATOR ASSY(2AZ-FE) GENERATOR ASSY(3MZ-FE) (09951-00470) Replacer 47 GENERATOR ASSY(2AZ-FE) GENERATOR ASSY(3MZ-FE) 09950-70010 Handle Set GENERATOR ASSY(2AZ-FE) GENERATOR ASSY(3MZ-FE) (09951-07100) Handle 100 GENERATOR ASSY(2AZ-FE) GENERATOR ASSY(3MZ-FE) TOYOTA Electrical Tester GENERATOR ASSY(2AZ-FE) STARTER ASSY(3MZ-FE) GENERATOR ASSY(3MZ-FE) Test Lead Set STARTER ASSY(2AZ-FE) GENERATOR ASSY(2AZ-FE) STARTING SYSTEM(3MZ-FE) (09958-0401 1) Recomended Tools 09082-00040 (09083-00150) STARTER ASSY(3MZ-FE) GENERATOR ASSY(3MZ-FE) 09904-00010 (09904-00050) Expander Set STARTER ASSY(2AZ-FE) STARTER ASSY(3MZ-FE) No. 4 Claw STARTER ASSY(2AZ-FE) STARTER ASSY(3MZ-FE) Equipment Ammeter Voltmeter Dial indicator Ohmmeter Sandpaper (#400) Service Wire Harness Torque wrench Vernier caliper 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 71 02-71 PREPARATION - EXTERIOR/INTERIOR TRIM EXTERIOR/INTERIOR TRIM 023H5-01 PREPARATION Recomended Tools 09070-20010 Moulding Remover FRONT DOOR BELT MOULDING ASSY LH REAR DOOR BELT MOULDING ASSY LH ROOF DRIP SIDE MOULDING CENTER LH FINISH ROOF HEADLINING ASSY Equipment Adhesive tape To avoid surface damage. Clip remover Knife Protective tape To avoid surface damage. Torque wrench 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 119 02-65 PREPARATION - WINDSHIELD/WINDOWGLASS/MIRROR WINDSHIELD/WINDOWGLASS/MIRROR 020XQ-03 PREPARATION Recomended Tools 09070-20010 Moulding Remover BACK DOOR GLASS 09082-00050 TOYOTA Electrical Tester Set POWER SYSTEM MIRROR CONTROL Test Lead Set POWER SYSTEM POWER WINDOW CONTROL MIRROR CONTROL (09083-00150) SYSTEM DEFOGGER SYSTEM Equipment Knife Piano wire Windshield Plastic sheet To avoid surface damage Sealer gun Tape To avoid surface damage Torque wrench Wooden block or similar object For tying both piano wire ends SSM 08833-00030 Three cement black or equivalent WINDSHIELD GLASS BACK DOOR GLASS QUARTER WINDOW ASSY LH 08850-00801 Windshield Glass Adhesive Set or equivalent WINDSHIELD GLASS BACK DOOR GLASS QUARTER WINDOW ASSY LH 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 113 02-70 PREPARATION - ENGINE HOOD/DOOR ENGINE HOOD/DOOR 023BO-02 PREPARATION SST 09812-00010 Door Hinge Set Bolt Wrench FRONT DOOR 09041-00020 Torx Driver T25 FRONT DOOR REAR DOOR 09042-00010 Torx Socket T30 FRONT DOOR REAR DOOR 09042-00020 Torx Socket T40 FRONT DOOR REAR DOOR BACK DOOR Recomended Tools Torx is a registered trademark of Textron Inc. SSM 08833-00070 ”Adhesive 1324,” THREE BOND 1324 or equivalent FRONT DOOR REAR DOOR Equipment Clip remover Tape To avoid surface damage Torque wrench 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 118 02-2 PREPARATION - ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM 023H9-01 PREPARATION Recomended Tools Hexagon Wrench Set THROTTLE BODY ASSY(3MZ-FE) (09043-20050) Socket Hexagon Wrench 5 THROTTLE BODY ASSY(3MZ-FE) KNOCK SENSOR(3MZ-FE) 09082-00040 TOYOTA Electrical Tester SFI SYSTEM(3MZ-FE) Test Lead Set SFI SYSTEM(2AZ-FE) SFI SYSTEM(3MZ-FE) 09040-0001 1 (09083-00150) Equipment Ohmmeter Radiator cap tester Service Wire Harness Torque wrench 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 50 02-16 PREPARATION - EXHAUST EXHAUST 023H8-01 PREPARATION Equipment Torque wrench 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 64 02-17 PREPARATION - COOLING COOLING 023HF-01 PREPARATION SST Radiator Service Tool Set RADIATOR ASSY(2AZ-FE) RADIATOR ASSY(3MZ-FE) (09231-01010) Overhaul Handle RADIATOR ASSY(2AZ-FE) RADIATOR ASSY(3MZ-FE) (09231-01030) Claw RADIATOR ASSY(2AZ-FE) RADIATOR ASSY(3MZ-FE) 09231-14010 Punch RADIATOR ASSY(2AZ-FE) RADIATOR ASSY(3MZ-FE) 09960-10010 Variable Pin Wrench Set WATER PUMP ASSY(2AZ-FE) (09962-01000) Variable Pin Wrench Arm Assy WATER PUMP ASSY(2AZ-FE) (09963-00700) Pin 7 WATER PUMP ASSY(2AZ-FE) 09082-00050 TOYOTA Electrical Tester Set COOLING FAN SYSTEM(2AZ-FE) COOLING FAN SYSTEM(3MZ-FE) 08826-00080 Seal Packing Black or equivalent (FIPG) WATER PUMP ASSY(2AZ-FE) WATER PUMP ASSY(3MZ-FE) 09230-01010 Recomended Tools Equipment Ohmmeter Radiator cap tester Thermomete Torque wrench Slide calipers Heater SSM 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 65 02-18 PREPARATION - LUBRICATION LUBRICATION 023H1-02 PREPARATION SST 09032-00100 Oil Pan Seal Cutter OIL PUMP ASSY(2AZ-FE) OIL PUMP ASSY(3MZ-FE) 09213-54015 Crankshaft Pulley Holding Tool OIL PUMP ASSY(2AZ-FE) OIL PUMP ASSY(3MZ-FE) Bolt OIL PUMP ASSY(2AZ-FE) OIL PUMP ASSY(3MZ-FE) 09223-00010 Cover & Seal Replacer OIL PUMP ASSY(3MZ-FE) 09228-06501 Oil Filter Wrench OIL FILTER SUB-ASSY(2AZ-FE) 09228-07501 Oil Filter Wrench OIL FILTER SUB-ASSY(3MZ-FE) 09249-63010 Torque Wrench Adaptor OIL PUMP ASSY(3MZ-FE) 09309-37010 Transmission Bearing Replacer OIL PUMP ASSY(2AZ-FE) 09330-00021 Companion Flange Holding Tool OIL PUMP ASSY(2AZ-FE) OIL PUMP ASSY(3MZ-FE) 09950-50013 Puller C Set OIL PUMP ASSY(2AZ-FE) OIL PUMP ASSY(3MZ-FE) (09951-05010) Hanger 150 OIL PUMP ASSY(2AZ-FE) OIL PUMP ASSY(3MZ-FE) (09952-05010) Slide Arm OIL PUMP ASSY(2AZ-FE) OIL PUMP ASSY(3MZ-FE) (91651-60855) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 66 02-19 PREPARATION - LUBRICATION (09953-05020) Center Bolt 150 OIL PUMP ASSY(2AZ-FE) OIL PUMP ASSY(3MZ-FE) (09954-0501 1) Claw No.1 OIL PUMP ASSY(3MZ-FE) (09954-05021) Claw No.2 OIL PUMP ASSY(2AZ-FE) (09954-05031) Claw No.3 OIL PUMP ASSY(3MZ-FE) Variable Pin Wrench Set OIL PUMP ASSY(3MZ-FE) (09962-01000) Variable Pin Wrench Arm Assy OIL PUMP ASSY(3MZ-FE) (09963-01000) Pin 10 OIL PUMP ASSY(3MZ-FE) Hexagon Wrench Set OIL PUMP ASSY(3MZ-FE) Socket Hexagon Wrench 10 OIL PUMP ASSY(3MZ-FE) 09090-04020 Engine Sling Device OIL PUMP ASSY(2AZ-FE) 09200-00010 Engine Adjust Kit OIL PUMP ASSY(2AZ-FE) OIL PUMP ASSY(3MZ-FE) 09960-10010 Equipment Feeler gauge Precision straight edge Radiator cap tester Torque wrench Recomended Tools 09040-0001 1 (09043-20100) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 67 02-20 PREPARATION - LUBRICATION SSM 08826-00080 Seal Packing Black or equivalent (FIPG) OIL PUMP ASSY(2AZ-FE) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 68 02-21 PREPARATION - IGNITION IGNITION 023HB-01 PREPARATION Recomended Tools 09082-00040 (09083-00150) 09200-00010 (09857-00031) TOYOTA Electrical Tester IGNITION SYSTEM(2AZ-FE) IGNITION SYSTEM(3MZ-FE) Test Lead Set IGNITION SYSTEM(2AZ-FE) IGNITION SYSTEM(3MZ-FE) Engine Adjust Kit IGNITION SYSTEM(2AZ-FE) IGNITION SYSTEM(3MZ-FE) Spark Plug Gap Gauge IGNITION SYSTEM(2AZ-FE) IGNITION SYSTEM(3MZ-FE) Equipment megaohmmeter Spark plug llener Torque wrench 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 69 02-1 PREPARATION - DIAGNOSTICS DIAGNOSTICS 020YV-02 PREPARATION SST 09816-30010 Oil Pressure Switch Socket SFI SYSTEM(2AZ-FE) 09843-18040 Diagnosis Check Wire No.2 ABS WITH BA & EBD SYSTEM ABS WITH EBD & BA & TRAC & VSC SYSTEM AIR CONDITIONING SYSTEM COMBINATION METER SFI SYSTEM(1MZ-FE) SUPPLEMENTAL SYSTEM RESTRAINT Recomended Tools 09082-00040 (09083-00150) TOYOTA Electrical Tester SFI SYSTEM(1MZ-FE) SFI SYSTEM(2AZ-FE) Test Lead Set AUDIO SYSTEM ABS WITH BA & EBD SYSTEM ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE[ECT] ABS WITH EBD & BA & TRAC & VSC SYSTEM AIR CONDITIONING SYSTEM COMBINATION METER CRUISE CONTROL SYSTEM SLIDING ROOF SYSTEM POWER DOOR LOCK CONTROL SYSTEM WIRELESS DOOR LOCK CONTROL SYSTEM BODY MULTIPLEX COMMUNICATION SYSTEM POWER WINDOW SYSTEM SFI SYSTEM(1MZ-FE) CONTROL SUPPLEMENTAL RESTRAINT SYSTEM SFI SYSTEM(2AZ-FE) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 49 02-37 PREPARATION - TRANSFER TRANSFER 023G9-01 PREPARATION SST 09223-00010 Cover & Seal Replacer TRANSFER ASSY(4WD) 09223-4601 1 Crankshaft Front Oil Seal Replacer TRANSFER RH BEARING RETAINER OIL SEAL(4WD) TRANSFER ASSY(4WD) 09308-00010 Oil Seal Puller TRANSFER RH BEARING RETAINER OIL SEAL(4WD) TRANSFER CASE OIL SEAL(4WD) TRANSFER EXTENSION HOUSING TYPE T OIL SEAL(4WD) TRANSFER ASSY(4WD) Transmission & Transfer Bearing Replacer TRANSFER ASSY(4WD) (09316-00021) Replacer ”A” TRANSFER ASSY(4WD) (09316-00041) Replacer ”C” TRANSFER ASSY(4WD) (09316-00061) Replacer ”E” TRANSFER ASSY(4WD) 09326-2001 1 Output Shaft Bearing Lock Nut Wrench TRANSFER ASSY(4WD) 09387-00010 Transfer Oil Seal Replacer TRANSFER CASE OIL SEAL(4WD) TRANSFER ASSY(4WD) 09387-00090 Senter Differential Sentering Tool TRANSFER ASSY(4WD) 09506-35010 Differential Drive Pinion Rear Bearing Replacer TRANSFER ASSY(4WD) 09520-01010 Drive Shaft Remover Attachment TRANSFER RH BEARING RETAINER OIL SEAL(4WD) 09316-6001 1 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 85 02-38 PREPARATION - TRANSFER 09520-10021 Drive Shaft Remover & Replacer TRANSFER ASSY(4WD) 09520-24010 Differential Side Gear Shaft Puller TRANSFER RH BEARING RETAINER OIL SEAL(4WD) Shocker Set TRANSFER RH BEARING RETAINER OIL SEAL(4WD) Differential Side Bearing Replacer TRANSFER EXTENSION HOUSING TYPE T OIL SEAL(4WD) (09951-00380) Replacer 38 TRANSFER EXTENSION HOUSING TYPE T OIL SEAL(4WD) TRANSFER ASSY(4WD) (09951-00580) Replacer 58 TRANSFER EXTENSION HOUSING TYPE T OIL SEAL(4WD) TRANSFER ASSY(4WD) (09952-06010) Adapter TRANSFER EXTENSION HOUSING TYPE T OIL SEAL(4WD) TRANSFER ASSY(4WD) Differential Drive Pinion Holding Tool 28 TRANSFER ASSY(4WD) Steering Pinion Bearing Replacer TRANSFER ASSY(4WD) 09628-6201 1 Boll Joint Puller TRANSFER RH BEARING RETAINER OIL SEAL(4WD) 09930-00010 Drive Shaft Nut Chisel TRANSFER RH BEARING RETAINER OIL SEAL(4WD) TRANSFER ASSY(4WD) 09950-00020 Bearing Remover TRANSFER ASSY(4WD) 09950-00030 Bearing Remover Attachment TRANSFER ASSY(4WD) (09520-32040) 09550-60010 09556-16030 (09612-10061) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 86 02-39 PREPARATION - TRANSFER 09950-4001 1 Puller B Set TRANSFER ASSY(4WD) (09951-04010) Hanger 150 TRANSFER ASSY(4WD) (09952-04010) Slide Arm TRANSFER ASSY(4WD) (09953-04020) Center Bolt 150 TRANSFER ASSY(4WD) (09954-04010) Arm 25 TRANSFER ASSY(4WD) (09955-04061) Claw No.6 TRANSFER ASSY(4WD) (09957-04010) Attachment TRANSFER ASSY(4WD) (09958-0401 1) Holder TRANSFER ASSY(4WD) 09950-60010 Replacer Set TRANSFER CASE OIL SEAL(4WD) TRANSFER ASSY(4WD) (09951-00350) Replacer 35 TRANSFER ASSY(4WD) (09951-00360) Replacer 36 TRANSFER ASSY(4WD) (09951-00380) Replacer 38 TRANSFER EXTENSION HOUSING TYPE T OIL SEAL(4WD) TRANSFER ASSY(4WD) (09951-00420) Replacer 42 TRANSFER ASSY(4WD) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 87 02-40 PREPARATION - TRANSFER (09951-00430) Replacer 43 TRANSFER ASSY(4WD) (09951-00560) Replacer 56 TRANSFER ASSY(4WD) (09951-00580) Replacer 58 TRANSFER EXTENSION HOUSING TYPE T OIL SEAL(4WD) TRANSFER ASSY(4WD) (09951-00610) Replacer 61 TRANSFER CASE OIL SEAL(4WD) TRANSFER ASSY(4WD) (09951-00620) Replacer 62 TRANSFER ASSY(4WD) (09952-06010) Adapter TRANSFER EXTENSION HOUSING TYPE T OIL SEAL(4WD) TRANSFER ASSY(4WD) Replacer Set No.2 TRANSFER ASSY(4WD) (09951-00710) Replacer 71 TRANSFER ASSY(4WD) (09951-00750) Replacer 75 TRANSFER ASSY(4WD) (09951-00770) Replacer 77 TRANSFER ASSY(4WD) (09951-00810) Replacer 81 TRANSFER ASSY(4WD) 09950-70010 Handle Set TRANSFER CASE OIL SEAL(4WD) TRANSFER EXTENSION HOUSING TYPE T OIL SEAL(4WD) 09950-60020 TRANSFER ASSY(4WD) (09951-07150) Handle 150 TRANSFER CASE OIL SEAL(4WD) TRANSFER EXTENSION HOUSING TYPE T OIL SEAL(4WD) TRANSFER ASSY(4WD) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 88 02-41 PREPARATION - TRANSFER Handle 200 TRANSFER ASSY(4WD) 09011-12301 Socket Wrench 30 mm TRANSFER RH BEARING RETAINER OIL SEAL(4WD) 09040-0001 1 Hexagon Wrench Set TRANSFER RH BEARING RETAINER OIL SEAL(4WD) TRANSFER EXTENSION HOUSING (09951-07200) Recomended Tools TYPE T OIL SEAL(4WD) (09043-20060) Socket Hexagon Wrench 6 TRANSFER RH BEARING RETAINER OIL SEAL(4WD) TRANSFER EXTENSION HOUSING TYPE T OIL SEAL(4WD) (09043-20060) Socket Hexagon Wrench 6 TRANSFER RH BEARING RETAINER OIL SEAL(4WD) TRANSFER EXTENSION HOUSING TYPE T OIL SEAL(4WD) 09090-04020 Engine Sling Device TRANSFER CASE OIL SEAL(4WD) TRANSFER ASSY(4WD) 09904-00010 Expander Set TRANSFER CASE OIL SEAL(4WD) TRANSFER ASSY(4WD) No. 1 Claw TRANSFER CASE OIL SEAL(4WD) TRANSFER ASSY(4WD) Snap Ring Pliers TRANSFER ASSY(4WD) Claw Set TRANSFER ASSY(4WD) ”Seal Packing 1281,” THREE BOND 1281 or equivalent (FIPG) TRANSFER ASSY(4WD) (09904-00020) 09905-00013 (09904-00090) SSM 08826-00090 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 89 02-42 PREPARATION - TRANSFER Equipment Torque wrench Dial gauge with magnetic base Transfer assy(4WD) V-block Transfer assy(4WD) Hexagon wrench (6 mm) Lubricant Item Transfer oil Capacity Classification 0.9 litters (0.95 US qts, 0.71 lmp.qts) Hypoid gear oil SAE 90 (GL-5) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 90 02-63 PREPARATION - AUDIO & VISUAL SYSTEM AUDIO & VISUAL SYSTEM 020VI-03 PREPARATION SST 09950-50013 Puller C Set ANTENNA CORD SUB-ASSY NO.2 NAVIGATION ANTENNA ASSY (09951-05010) Hanger 150 ANTENNA CORD SUB-ASSY NO.2 NAVIGATION ANTENNA ASSY (09952-05010) Slide Arm ANTENNA CORD SUB-ASSY NO.2 NAVIGATION ANTENNA ASSY (09953-05020) Center Bolt 150 ANTENNA CORD SUB-ASSY NO.2 NAVIGATION ANTENNA ASSY (09954-05021) Claw No.2 ANTENNA CORD SUB-ASSY NO.2 NAVIGATION ANTENNA ASSY 09042-00010 Torx Socket T30 ANTENNA CORD SUB-ASSY NO.2 STEERING PAD SWITCH LH NAVIGATION ANTENNA ASSY 09070-20010 Moulding Remover AMPLIFIER ANTENNA ASSY ANTENNA CORD SUB-ASSY NO.3 ANTENNA CORD SUB-ASSY NO.2 Recomended Tools POWER OUTLET SOCKET ASSY VOLTAGE INVERTER ASSY VIDEO(VIDEO ADAPTER) TERMINAL RADIO RECEIVER ASSY MULTI-DISPLA Y (CRT DISPLAY) DISPLAY AMPLIFIER ANTENNA ASSY NAVIGATION ANTENNA ASSY CIGARETTE LIGHTER ASSY Torx is a registered trademark of Textron Inc. Equipment Clip remover Torque wrench 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 111 02-66 PREPARATION - INSTRUMENT PANEL/METER INSTRUMENT PANEL/METER 020WE-04 PREPARATION SST 09950-50013 Puller C Set INSTRUMENT PANEL SAFETY PAD SUB-ASSY (09951-05010) Hanger 150 INSTRUMENT PANEL SAFETY PAD SUB-ASSY (09952-05010) Slide Arm INSTRUMENT PANEL SAFETY PAD SUB-ASSY (09953-05020) Center Bolt 150 INSTRUMENT PANEL SAFETY PAD SUB-ASSY (09954-05021) Claw No.2 INSTRUMENT PANEL SAFETY PAD SUB-ASSY 09042-00010 Torx Socket T30 INSTRUMENT PANEL SAFETY PAD SUB-ASSY 09070-20010 Moulding Remover INSTRUMENT PANEL SAFETY PAD SUB-ASSY COMBINATION METER ASSY Recomended Tools Torx is a registered trademark of Textron Inc. Equipment Torque wrench Tape To avoid surface damage 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 114 02-46 PREPARATION - AUTOMATIC TRANSMISSION / TRANS AUTOMATIC TRANSMISSION / TRANS 023B6-02 PREPARATION SST 09023-12701 Union Nut Wrench 17 mm AUTOMATIC ASSY(U151E/U151F) AUTOMATIC TRANSAXLE TRANSAXLE ASSY(U241E/U140F) 09223-15020 Oil Seal & Bearing Replacer FRONT DIFFERENTIAL SEAL(U151E) FRONT DIFFERENTIAL OIL OIL SEAL(U151F) 09249-63010 Torque Wrench Adaptor AUTOMATIC ASSY(U241E/U140F) TRANSAXLE 09308-00010 Oil Seal Puller FRONT DIFFERENTIAL SEAL(U140F) FRONT DIFFERENTIAL SEAL(U151E) FRONT DIFFERENTIAL SEAL(U151F) OIL OIL OIL FRONT DIFFERENTIAL SEAL(U241E) OIL 09309-37010 Transmission Bearing Replacer FRONT DIFFERENTIAL SEAL(U140F) OIL 09316-6001 1 Transmission & Transfer Bearing Replacer FRONT DIFFERENTIAL SEAL(U151E) FRONT DIFFERENTIAL OIL OIL SEAL(U241E) (09316-0001 1) Replacer Pipe FRONT DIFFERENTIAL SEAL(U151E) FRONT DIFFERENTIAL OIL OIL SEAL(U241E) 09325-20010 Transmission Oil Plug AUTOMATIC ASSY(U241E/U140F) 09350-32014 TOYOTA Automatic Transmission Tool Set TORQUE CONVERTER CLUTCH AND DRIVE PLATE(ATM) AUTOMATIC TRANSAXLE ASSY(U151E/U151F) AUTOMATIC ASSY(U241E/U140F) (09351-32010) One-way Clutch Test Tool TRANSAXLE TRANSAXLE TORQUE CONVERTER CLUTCH AND DRIVE PLATE(ATM) AUTOMATIC TRANSAXLE ASSY(U151E/U151F) AUTOMATIC ASSY(U241E/U140F) TRANSAXLE 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 94 02-47 PREPARATION (09351-32020) - AUTOMATIC TRANSMISSION / TRANS Stator Stopper TORQUE CONVERTER CLUTCH AND DRIVE PLATE(ATM) AUTOMATIC TRANSAXLE ASSY(U151E/U151F) AUTOMATIC ASSY(U241E/U140F) 09520-01010 Drive Shaft Remover Attachment FRONT DIFFERENTIAL SEAL(U151E) TRANSMISSION VALVE ASSY(U151E/U151F) AUTOMATIC ASSY(U151E/U151F) 09520-24010 Differential Side Gear Shaft Puller Shocker Set OIL BODY TRANSAXLE FRONT DIFFERENTIAL SEAL(U151F) OIL FRONT DIFFERENTIAL SEAL(U151E) TRANSMISSION VALVE OIL ASSY(U151E/U151F) AUTOMATIC ASSY(U151E/U151F) (09520-32040) TRANSAXLE BODY TRANSAXLE FRONT DIFFERENTIAL SEAL(U151F) OIL FRONT DIFFERENTIAL SEAL(U151E) TRANSMISSION VALVE OIL ASSY(U151E/U151F) AUTOMATIC ASSY(U151E/U151F) BODY TRANSAXLE FRONT DIFFERENTIAL SEAL(U151F) 09628-6201 1 Boll Joint Puller AUTOMATIC ASSY(U241E/U140F) 09649-17010 Steering Knuckle Tool FRONT DIFFERENTIAL SEAL(U151F) FRONT DIFFERENTIAL OIL TRANSAXLE OIL OIL SEAL(U241E) Front Suspension Arm Bushing Remover & Replacer FRONT DIFFERENTIAL SEAL(U140F) OIL Replacer FRONT DIFFERENTIAL SEAL(U140F) OIL 09930-00010 Drive Shaft Nut Chisel AUTOMATIC ASSY(U241E/U140F) 09950-70010 Handle Set FRONT DIFFERENTIAL SEAL(U140F) FRONT DIFFERENTIAL 09726-27012 (09726-02041) TRANSAXLE SEAL(U151E) FRONT DIFFERENTIAL SEAL(U151F) FRONT DIFFERENTIAL SEAL(U241E) OIL OIL OIL OIL 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 95 02-48 PREPARATION (09951-07150) - AUTOMATIC TRANSMISSION / TRANS Handle 150 FRONT DIFFERENTIAL SEAL(U151E) FRONT DIFFERENTIAL OIL OIL SEAL(U241E) (09951-07200) Handle 200 FRONT DIFFERENTIAL SEAL(U140F) FRONT DIFFERENTIAL OIL OIL SEAL(U151F) Recomended Tools 09011-12301 Socket Wrench 30 mm AUTOMATIC ASSY(U241E/U140F) 09040-0001 1 Hexagon Wrench Set TRANSMISSION WIRE(U151E/U151F) AUTOMATIC TRANSAXLE TRANSAXLE ASSY(U241E/U140F) TRANSMISSION VALVE ASSY(U241E/U140F) (09043-20060) Socket Hexagon Wrench 6 AUTOMATIC ASSY(U241E/U140F) (09043-20100) Socket Hexagon Wrench 10 FRONT DIFFERENTIAL SEAL(U140F) FRONT DIFFERENTIAL BODY TRANSAXLE OIL OIL SEAL(U151E) TRANSMISSION WIRE(U151E/U151F) FRONT DIFFERENTIAL SEAL(U151F) FRONT DIFFERENTIAL SEAL(U241E) AUTOMATIC ASSY(U241E/U140F) Socket Hexagon Wrench 10 OIL TRANSAXLE TRANSMISSION WIRE(U241E/U140F) TRANSMISSION VALVE ASSY(U241E/U140F) (09043-20100) OIL FRONT DIFFERENTIAL SEAL(U140F) FRONT DIFFERENTIAL BODY OIL OIL SEAL(U151E) TRANSMISSION WIRE(U151E/U151F) FRONT DIFFERENTIAL SEAL(U151F) FRONT DIFFERENTIAL SEAL(U241E) AUTOMATIC ASSY(U241E/U140F) OIL OIL TRANSAXLE TRANSMISSION WIRE(U241E/U140F) TRANSMISSION VALVE ASSY(U241E/U140F) BODY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 96 02-49 PREPARATION - AUTOMATIC TRANSMISSION / TRANS 09070-20010 Moulding Remover SHIFT LEVER ASSY(ATM) TRANSMISSION CONTROL CABLE ASSY(ATM) 09090-04020 Engine Sling Device FRONT DIFFERENTIAL SEAL(U140F) TRANSMISSION VALVE ASSY(U151E/U151F) AUTOMATIC ASSY(U151E/U151F) Socket Hexagon Wrench 6 AUTOMATIC ASSY(U241E/U140F) BODY TRANSAXLE FRONT DIFFERENTIAL SEAL(U151F) (09043-20060) OIL OIL TRANSAXLE SSM 08833-00070 ”Adhesive 1324,” THREE BOND 1324 or equivalent 08833-00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent Equipment Straight edge Torque converter Vernier calipers Torque converter Dial indicator or dial indicator with magnetic base Drive plate Punch Torque wrench Lubricant Item Capacity Classification U140F: Automatic transaxle fluid Dry fill w/ air cooled oil cooler w/o air cooled oil cooler Drain and refill 8.75 liters (9.2 US qts, 7.7 lmp.qts) 8.35 liters (8.8 US qts, 7.3 lmp.qts) 3.90 liters (4.1 US qts, 3.4 lmp.qts) U241E: Automatic transaxle fluid Dry fill w/ air cooled oil cooler w/o air cooled oil cooler Drain and refill 9.00 liters (9.5 US qts, 7.9 lmp.qts) 8.60 liters (9.1 US qts, 7.6 lmp.qts) 3.30 liters (3.5 US qts, 2.9 lmp.qts) U151E Automatic transaxle fluid Dry fill Drain and refill 8.8 liter (9.3 USqts, 7.7 lmp.qts) 3.5 liter (3.7 USqts, 3.1 lmp.qts) U151F Automatic transaxle fluid Dry fill Drain and refill 9.0 liter (9.5 USqts, 7.9 lmp.qts) 3.6 liter (3.8 USqts, 3.2 lmp.qts) ATF Type T-IV ATF Type T-IV ATF type T-IV ATF type T-IV 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 97 02-28 PREPARATION - DIFFERENTIAL DIFFERENTIAL 023GL-01 PREPARATION SST 09223-00010 Cover & Seal Replacer REAR DIFFERENTIAL CARRIER OIL SEAL(4WD) DIFFERENTIAL CARRIER ASSY REAR(4WD) 09308-00010 Oil Seal Puller REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL(4WD) DIFFERENTIAL CARRIER ASSY REAR(4WD) 09308-10010 Oil Seal Puller REAR DIFFERENTIAL CARRIER OIL SEAL(4WD) DIFFERENTIAL CARRIER ASSY REAR(4WD) 09316-12010 Transfer Bearing Replacer DIFFERENTIAL REAR(4WD) CARRIER ASSY 09325-20010 Transmission Oil Plug REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL(4WD) DIFFERENTIAL CARRIER ASSY REAR(4WD) 09330-00021 Companion Flange Holding Tool REAR DIFFERENTIAL CARRIER OIL SEAL(4WD) DIFFERENTIAL CARRIER ASSY REAR(4WD) 09370-50010 Drive Line Angle Gauge REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL(4WD) DIFFERENTIAL CARRIER ASSY REAR(4WD) 09504-2201 1 Differential Side Bearing Replacer DIFFERENTIAL REAR(4WD) CARRIER ASSY 09506-30012 Differential Drive Pinion Rear Bearing Cone Replacer DIFFERENTIAL REAR(4WD) CARRIER ASSY 09550-00032 Replacer REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL(4WD) DIFFERENTIAL CARRIER ASSY REAR(4WD) 09554-22010 Differential Oil Seal Replacer REAR DIFFERENTIAL CARRIER OIL SEAL(4WD) DIFFERENTIAL CARRIER ASSY REAR(4WD) 09556-22010 Drive Pinion Front Bearing Remover REAR DIFFERENTIAL CARRIER OIL SEAL(4WD) DIFFERENTIAL CARRIER ASSY REAR(4WD) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 76 02-29 PREPARATION - DIFFERENTIAL 09570-24010 Differential Mounting Cushion Remover & Replacer DIFFERENTIAL REAR(4WD) CARRIER ASSY 09636-20010 Upper Ball Joint Dust Cover Replacer DIFFERENTIAL REAR(4WD) CARRIER ASSY 09930-00010 Drive Shaft Nut Chisel REAR DIFFERENTIAL CARRIER OIL SEAL(4WD) REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL(4WD) DIFFERENTIAL CARRIER REAR(4WD) 09950-00020 Bearing Remover ASSY REAR DIFFERENTIAL CARRIER OIL SEAL(4WD) DIFFERENTIAL CARRIER ASSY REAR(4WD) 09950-30012 Puller A Set REAR DIFFERENTIAL CARRIER OIL SEAL(4WD) DIFFERENTIAL CARRIER ASSY REAR(4WD) (09951-03010) Upper Plate REAR DIFFERENTIAL CARRIER OIL SEAL(4WD) DIFFERENTIAL CARRIER ASSY REAR(4WD) (09953-03010) Center Bolt REAR DIFFERENTIAL CARRIER OIL SEAL(4WD) DIFFERENTIAL CARRIER ASSY REAR(4WD) (09954-03010) Arm REAR DIFFERENTIAL CARRIER OIL SEAL(4WD) DIFFERENTIAL CARRIER ASSY REAR(4WD) (09955-03030) Lower Plate 130 REAR DIFFERENTIAL CARRIER OIL SEAL(4WD) DIFFERENTIAL CARRIER ASSY REAR(4WD) (09956-03020) Adapter 18 REAR DIFFERENTIAL CARRIER OIL SEAL(4WD) DIFFERENTIAL CARRIER ASSY REAR(4WD) 09950-4001 1 Puller B Set DIFFERENTIAL REAR(4WD) CARRIER ASSY (09951-04020) Hanger 200 DIFFERENTIAL REAR(4WD) CARRIER ASSY (09952-04010) Slide Arm DIFFERENTIAL REAR(4WD) CARRIER ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 77 02-30 PREPARATION - DIFFERENTIAL (09953-04030) Center Bolt 200 DIFFERENTIAL REAR(4WD) CARRIER ASSY (09954-04010) Arm 25 DIFFERENTIAL REAR(4WD) CARRIER ASSY (09955-04061) Claw No.6 DIFFERENTIAL REAR(4WD) CARRIER ASSY (09957-04010) Attachment DIFFERENTIAL REAR(4WD) CARRIER ASSY (09958-0401 1) Holder DIFFERENTIAL REAR(4WD) CARRIER ASSY Replacer Set REAR DIFFERENTIAL CARRIER OIL SEAL(4WD) DIFFERENTIAL CARRIER ASSY 09950-60010 REAR(4WD) (09951-00360) Replacer 36 REAR DIFFERENTIAL CARRIER OIL SEAL(4WD) DIFFERENTIAL CARRIER ASSY REAR(4WD) Replacer 62 DIFFERENTIAL REAR(4WD) CARRIER ASSY Replacer Set No.2 DIFFERENTIAL REAR(4WD) CARRIER ASSY (09951-00710) Replacer 71 DIFFERENTIAL REAR(4WD) CARRIER ASSY 09950-70010 Handle Set REAR DIFFERENTIAL CARRIER OIL SEAL(4WD) REAR DIFFERENTIAL SIDE GEAR (09951-00620) 09950-60020 SHAFT SEAL OIL(4WD) DIFFERENTIAL CARRIER REAR(4WD) (09951-07150) Handle 150 ASSY REAR DIFFERENTIAL CARRIER OIL SEAL(4WD) DIFFERENTIAL CARRIER ASSY REAR(4WD) (09951-07200) Handle 200 REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL(4WD) DIFFERENTIAL CARRIER ASSY REAR(4WD) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 78 02-31 PREPARATION - DIFFERENTIAL Recomended Tools 09011-12301 Socket Wrench 30 mm REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL(4WD) DIFFERENTIAL CARRIER ASSY REAR(4WD) 09025-00010 Torque Wrench (30 kgf-cm) DIFFERENTIAL REAR(4WD) CARRIER 09040-0001 1 Hexagon Wrench Set REAR DIFFERENTIAL CARRIER OIL SEAL(4WD) REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL(4WD) DIFFERENTIAL CARRIER REAR(4WD) ASSY ASSY Equipment Dial indicator Torque wrench Alignment tester Toe-in gauge Deep socket wrench 24 mm Lubricant Item Differential oil Capacity Classification 0.90
0.05 liters (0.95
0.05 US qts, 0.75
0.04 lmp.qts) Hypoid gear oil API GL-5 Above -18
C (0
F) SAE 90 Below -18
C (0
F) SAE 80W or 80W-90 SSM 08826-00090 ”Seal Packing 1281,” THREE BOND 1281 or equivalent (FIPG) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 79 02-32 PREPARATION - DRIVE SHAFT / PROPELLER SHAFT DRIVE SHAFT / PROPELLER SHAFT 023GF-01 PREPARATION SST 09240-00020 Wire Gauge Set FRONT DRIVE SHAFT REAR DRIVE SHAFT(4WD) 09316-6001 1 Transmission & Transfer Bearing Replacer FRONT AXLE HUB SUB-ASSY LH (09316-0001 1) Replacer Pipe FRONT AXLE HUB SUB-ASSY LH (09316-00031) Replacer ”B” FRONT AXLE HUB SUB-ASSY LH 09325-20010 Transmission Oil Plug PROPELLER W/CENTER BEARING SHAFT ASSY(4WD) 09330-00021 Companion Flange Holding Tool PROPELLER W/CENTER BEARING SHAFT ASSY(4WD) 09370-50010 Drive Line Angle Gauge PROPELLER W/CENTER BEARING SHAFT ASSY(4WD) 09520-00031 Rear Axle Shaft Puller FRONT AXLE HUB SUB-ASSY LH 09520-01010 Drive Shaft Remover Attachment FRONT DRIVE SHAFT 09520-24010 Differential Side Gear Shaft Puller FRONT DRIVE SHAFT Shocker Set FRONT DRIVE SHAFT Rear Axle Shaft Puller FRONT DRIVE SHAFT REAR DRIVE SHAFT(4WD) (09520-32040) 09521-24010 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 80 02-33 PREPARATION - DRIVE SHAFT / PROPELLER SHAFT 09527-1001 1 Rear Axle Shaft Bearing Remover FRONT DRIVE SHAFT 09527-1701 1 Rear Axle Shaft Bearing Remover FRONT AXLE HUB SUB-ASSY LH 09527-2101 1 Rear Axle Shaft Bearing Remover REAR DRIVE SHAFT(4WD) 09608-16042 Front Hub Bearing Adjusting Tool FRONT DRIVE SHAFT (09608-02021) Bolt & Nut FRONT DRIVE SHAFT (09608-02041) Retainer FRONT DRIVE SHAFT 09608-32010 Steering Knuckle Oil Seal Replacer FRONT AXLE HUB SUB-ASSY LH 09628-1001 1 Ball Joint Puller FRONT AXLE LH HUB BOLT REAR AXLE LH HUB BOLT 09628-6201 1 Boll Joint Puller FRONT AXLE HUB SUB-ASSY LH FRONT DRIVE SHAFT 09710-04081 Base FRONT DRIVE SHAFT 09710-30021 Suspension Bushing Tool Set FRONT DRIVE SHAFT Bushing Remover Base FRONT DRIVE SHAFT Lower Control Shaft Bearing Replacer FRONT DRIVE SHAFT (09710-03141) 09726-40010 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 81 02-34 PREPARATION 09930-00010 - DRIVE SHAFT / PROPELLER SHAFT Drive Shaft Nut Chisel FRONT AXLE HUB SUB-ASSY LH FRONT DRIVE SHAFT REAR DRIVE SHAFT(4WD) REAR AXLE CARRIER SUB-ASSY LH(4WD) REAR AXLE HUB & BEARING ASSY LH(4WD) 09950-00020 Bearing Remover FRONT AXLE HUB SUB-ASSY LH FRONT DRIVE SHAFT REAR DRIVE SHAFT(4WD) 09950-4001 1 Puller B Set PROPELLER W/CENTER BEARING SHAFT ASSY(4WD) (09951-04020) Hanger 200 PROPELLER W/CENTER BEARING SHAFT ASSY(4WD) (09952-04010) Slide Arm PROPELLER W/CENTER BEARING SHAFT ASSY(4WD) (09953-04030) Center Bolt 200 PROPELLER W/CENTER BEARING SHAFT ASSY(4WD) (09954-04010) Arm 25 PROPELLER W/CENTER BEARING SHAFT ASSY(4WD) (09955-04061) Claw No.6 PROPELLER W/CENTER BEARING SHAFT ASSY(4WD) (09957-04010) Attachment PROPELLER W/CENTER BEARING SHAFT ASSY(4WD) (09958-0401 1) Holder PROPELLER W/CENTER BEARING SHAFT ASSY(4WD) 09950-60010 Replacer Set FRONT AXLE HUB SUB-ASSY LH (09951-00430) Replacer 43 FRONT AXLE HUB SUB-ASSY LH Replacer Set No.2 FRONT AXLE HUB SUB-ASSY LH FRONT DRIVE SHAFT 09950-60020 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 82 02-35 PREPARATION - DRIVE SHAFT / PROPELLER SHAFT (09951-00710) Replacer 71 FRONT DRIVE SHAFT (09951-00750) Replacer 75 FRONT AXLE HUB SUB-ASSY LH (09951-00810) Replacer 81 FRONT AXLE HUB SUB-ASSY LH 09950-70010 Handle Set FRONT AXLE HUB SUB-ASSY LH FRONT DRIVE SHAFT (09951-07100) Handle 100 FRONT AXLE HUB SUB-ASSY LH FRONT DRIVE SHAFT Socket Wrench 30 mm FRONT AXLE HUB SUB-ASSY LH FRONT DRIVE SHAFT REAR DRIVE SHAFT(4WD) Recomended Tools 09011-12301 REAR AXLE CARRIER SUB-ASSY LH(4WD) REAR AXLE HUB & BEARING ASSY LH(4WD) 09040-0001 1 Hexagon Wrench Set FRONT DRIVE SHAFT PROPELLER W/CENTER BEARING SHAFT ASSY(4WD) 09042-00010 Torx Socket T30 FRONT AXLE HUB SUB-ASSY LH Socket Hexagon Wrench 6 FRONT DRIVE SHAFT PROPELLER W/CENTER BEARING SHAFT ASSY(4WD) Expander Set REAR DRIVE SHAFT(4WD) No. 4 Claw REAR DRIVE SHAFT(4WD) Snap Ring No.1 Expander FRONT DRIVE SHAFT (09043-20060) 09904-00010 (09904-00050) 09905-00012 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 83 02-36 PREPARATION 09905-00013 - DRIVE SHAFT / PROPELLER SHAFT Snap Ring Pliers FRONT AXLE HUB SUB-ASSY LH Equipment Torque wrench Dial gauge with magnetic base Dial indicator Alighment tester Toe-in gauge Lubricant Item Front drive shaft 3MZ-FE (FF) Except 3MZ-FE (FF) Capacity Outboard joint grease Inboard joint grease Outboard joint grease Inboard joint grease 205 to 225 g (7.2 to 8.0 oz.) 155 to 175 g (5.5 to 6.2 oz.) 190 to 200 g (6.7 to 7.0 oz.) 175 to 155 g (6.2 to 6.5 oz.) Outboard joint grease Inboard joint grease 95 to 105 g (3.4 to 3.7 oz.) 125.5 to 135.5 g (4.4 to 4.7 oz.) Rear drive shaft 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 84 02-69 PREPARATION - SLIDING ROOF/CONVERTIBLE SLIDING ROOF/CONVERTIBLE 020XS-03 PREPARATION Equipment Torque wrench 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 117 02-62 PREPARATION - WIPER & WASHER WIPER & WASHER 023HE-01 PREPARATION SST 09843-18040 Diagnosis Check Wire No.2 WIPER AND WASHER SYSTEM 09042-00010 Torx Socket T30 WINDSHIELD WIPER MOTOR ASSY 09082-00040 TOYOTA Electrical Tester WIPER AND WASHER SYSTEM Test Lead Set WIPER AND WASHER SYSTEM Recomended Tools (09083-00150) Equipment Voltmeter Torque wrench 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 110 02-43 PREPARATION - BRAKE BRAKE 023GV-03 PREPARATION SST 09023-00101 Union Nut Wrench 10 mm BRAKE FLUID BRAKE MASTER CYLINDER SUB-ASSY W/PLATE BRAKE BOOSTER ASSY FRONT BRAKE REAR BRAKE BRAKE ACTUATOR ASSY 09214-7601 1 Crankshaft Pulley Replacer SKID CONTROL SENSOR(FF) 09520-00031 Rear Axle Shaft Puller SKID CONTROL SENSOR(FF) Shocker SKID CONTROL SENSOR(FF) 09521-00020 Drive Shaft Boot Clamping Tool SKID CONTROL SENSOR(FF) 09737-00020 Brake Booster Push Rod Wrench BRAKE MASTER CYLINDER SUB-ASSY BRAKE BOOSTER ASSY 09950-00020 Bearing Remover SKID CONTROL SENSOR(FF) 09950-50013 Puller C Set STEERING SENSOR (09951-05010) Hanger 150 STEERING SENSOR (09952-05010) Slide Arm STEERING SENSOR (09953-05020) Center Bolt 150 STEERING SENSOR (09954-05021) Claw No.2 STEERING SENSOR (09520-00040) W/PLATE 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 91 02-44 PREPARATION - BRAKE Recomended Tools 09042-00010 Torx Socket T30 STEERING SENSOR 09070-20010 Moulding Remover BRAKE PEDAL SUB-ASSY Torx is a registered trademark of Textron Inc. Equipment Dial indicator with magnetic base Micrometer Torque wrench Slide calipers Lubricant Item Capacity Classification Brake fluid - SAE J1703 or FMVSS No. 116 DOT3 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 92 02-64 PREPARATION - COMMUNICATION SYSTEM COMMUNICATION SYSTEM 020XP-03 PREPARATION Recomended Tools 09082-00040 (09083-00150) TOYOTA Electrical Tester HORN SYSTEM Test Lead Set HORN SYSTEM 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 112 02-61 PREPARATION - LIGHTING LIGHTING 023HD-01 PREPARATION Recomended Tools TOYOTA Electrical Tester LIGHTING SYSTEM (09083-00150) Test Lead Set LIGHTING SYSTEM (09083-00150) Test Lead Set LIGHTING SYSTEM 09082-00040 Equipment Voltmeter Ohmmeter Torque wrench LICENCE PLATE LAMP ASSY Sandpaper (#400) HEADLAMP UNIT LH 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 109 02-58 PREPARATION - SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM 023H4-02 PREPARATION SST 09082-00700 SRS Airbag Deployment Tool HORN BUTTON ASSY FRONT PASSENGER AIRBAG ASSY CURTAIN SHIELD AIR BAG ASSY LH FRONT SEAT AIRBAG ASSY LH 09082-00750 Airbag Deployment Wire Sub-harness No.3 FRONT SEAT AIRBAG ASSY LH 09082-00780 Airbag Deployment Wire Sub-harness No.6 HORN BUTTON ASSY FRONT PASSENGER AIRBAG ASSY 09082-00802 Airbag Deployment Wire Sub-Harness No. 8 HORN BUTTON ASSY CURTAIN SHIELD AIR BAG ASSY LH (09082-10801) Wire A HORN BUTTON ASSY CURTAIN SHIELD AIR BAG ASSY LH (09082-20801) Wire B CURTAIN SHIELD AIR BAG ASSY LH (09082-30801) Wire C HORN BUTTON ASSY 09950-50013 Puller C Set SPIRAL CABLE SUB-ASSY (09951-05010) Hanger 150 SPIRAL CABLE SUB-ASSY (09952-05010) Slide Arm SPIRAL CABLE SUB-ASSY (09953-05020) Center Bolt 150 SPIRAL CABLE SUB-ASSY (09954-05021) Claw No.2 SPIRAL CABLE SUB-ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 106 02-59 PREPARATION - SUPPLEMENTAL RESTRAINT SYSTEM Recomended Tools 09042-00010 Torx Socket T30 HORN BUTTON ASSY SPIRAL CABLE SUB-ASSY SEAT POSITION AIR BAG SENSOR Torx is a registered trademark of Textron Inc. Equipment Torque wrench Feeler gauge Bolt Length: 35.0 mm (1.378 in.) Pitch: 1.0 mm (0.039 in.) Diameter: 6.0 mm (0.236 in.) Airbag disposal Tire Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) Airbag disposal Tire with disc wheel Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) Airbag disposal Plastic bag Airbag disposal 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 107 02-27 PREPARATION - TIRE & WHEEL TIRE & WHEEL 020XE-01 PREPARATION Equipment Tire pressure gauge Dial indicator with magnetic base Wheel balancer 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 75 02-24 PREPARATION - FRONT SUSPENSION FRONT SUSPENSION 023DS-03 PREPARATION SST 09023-12701 Union Nut Wrench 17 mm STABILIZER BAR FRONT(4WD) STABILIZER BAR FRONT(FF) 09628-6201 1 Boll Joint Puller LOWER BALL JOINT ASSY FRONT LH STABILIZER BAR FRONT(4WD) STABILIZER BAR FRONT(FF) Coil Spring Compressor SHOCK ABSORBER ASSY FRONT LH (09727-00010) Bolt Set SHOCK ABSORBER ASSY FRONT LH (09727-00021) Arm Set SHOCK ABSORBER ASSY FRONT LH 09930-00010 Drive Shaft Nut Chisel LOWER BALL JOINT ASSY FRONT LH 09011-12301 Socket Wrench 30 mm LOWER BALL JOINT ASSY FRONT LH 09040-0001 1 Hexagon Wrench Set SHOCK ABSORBER ASSY FRONT LH STABILIZER BAR FRONT(4WD) 09727-30021 Recomended Tools STABILIZER BAR FRONT(FF) (09043-20060) Socket Hexagon Wrench 6 SHOCK ABSORBER ASSY FRONT LH STABILIZER BAR FRONT(4WD) STABILIZER BAR FRONT(FF) (09043-20060) Socket Hexagon Wrench 6 SHOCK ABSORBER ASSY FRONT LH STABILIZER BAR FRONT(4WD) STABILIZER BAR FRONT(FF) 09044-00020 Torx Socket E10 PNEUMATIC FRONT LH W/SHOCK ABSORBER CYLINDER ASSY Torx is a registered trademark of Textron Inc. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 72 02-25 PREPARATION - FRONT SUSPENSION Equipment Torque wrench Dial indicator with magnetic base Drill (Safety equipment: protective goggles, etc.) Shock absorber disposal Tire pressure gauge Alignment tester Toe-in gauge Angle gauge Slide Calipers 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 73 02-26 PREPARATION - REAR SUSPENSION REAR SUSPENSION 023HG-01 PREPARATION SST 09325-20010 Transmission Oil Plug REAR SUSPENSION ARM ASSY NO.1 LH(4WD) 09727-30021 Coil Spring Compressor REAR SHOCK ABSORBER WITH COIL SPRING (09727-00010) Bolt Set REAR SHOCK ABSORBER WITH COIL SPRING (09727-00021) Arm Set REAR SHOCK ABSORBER WITH COIL SPRING (09727-00031) Compressor REAR SHOCK ABSORBER WITH COIL SPRING Hexagon Wrench Set REAR SHOCK ABSORBER WITH COIL SPRING STABILIZER BAR REAR(4WD) Recomended Tools 09040-0001 1 REAR SUSPENSION ARM ASSY NO.1 LH(FF) STABILIZER BAR REAR(FF) (09043-20050) Socket Hexagon Wrench 5 REAR SHOCK ABSORBER WITH COIL SPRING STABILIZER BAR REAR(4WD) REAR SUSPENSION ARM ASSY NO.1 LH(FF) STABILIZER BAR REAR(FF) 09070-20010 Moulding Remover REAR SHOCK ABSORBER WITH COIL SPRING Equipment Torque wrench Dial indicator with magnetic base Slide calipers Wheel balancer Tire pressure gauge Alignment tester Toe-in gauge Camber-caster-kingpin gauge Drill (Safety equipment: protective goggles, etc.) Shock absorber disposal 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 74 02-45 PREPARATION - PARKING BRAKE PARKING BRAKE 023CK-01 PREPARATION SST 09930-00010 Drive Shaft Nut Chisel PARKING BRAKE CABLE ASSY NO.3 PARKING BRAKE ASSY 09011-12301 Socket Wrench 30 mm PARKING BRAKE CABLE ASSY NO.3 PARKING BRAKE ASSY 09070-20010 Moulding Remover PARKING BRAKE CONTROL PEDAL ASSY PARKING BRAKE CABLE ASSY NO.1 Recomended Tools Equipment Torque wrench Slide calipers Dial indicator Brake drum gauge Feeler gauge 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 93 02-72 PREPARATION - VEHICLE CONTROL SYSTEM VEHICLE CONTROL SYSTEM 021SF-02 PREPARATION Recomended Tools 09082-00040 TOYOTA Electrical Tester IGNITION SWITH 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 120 02-68 PREPARATION - THEFT DETERRENT & DOOR LOCK THEFT DETERRENT & DOOR LOCK 020XH-04 PREPARATION Recommended tools 09082-00040 TOYOTA Electrical Tester. Power Door Lock System Transmitter Battery Door Control Transmitter 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 116 02-50 PREPARATION - STEERING COLUMN STEERING COLUMN 020WQ-02 PREPARATION SST 09608-06041 Front Hub Inner Bearing Cone Replacer STEERING COLUMN ASSY 09950-50013 Puller C Set STEERING COLUMN ASSY (09951-05010) Hanger 150 STEERING COLUMN ASSY (09952-05010) Slide Arm STEERING COLUMN ASSY (09953-05020) Center Bolt 150 STEERING COLUMN ASSY (09954-05021) Claw No.2 STEERING COLUMN ASSY 09042-00010 Torx Socket T30 STEERING COLUMN ASSY 09904-00010 Expander Set STEERING COLUMN ASSY No. 1 Claw STEERING COLUMN ASSY Recomended Tools (09904-00020) EQUIPMENT Torque wrench 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 98 02-51 PREPARATION - POWER STEERING POWER STEERING 023GW-02 PREPARATION SST 09023-12701 Union Nut Wrench 17 mm POWER STEERING LINK ASSY 09023-38201 Union Nut Wrench 12mm POWER STEERING LINK ASSY 09249-63010 Torque Wrench Adaptor VANE PUMP ASSY(2AZ-FE) 09521-24010 Rear Axle Shaft Puller POWER STEERING LINK ASSY 09527-2101 1 Rear Axle Shaft Bearing Remover POWER STEERING LINK ASSY 09612-00012 Rack & Pinion Steering Rack Housing Stand POWER STEERING LINK ASSY 09612-2201 1 Tilt Handle Bearing Replacer POWER STEERING LINK ASSY 09612-24014 Steering Gear Housing Overhaul Tool Set POWER STEERING LINK ASSY Steering Rack Shaft Bushing Puller POWER STEERING LINK ASSY 09616-0001 1 Steering Worm Bearing Adjusting Socket POWER STEERING LINK ASSY 09628-6201 1 Boll Joint Puller POWER STEERING LINK ASSY 09630-00014 Power Steering Gear Housing Overhaul Tool Set VANE PUMP ASSY(2AZ-FE) (09613-2201 1) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 99 02-52 PREPARATION - POWER STEERING Vane Pump Bracket VANE PUMP ASSY(2AZ-FE) 09631-10021 Rack Stopper Wrench POWER STEERING LINK ASSY 09631-12071 Steering Rack Oil Seal Test Tool POWER STEERING LINK ASSY Packing POWER STEERING LINK ASSY 09631-20081 Seal Ring Tool POWER STEERING LINK ASSY 09631-33010 Steering Rack Cover ”I” POWER STEERING LINK ASSY 09922-10010 Variable Open Wrench POWER STEERING LINK ASSY 09950-60010 Replacer Set POWER STEERING LINK ASSY VANE PUMP ASSY(2AZ-FE) VANE PUMP ASSY(3MZ-FE) (09951-00180) Replacer 18 POWER STEERING LINK ASSY (09951-00250) Replacer 25 POWER STEERING LINK ASSY (09951-00280) Replacer 28 VANE PUMP ASSY(2AZ-FE) (09951-00290) Replacer 29 POWER STEERING LINK ASSY (09951-00320) Replacer 32 POWER STEERING LINK ASSY (09631-00132) (09633-00010) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 100 02-53 PREPARATION - POWER STEERING (09951-00330) Replacer 33 VANE PUMP ASSY(3MZ-FE) (09951-00340) Replacer 34 POWER STEERING LINK ASSY (09951-00400) Replacer 40 POWER STEERING LINK ASSY (09951-00450) Replacer 45 POWER STEERING LINK ASSY (09952-06010) Adapter POWER STEERING LINK ASSY 09950-70010 Handle Set POWER STEERING LINK ASSY VANE PUMP ASSY(2AZ-FE) VANE PUMP ASSY(3MZ-FE) (09951-07100) Handle 100 POWER STEERING LINK ASSY VANE PUMP ASSY(2AZ-FE) VANE PUMP ASSY(3MZ-FE) (09951-07150) Handle 150 POWER STEERING LINK ASSY (09951-07360) Handle 360 POWER STEERING LINK ASSY Variable Pin Wrench Set VANE PUMP ASSY(3MZ-FE) (09962-01000) Variable Pin Wrench Arm Assy VANE PUMP ASSY(3MZ-FE) (09963-01000) Pin 10 VANE PUMP ASSY(3MZ-FE) 09960-10010 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 101 02-54 PREPARATION - POWER STEERING Recomended Tools 09025-00010 Torque Wrench (30 kgf-cm) POWER STEERING LINK ASSY VANE PUMP ASSY(2AZ-FE) 09040-0001 1 Hexagon Wrench Set POWER STEERING LINK ASSY (09043-20060) Socket Hexagon Wrench 6 POWER STEERING LINK ASSY 09905-00012 Snap Ring No.1 Expander VANE PUMP ASSY(2AZ-FE) VANE PUMP ASSY(3MZ-FE) Equipment Caliper gauge Belt tension gauge Vernier calipers Dial indicator Feeler gauge Micrometer Torque wrench Lubricant Item Power steering fluid (Total) Capacity Classification 1.0 liters (1.1 US qts, 0.9 lmp.qts) ATF DEXRON® II or III SSM 08833-00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent RACK & PINION POWER STEERING GEAR ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 102 02-73 PREPARATION - CRUISE CONTROL CRUISE CONTROL 023FD-02 PREPARATION Recomended Tools 09042-00010 Torx Socket T30 CRUISE CONTROL MAIN SWITCH Torx is a registered trademark of Textron Inc. Equipment Torque wrench 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 121 02-6 PREPARATION - INTAKE INTAKE 023H7-01 PREPARATION Equipment Hand-held vacuum pump Ohmmeter Torque wrench 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 54 03-1 SERVICE SPECIFICATIONS - STANDARD BOLT STANDARD BOLT 0305S-04 HOW TO DETERMINE BOLT STRENGTH Bolt Type Hexagon Head Bolt Normal Recess Bolt Deep Recess Bolt Stud Bolt Weld Bolt 4 Class 4T No Mark No Mark No Mark 5 5T 6 6T w/ Washer w/ Washer 7 7T 8 8T 9 9T 10 10T 11 11T B06431 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 122 03-3 SERVICE SPECIFICATIONS - STANDARD BOLT 0305U-04 HOW TO DETERMINE NUT STRENGTH Nut Type Present Standard Hexagon Nut Old Standard Hexagon Nut Cold Forging Nut Class Cutting Processed Nut 4N No Mark 5N (4T) No Mark (w/ Washer) No Mark (w/ Washer) No Mark 6N 6N 7N (5T) * 8N 8N 10N (7T) 10N No Mark 11N 11N 12N 12N *: Nut with 1 or more marks on one side surface of the nut. B06432 HINT: Use the nut with the same number of the nut strength classification or the greater than the bolt strength classification number when tightening parts with a bolt and nut. Example: Bolt = 4T Nut = 4N or more 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 124 03-2 SERVICE SPECIFICATIONS - STANDARD BOLT 0305T-04 SPECIFIED TORQUE FOR STANDARD BOLTS Specified torque Class Diameter mm Pitch mm Hexagon head bolt Hexagon flange bolt N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf 4T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 5 12.5 26 47 74 115 55 130 260 480 760 1,150 48 in.·lbf 9 19 35 55 83 6 14 29 53 84 - 60 145 290 540 850 - 52 in.·lbf 10 21 39 61 - 5T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 6.5 15.5 32 59 91 140 65 160 330 600 930 1,400 56 in.·lbf 12 24 43 67 101 7.5 17.5 36 65 100 - 75 175 360 670 1,050 - 65 in.·lbf 13 26 48 76 - 6T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 8 19 39 71 110 170 80 195 400 730 1,100 1,750 69 in.·lbf 14 29 53 80 127 9 21 44 80 125 - 90 210 440 810 1,250 - 78 in.·lbf 15 32 59 90 - 7T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 10.5 25 52 95 145 230 110 260 530 970 1,500 2,300 8 19 38 70 108 166 12 28 58 105 165 - 120 290 590 1,050 1,700 - 9 21 43 76 123 - 8T 8 10 12 1.25 1.25 1.25 29 61 110 300 620 1,100 22 45 80 33 68 120 330 690 1,250 24 50 90 9T 8 10 12 1.25 1.25 1.25 34 70 125 340 710 1,300 25 51 94 37 78 140 380 790 1,450 27 57 105 10T 8 10 12 1.25 1.25 1.25 38 78 140 390 800 1,450 28 58 105 42 88 155 430 890 1,600 31 64 116 11T 8 10 12 1.25 1.25 1.25 42 87 155 430 890 1,600 31 64 116 47 97 175 480 990 1,800 35 72 130 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 123 03-34 SERVICE SPECIFICATIONS - FRONT SUSPENSION FRONT SUSPENSION 03052-03 SERVICE DATA Vehicle height FF Front: A Rear: D Front: A Rear: D - 4WD Toe-in (total) Wheel angle FF 4WD Front wheel al alignmwnt B: C: B: C: 120.1 mm (4.73 in.) 40.5 mm (1.59 in.) 110.1 mm (4.33 in.) 30.5 mm (1.20 in.) 0

10’ (0

0.16
, 0
2 mm, 0
0.08 in.) Rack end length difference 1.5 mm (0.059 in.) or less Inside wheel: Outside wheel: Reference: Inside wheel: Outside wheel: Reference: 35°28’ ± 2° (35.47° ± 2°) 31°13’ (31.22°) 35°41’ ± 2° (35.68° ± 2°) 31°22’ (31.37°) Camber FF: 4WD: Right-left error -0 °40’ ± 45’ (-0.67° ± 0.75°) -0 °35’ ± 45’ (-0.58° ± 0.75°) 45’ (0.75°) or less 2°45’ ± 45’ (2.75° ± 0.75°) Caster Right-left error 45’ (0.75°) or less Steering axis inclination FF: 4WD: Right-left error Front suspension 10°45’ ± 45’ (10.75° ± 0.75°) 10°35’ ± 45’ (10.58° ± 0.75°) 45’ (0.75°) or less Lower ball joint turning torque 0.98 to 3.43 N·m (10 to 35 kgf·cm, 8.7 to 30 in.·lbf) Stabilizer bar link ball joint turning torque 0.05 to 1.96 N·m (0.5 to 20 kgf·cm, 0.4 to 17.4 in.·lbf) A: Ground clearance of front wheel center B: Ground clearance of lower suspension arm No. 2 set bolt center C: Ground clearance of strut rod set bolt center D: Ground clearance of rear wheel center 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 155 03-35 SERVICE SPECIFICATIONS - FRONT SUSPENSION 03053-03 TORQUE SPECIFICATION Part Tightened N⋅m kgf⋅cm ft⋅lbf Hub nut 103 1,050 76 Tie rod end lock nut 74 755 55 Steering knuckle x Shock absorber 230 2,350 170 Lower ball joint x Lower suspension arm 127 1,300 94 Suspension support x Body 80 816 59 Suspension support x Piston rod 49 500 36 Flexible hose and ABS speed sensor wire harness bracket x Shock absorber 19 194 14 Lower suspension arm set bolt 200 206 2,040 2,100 148 152 Transverse engine engine mounting insulator set nut 87 887 64 Stabilizer bar bracket x Suspension member 16 163 12 Stabilizer bar link set nut 74 755 55 Front axle assy x Front brake caliper assy 104 1060 77 Lower ball joint assy front set nut 123 1250 91 Front side: Rear side: 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 156 03-38 SERVICE SPECIFICATIONS - TIRE & WHEEL TIRE & WHEEL 03050-02 SERVICE DATA Tire size: P225/70R16 101S Front, Rear 210 kPa (2.1 kgf/cm2, 30 psi) Tire runout 1.4 mm (0.055 in.) or less Imbalance after adjustment 8.0 g (0.018 lb) or less 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 159 03-49 SERVICE SPECIFICATIONS - PARKING BRAKE PARKING BRAKE 0305C-02 SERVICE DATA Parking brake pedal travel at 300 N (31 kgf, 67.46 lbf): 5 to 7 clicks Rear brake disc inside diameter Standard 190 mm (7.480 in.) Maximum 191 mm (7.520 in.) Parking brake shoe lining thickness Standard 2.5 mm (0.098 in.) Maximum 1.0 mm (0.039 in.) Parking brake shoe clearance between rear shoe and lever Less than 0.35 mm (0.014 in.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 170 03-50 SERVICE SPECIFICATIONS - PARKING BRAKE 0305D-02 TORQUE SPECIFICATION Part Tightened Wheel nut N⋅m kgf⋅cm ft⋅lbf 103 1,050 76 Parking brake cable lock nut 6 61 53 in.⋅lbf Parking brake control pedal set bolt 39 400 29 Parking brake cable assy No.1 x Body Bolt nut 8.5 6 87 61 75 in.⋅lbf 53 in.⋅lbf Parking brake cable assy No.3 x Body Bolt A Bolt B nut 8.5 39 6 87 400 61 75 in.⋅lbf 29 53 in.⋅lbf 8 82 71 in.⋅lbf Parking brake cable No.3 x Backing plate 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 171 03-55 SERVICE SPECIFICATIONS - STEERING COLUMN STEERING COLUMN 0304Y-03 SERVICE DATA Steering wheel freeplay Steering main shaft length Maximum 30 mm (1.18 in.) Standard length 504.5
1 mm (19.862
0.039 in.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 176 03-56 SERVICE SPECIFICATIONS - STEERING COLUMN 0304Z-04 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Universal joint assy x Main shaft assy 35 360 26 Steering column assembly set bolt and nut 21 210 15 Intermediate shaft sub-assy x Universal joint assembly 35 360 26 Intermediate shaft sub-assy x Control valve shaft 35 360 26 Steering wheel set nut 50 510 37 Steering wheel pad set screw (Torx screw) 8.8 90 78 in.·lbf 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 177 03-57 SERVICE SPECIFICATIONS - POWER STEERING POWER STEERING 0304W-05 SERVICE DATA POWER STEERING FLUID Fluid level rise Fluid pressure at idle speed with valve closed Maximum 5 mm (0.20 in.) 7,800 to 8,300 kPa (80 to 85 kgf/cm2, 1,131 to 1,204 psi) STEERING WHEEL Steering effort at idle speed (Reference) 6.0 N·m (60 kgf·cm, 53 in.·lbf) VANE PUMP ASSY (2AZ-FE) Vane pump rotating torque Vane pump shaft and vane pump housing bush clearance Vane plate thickness Vane plate and vane rotor groove clearance Spring free length 0.27 N⋅m (2.8 kgf⋅cm, 2.4 in.⋅lbf) or less Maximum 0.07 mm (0.0028 in.) Minimum 1.405 to 1.411 mm (0.05531 to 0.05555 in.) Maximum 0.03 mm (0.0012 in.) Minimum 30.3 mm (1.193 in.) VANE PUMP ASSY (3MZ-FE) Vane pump rotating torque Vane pump shaft and vane pump housing oil clearance Vane plate thickness Clearance between the rotor groove and plate Spring free length 0.27 N·m (2.8 kgf·cm, 2.4 in.·lbf) or less STD 0.027 to 0.054 mm (0.00106 to 0.00213 in.) Maximum 0.07 mm (0.0028 in.) Minimum 1.397 to 1.403 mm (0.0550 to 0.0552 in.) Maximum 0.03 mm (0.0012 in.) Minimum 32.24 mm (1.2693 in.) POWER STEERING LINK ASSY Steering rack runout Maximum 0.3 mm (0.0118 in.) Tie rod assy stad bolt torque (Turning) 0.49 to 3.43 N·m (5.0 to 35.0 kgf·cm, 4.3 to 30.4 in.·lbf) Total preload (Control valve rotating torque) (Turning) 1.2 to 1.5 N·m (12.2 to 15.3 kgf·cm, 10.6 to 13.3 in.·lbf) Rack boot clamp clearance 3.0 mm (0.118 in.) or less 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 178 03-58 SERVICE SPECIFICATIONS - POWER STEERING 0304X-05 TORQUE SPECIFICATION Part tightened N⋅m kgf⋅cm ft⋅lbf Housing rear x Housing front 22 224 16 Oil pressure switch 21 214 15 Pressure port union 69 704 51 Suction port union set bolt 12 122 9 37 (26) 264 (377) 19 (27) 52 525 38 Pump bracket front x Housing front 43 438 32 Housing rear x Housing front 24 245 18 VANE PUMP ASSY (2AZ-FE) Pump assy set bolt Pressure feed tube assy set union bolt VANE PUMP ASSY (3MZ-FE) Pump bracket rear x Housing rear 43 438 32 Pressure port union 83 846 61 Suction port union set bolt 13 133 10 Vane pump pulley set nut 44 449 32 Pump assy set bolt 43 440 32 Pressure feed tube assy set union bolt 52 525 38 Oil pressure switch 21 214 15 Control valve housing set bolt 21 214 15 Control valve shaft lock nut 25 250 18 Rack housing cap 59 597 43 Rack guide spring cap lock nut 51 (69) 515 (699) 38 (51) Rack x Rack end sub-assy 60 (84) 616 (851) 45 (62) 74 750 54 11 (13) 116 (127) 8 (9) 70 714 52 Pressure feed tube assy union nut 22 (25) 230 (250) 16 (18) POWER STEERING LINK ASSY Tie rod assy lock nut Turn pressure tube union nut Steering link assy set bolt Pressure feed tube clamp set bolt 9.8 100 87 in.⋅lbf Return tube clamp set nut 9.8 100 87 in.⋅lbf Stabilizer bracket No.1 x Suspension crossmember 16 163 12 Intermediate shaft assy x Steering link assy 35 360 26 ( ): For use without SST 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 179 03-61 SERVICE SPECIFICATIONS - SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM 0305F-03 TORQUE SPECIFICATION N⋅m kgf⋅cm ft⋅lbf Horn button assy x Steering wheel assy Part Tightened 8.8 90 78 in.⋅lbf Steering wheel assy x Steering column assy 50 510 37 Front passenger airbag assy x Instrument panel reinforcement 20 204 15 Front passenger airbag assy x Instrument panel sub-assy 5.6 57 49 in. lbf Curtain shield airbag assy x Body 14 143 10 Airbag sensor assy center x Body 17.5 179 13 Airbag front sensor x Body 9.0 92 80 in.⋅lbf Side airbag sensor assy x Body 17.5 179 13 Front seat outer belt assy x Body 7.5 75 67 in. lbf Airbag sensor rear x Body 17.5 179 13 Seat position airbag sensor x Front LH seat assy 8.0 82 71 in.⋅lbf Front LH seat assy x Body 36.7 374 27 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 182 03-4 SERVICE SPECIFICATIONS - ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM 03048-02 SERVICE DATA 2AZ-FE: Throttle body Standard throttle valve opening percentage 60% or more Accelerator pedal position sensor Intake air flow meter assy Resistance Camshaft timing oil control valve assy Resistance Throttle body assy Resistance E.F.I. engine coolant temperature sensor Resistance Knock sensor Resistance Standard voltage 0.6 to 1.0 V 4 (THA) - 5 (E2) at -20
C (-4
F) at 20
C (68
F) at 60
C (140
F) 13.6 to 18.4 kΩ 2.21 to 2.69 kΩ 0.493 to 0.667 kΩ at 20
C (68
F) 6.9 to 7.9 Ω at 20
C (68
F) 2 (M+) - 1 (M-) 0.3 to 100 kΩ Approx. 20
C (68
F) Approx. 80
C (176
F) at 20
C (68
F) EFI relay Specified condition C/OPN relay Specified condition 2.32 to 2.59 kΩ 0.310 to 0.326 kΩ 120 to 280 kΩ 3-5 3-5 10 kΩ or higher Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 3-5 3-5 10 kΩ or higher Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 3MZ-FE: Throttle body Standard throttle valve opening percentage 60% or more Accelerator pedal position sensor Intake air flow meter assy Resistance Camshaft timing oil control valve assy Resistance Throttle body assy Resistance E.F.I. engine coolant temperature sensor Resistance Knock sensor Resistance EFI relay Specified condition C/OPN relay Specified condition Standard voltage 0.6 to 1.0 V 4 (THA) - 5 (E2) at -20
C (-4
F) at 20
C (68
F) at 60
C (140
F) 13.6 to 18.4 kΩ 2.21 to 2.69 kΩ 0.493 to 0.667 kΩ at 20
C (68
F) 6.9 to 7.9 Ω at 20
C (68
F) 2 (M+) - 1 (M-) 0.3 to 100 kΩ Approx. 20
C (68
F) Approx. 80
C (176
F) at 20
C (68
F) 2.32 to 2.59 kΩ 0.310 to 0.326 kΩ 120 to 280 kΩ 3-5 3-5 10 kΩ or higher Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 3-5 3-5 10 kΩ or higher Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 125 03-5 SERVICE SPECIFICATIONS - ENGINE CONTROL SYSTEM 03049-02 TORQUE SPECIFICATION 2AZ-FE: N⋅m kgf⋅cm ft⋅lbf Throttle body assy x Intake manifold Part Tightened 30 305 22 Knock sensor x Cylinder block sub-assy 20 199 14 Intake manifold x Cylinder head sub-assy 30 305 22 ECM x Instrument panel reinforcement 5.5 56 49 in.⋅lbf ECM x Blower assy 5.5 56 49 in.⋅lbf Accelerator pedal rod assy x Body 4.9 50 43 in.⋅lbf N⋅m kgf⋅cm ft⋅lbf 3MZ-FE: Part Tightened Front suspension upper brace center x Body 80 815 59 V-bank cover sub-assy x Cylinder head cover sub-assy LH (w/ Performance Rod) 7.9 81 70 in.⋅lbf Throttle body assy x Intake air connector 11 112 8 Knock sensor x Cylinder block sub-assy 20 199 14 Water outlet x Cylinder head sub-assy 15 153 11 Water outlet x Cylinder head LH 15 153 11 Intake manifold x Cylinder head sub-assy 15 153 11 Intake manifold x Cylinder head LH 15 153 11 Ground cable x Intake manifold 8.4 86 74 in.⋅lbf ECM x Instrument panel reinforcement 5.5 56 49 in.⋅lbf ECM x Blower assy 5.5 56 49 in.⋅lbf Accelerator pedal rod assy x Body 4.9 50 43 in.⋅lbf 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 126 03-6 SERVICE SPECIFICATIONS - FUEL FUEL 0304A-02 SERVICE DATA 2AZ-FE: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi) Fuel pressure Fuel injector Resistance Injection volume Difference between each cylinder Fuel leakage Fuel pump Resistance at 20
C (68
F) 11.6 to 12.4 Ω 76 to 92 cm2 (4.6 to 5.6 cu in.) per 15 seconds 16 cm3 (1.0 cu in.) or less 1 drop or less per 12 minutes at 20
C (68
F) 0.2 to 3.0 Ω 3MZ-FE: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi) Fuel pressure Fuel injector Resistance Injection volume Difference between each cylinder Fuel leakage Fuel pump Resistance at 20
C (68
F) 13.4 to 14.2Ω 60 to 73 cm2 (3.7 to 4.5 cu in.) per 15 seconds 13 cm3 (0.8 cu in.) or less 1 drop or less per 12 minutes at 20
C (68
F) 0.2 to 3.0 Ω 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 127 03-7 SERVICE SPECIFICATIONS - FUEL 0304B-02 TORQUE SPECIFICATION 2AZ-FE: N⋅m kgf⋅cm ft⋅lbf Fuel delivery pipe x Cylinder head Part Tightened 20 204 15 Fuel tank band sub-assy No. 1 RH x Body 39 400 29 Fuel tank band sub-assy No. 1 LH x Body 39 400 29 Fuel tank protector x Fuel tank assy 5.5 56 49 in.⋅lbf Exhaust pipe assy center x Exhaust pipe assy front 48 490 35 Exhaust pipe assy center x Exhaust pipe assy tail 48 490 35 N⋅m kgf⋅cm ft⋅lbf Fuel delivery pipe sub-assy x Intake manifold 10 102 7 Fuel delivery pipe No. 2 x Intake manifold 10 102 7 Fuel pipe No. 2 union bolt x Fuel delivery pipe No. 2 33 331 24 Fuel pressure pulsation damper assy x Fuel delivery pipe sub-assy 33 331 24 Fuel pipe sub-assy No. 1 x Intake manifold 20 199 14 Surge tank stay No. 2 x Intake air surge tank 20 199 14 Surge tank stay No. 2 x Cylinder head 20 199 14 Surge tank stay No. 1 x Intake air surge tank 20 199 14 Surge tank stay No. 1 x Cylinder head 20 199 14 Engine hunger No. 1 x Intake air surge tank 20 199 14 Engine hunger No. 1 x Cylinder head 20 199 14 Pressure feed tube assy x Engine hunger No. 1 7.8 80 69 in.⋅lbf Intake air surge tank x Intake manifold 28 286 21 Emission control valve set x Emission control valve bracket 8.0 82 71 in.⋅lbf Fuel tank band sub-assy No. 1 RH x Body 39 400 29 Fuel tank band sub-assy No. 1 LH x Body 39 400 29 Fuel tank protector lower center x Fuel tank assy 5.5 56 49 in.⋅lbf Packing brake cable assy No. 2 x Body 5.4 55 48 in.⋅lbf Exhaust pipe assy center x Exhaust pipe assy front 48 490 35 Exhaust pipe assy center x Exhaust pipe assy tail 48 490 35 3MZ-FE: Part Tightened 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 128 03-8 SERVICE SPECIFICATIONS - EMISSION CONTROL EMISSION CONTROL 0304C-02 SERVICE DATA 2AZ-FE A/F sensor (bank 1 sensor 1) resistance Oxygen sensor (bank 1 sensor 2) resistance VSV for EVAP resistance at 20
C (68
F) at 800
C (1,472
F) 0.8 to 1.4 Ω 1.8 to 3.2 Ω at 20
C (68
F) at 800
C (1,472
F) 11 to 16 Ω 23 to 32 Ω at 20
C (68
F) 26 to 30 Ω 3MZ-FE A/F sensor (bank 1 sensor 1) resistance A/F sensor (bank 2 sensor 1) resistance Oxygen sensor (bank 1 sensor 2) resistance Oxygen sensor (bank 2 sensor 2) resistance VSV for CCV resistance VSV for EVAP resistance at 20
C (68
F) at 800
C (1,472
F) 0.8 to 1.4 Ω 1.8 to 3.2 Ω at 20
C (68
F) at 800
C (1,472
F) 0.8 to 1.4 Ω 1.8 to 3.2 Ω at 20
C (68
F) at 800
C (1,472
F) 11 to 16 Ω 23 to 32 Ω at 20
C (68
F) at 800
C (1,472
F) 11 to 16 Ω 23 to 32 Ω at 20
C (68
F) at 100
C (212
F) 25 to 30 Ω 32 to 40 Ω at 20
C (68
F) 26 to 30 Ω 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 129 03-9 SERVICE SPECIFICATIONS - INTAKE INTAKE 0304D-02 SERVICE DATA 3MZ-FE Vacuum switching valve assy for IAC valve No.2 Resistance at 20
C (68
F) 33 to 39 Ω 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 130 03-10 SERVICE SPECIFICATIONS - INTAKE 0304E-02 TORQUE SPECIFICATION 3MZ-FE Part Tightened Intake air control valve assy No. 2 x Intake air surge tank N⋅m kgf⋅cm ft⋅lbf 10 102 7 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 131 03-1 1 SERVICE SPECIFICATIONS - ENGINE MECHANICAL ENGINE MECHANICAL 0304P-02 SERVICE DATA 2AZ-FE Ignition timing w/ Terminals TC and CG of DLC3 connected w/ Terminals TC and CG of DLC3 disconnected Idle speed Compression A/T Compression pressure Minimum pressure Difference between each cylinder Valve clearance (cold) 8 to 12
BTDC @ idle 5 to 15
BTDC @ idle 610 to 710 rpm 1.360 kPa (13.9 kgf/cm2, 198 psi) 0.98 MPa (10 kgf/cm2, 142 psi) 100 kPa (1.0 kgf/cm2, 14 psi) Intake 0.19 to 0.29 mm (0.008 to 0.011 in.) Exhaust 0.30 to 0.40 mm (0.012 to 0.016 in.) Balanceshaft Standard thrust clearance Maximum thrust clearance Standard oil clearance Maximum oil clearance Housing journal bore diameter Mark 1 Mark 2 Mark 3 Journal diameter Bearing center wall thickness Mark 1 Mark 2 Mark 3 0.050 to 0.090 mm (0.0020 to 0.0035 in.) 0.090 mm (0.0035 in.) 0.031 mm (0.0012 in.) 0.004 to 0.031 mm (0.0002 to 0.0012 in.) 26.000 to 26.006 mm (1.0236 to 1.0239 in.) 26.007 to 26.012 mm (1.0239 to 1.0241 in.) 26.013 to 26.018 mm (1.0241 to 1.0243 in.) 22.985 to 23.000 mm (0.9049 to 0.9055 in.) 1.486 to 1.489 mm (0.0585 to 0.0586 in.) 1.489 to 1.492 mm (0.0586 to 0.0587 in.) 1.492 to 1.495 mm (0.0587 to 0.0589 in.) Oil pump drive sprocket Minimum sprocket diameter (w/ chain) 48.2 mm (1.898 in.) Crankshaft timing sprocket Minimum sprocket diameter (w/ chain) 51.6 mm (2.031 in.) Chain tensioner slipper Maximum wear 1.0 mm (0.039 in.) Chain vibration damper No. 1 Maximum wear 1.0 mm (0.039 in.) Cylinder head set bolt Specified bolt length 161.3 to 162.7 mm (6.3503 to 6.4055 in.) Chain sub-assy Maximum chain elongation 115.4 mm (4.543 in.) Camshaft timing gear or sprocket Minimum gear or sprocket diameter (w/ chain) 97.3 mm (3.831 in.) Camshaft (Intake) Maximum circle runout Standard cam lobe height MInimum cam lobe height No. 1 journal diameter Other journal diameter Standard journal thrust clearance Maximum journal thrust clearance Standard journal oil clearance Maximum journal oil clearance Cylinder head journal bore diameter Standard bearing center wall thickness No. 1 journal bearing mark 1 No. 1 journal bearing mark 2 No. 1 journal bearing mark 3 Other journals No. 1 journal Other journals Mark 1 Mark 2 Mark 3 Mark 1 Mark 2 Mark 3 Camshaft journal diameter 0.03 mm (0.0012 in.) 46.495 to 46.595 mm (1.8305 to 1.8344 in.) 46.385 mm (1.8262 in.) 35.971 to 35.985 mm (1.4162 to 1.4167 in.) 22.959 to 22.975 mm (0.9039 to 0.9045 in.) 0.040 to 0.095 mm (0.0016 to 0.0037 in.) 0.11 mm (0.0043 in.) 0.007 to 0.038 mm (0.0028 to 0.0015 in.) 0.008 to 0.038 mm (0.0031 to 0.0015 in.) 0.008 to 0.038 mm (0.0031 to 0.0015 in.) 0.025 to 0.062 mm (0.00098 to 0.00244 in.) 0.07 mm (0.0028 in.) 0.10 mm (0.0039 in.) 40.000 to 40.008 mm (1.57480 to 1.57511 in.) 40.009 to 40.017 mm (1.57515 to 1.57547 in.) 40.018 to 40.025 mm (1.57551 to 1.57578 in.) 2.000 to 2.004 mm (0.07874 to 0.07890 in.) 2.004 to 2.008 mm (0.07894 to 0.07905 in.) 2.009 to 2.012 mm (0.07909 to 0.07921 in.) 35.971 to 35.985 mm (1.41618 to 1.41673 in.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 132 03-12 SERVICE SPECIFICATIONS Camshaft No. 2 (Exhaust) Maximum circle runout Standard cam lobe height Minimum cam lobe height No. 1 journal diameter Other journal diameter Standard thrust clearance Maximum thrust clearance Standard journal oil clearance Cylinder head journal bore diameter Standard bearing center wall thickness - ENGINE MECHANICAL No. 1 journal Other journals Mark 1 Mark 2 Mark 3 Mark 1 Mark 2 Mark 3 Camshaft journal diameter 0.03 mm (0.0012 in.) 46.873 to 46.083 mm (1.8060 to 1.8143 in.) 45.873 mm (1.8060 in.) 35.971 to 35.985 mm (1.41618 to 1.41673 in.) 22.959 to 22.975 mm (0.9039 to 0.9045 in.) 0.080 to 0.135 mm (0.0032 to 0.0053 in.) 0.15 mm (0.0059 in.) 0.040 to 0.079 mm (0.00157 to 0.00311 in.) 0.025 to 0.062 mm (0.00098 to 0.00244 in.) 40.000 to 40.008 mm (1.57480 to 1.57511 in.) 40.009 to 40.017 mm (1.57515 to 1.57547 in.) 40.018 to 40.025 mm (1.57551 to 1.57578 in.) 2.000 to 2.004 mm (0.07874 to 0.07890 in.) 2.004 to 2.008 mm (0.07894 to 0.07905 in.) 2.009 to 2.012 mm (0.07909 to 0.07921 in.) 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Intake manifold Maximum warpage 0.20 mm (0.079 in.) Exhaust manifold Maximum warpage 0.70 mm (0.0276 in.) Cylinder head Maximum warpage Cylinder block side Intake manifold side Exhaust manifold side 0.05 mm (0.0020 in.) 0.08 mm (0.0031 in.) 0.08 mm (0.0031 in.) Inner compression spring Free length Maximum deviation 45.7 mm (1.799 in.) 1.6 mm (0.063 in.) Intake valve Standard overall length Minimum overall length Valve stem diameter Standard margin thickness Minimum margin thickness 101.71 mm (4.0043 in.) 101.21 mm (3.9846 in.) 5.470 to 5.485 mm (0.2154 to 0.2159 in.) 1.05 to 1.45 mm (0.0413 to 0.0571 in.) 0.50 to (0.0197 in.) Exhaust valve Standard overall length Minimum overall length Valve stem diameter Standard margin thickness Minimum margin thickness 101.15 mm (3.9823 in.) 100.70 mm (3.9646 in.) 5.465 to 5.480 mm (0.2152 to 0.2157 in.) 1.20 to1.60 mm (0.0470 to 0.0630 in.) 0.50 mm (0.020 in.) Intake valve guide bush Bush inside diameter standard oil clearance Maximum oil clearance 5.510 to 5.530 mm (0.2169 to 0.2177 in.) 0.025 to 0.060 mm (0.0010 to 0.0024 in.) 0.08 mm (0.0031 in.) Exhaust valve guide bush Bush inside diameter Standard oil clearance Maximum oil clearance 5.510 to 5.530 mm (0.2169 to 0.2177 in.) 0.030 to 0.065 mm (0.0012 to 0.0026 in.) 0.10 mm (0.0039 in.) Valve lifter Lifter diameter Lifter bore diameter Standard oil clearance Maximum oil clearance 30.966 to 30.976 mm (1.2191 to 1.2195 in.) 31.009 to 31.025 mm (1.2208 to 1.2215 in.) 0.033 to 0.059 mm (0.0013 to 0.0023 in.) 0.07 mm (0.0028 in.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 133 03-13 SERVICE SPECIFICATIONS Connecting rod Standard thrust clearance Maximum thrust clearance Standard oil clearance Maximum oil clearance Connecting rod bearing center wall thickness (Reference) Bush inside diameter Bush inside diameter (Reference) - ENGINE MECHANICAL Mark 1 Mark 2 Mark 3 Mark A Mark B Mark C Maximum rod out-of-alignment per 100 mm (3.94 in.) Maximum rod twist per 100 mm (3.94 in.) Cylinder block Maximum warpage Standard cylinder bore diameter Maximum cylinder bore diameter Piston Piston diameter Specified piston oil clearance Piston pin hole bush inside diameter Piston pin hole bush inside diameter (Reference) Piston ring Ring groove clearance Standard end gap Maximum end gap Piston pin Piston pin diameter Piston pin diameter (Reference) 0.160 to 0.362 mm (0.0063 to 0.0143 in.) 0.362 mm (0.0143 in.) 0.024 to 0.048 mm (0.0009 to 0.0019 in.) 0.08 mm (0.0031 in.) 1.485 to 1.488 mm (0.05854 to 0.05858 in.) 1.489 to 1.491 mm (0.05862 to 0.05870 in.) 1.492 to 1.494 mm (0.05874 to 0.05881 in.) 22.005 to 22.014 mm (0.8663 to 0.8667 in.) 22.005 to 22.008 mm (0.8663 to 0.8665 in.) 22.008 to 22.011 mm (0.8665 to 0.8666 in.) 22.011 to 22.014 mm (0.8666 to 0.8667 in.) 0.05 mm (0.0020 in.) 0.15 mm (0.0059 in.) 0.05 mm (0.0020 in.) 88.500 to 88.513 mm (3.4842 to 3.4848 in.) 88.633 mm (3.4895 in.) Mark A Mark B Mark C No. 1 No. 2 Oil (side rail) No. 1 No. 2 Oil (side rail) 88.439 to 88.449 mm (3.4818 to 3.4822 in.) 0.051 to 0.100 mm (0.0020 to 0.0039 in.) 22.001 to 22.010 mm (0.8662 to 0.8665 in.) 22.001 to 22.004 mm (0.86618 to 0.86630 in.) 22.005 to 22.007 mm (0.86634 to 0.86612 in.) 22.008 to 22.010 mm (0.86645 to 0.86653 in.) 0.22 to 0.32 mm (0.0087 to 0.0126 in.) 0.50 to 0.60 mm (0.0197 to 0.0236 in.) 0.10 to 0.35 mm (0.0039 to 0.0138 in.) 0.89 mm (0.0350 in.) 1.35 mm (0.0531 in.) 0.73 mm (0.0287 in.) Standard oil clearance Maximum oil clearance 21.997 to 22.009 mm (0.8660 to 0.8665 in.) 21.997 to 22.000 mm (0.86602 to 0.86614 in.) 22.001 to 22.003 mm (0.86618 to 0.86626 in.) 22.004 to 22.006 mm (0.86630 to 0.86638 in.) 0.001 to 0.007 mm (0.00004 to 0.00028 in.) 0.010 mm (0.0020 in.) Connecting rod bolt Standard diameter MInimum diameter 7.2 to 7.3 mm (0.283 to 0.287 in.) 7.0 mm (0.276 in.) Mark A Mark B Mark C 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 134 03-14 SERVICE SPECIFICATIONS Crankshaft Standard thrust clearance Maximum thrust clearance Thrust washer thickness Cylinder block main journal bore diameter (Reference) Main journal diameter Main journal diameter (Reference) Standard main bearing center wall thickness (Reference) Maximum circle runout Standard main journal oil clearance Maximum main journal taper and out-of-round Maximum crank pin taper and out-of-round Crank pin diameter Crankshaft bearing cap set bolt Standard diameter Minimum diameter - ENGINE MECHANICAL Mark 0 Mark 1 Mark 2 Mark 3 Mark 4 Mark 5 Mark 6 Mark 0 Mark 1 Mark 2 Mark 3 Mark 4 Mark 5 Mark 1 Mark 2 Mark 3 Mark 4 0.040 to 0.240 mm (0.0016 to 0.0094 in.) 0.30 mm (0.0118 in.) 1.930 to 1.980 mm (0.0760 to 0.0780 in.) 59.000 to 59.002 mm (2.32283 to 2.32291 in.) 59.003 to 59.004 mm (2.32294 to 2.32299 in.) 59.005 to 59.006 mm (2.32303 to 2.32307 in.) 59.007 to 59.009 mm (2.32311 to 2.32318 in.) 59.009 to 59.011 mm (2.32322 to 2.32326 in.) 59.012 to 59.013 mm (2.32330 to 2.32334 in.) 59.014 to 59.016 mm (2.32338 to 2.32346 in.) 54.988 to 55.000 mm (2.1648 to 2.1654 in.) 54.999 to 55.000 mm (2.16531 to 2.16535 in.) 54.997 to 54.998 mm (2.16523 to 2.16527 in.) 54.995 to 54.996 mm (2.16515 to 2.16519 in.) 54.993 to 54.994 mm (2.16507 to 2.16511 in.) 54.991 to 54.992 mm (2.16500 to 2.16504 in.) 54.989 to 54.990 mm (2.16489 to 2.16496 in.) 1.993 to 1.996 mm (0.07846 to 0.07858 in.) 1.997 to 1.999 mm (0.07862 to 0.07870 in.) 2.000 to 2.002 mm (0.07874 to 0.07882 in.) 2.003 to 2.005 mm (0.07886 to 0.07894 in.) 0.03 mm (0.0012 in.) 0.024 to 0.048 mm (0.00094 to 0.00189 in.) 0.003 mm (0.0001 in.) 0.003 mm (0.0001 in.) 47.990 to 48.000 mm (1.8894 to 1.8898 in.) 7.3 to 7.6 mm (0.287 to 0.299 in.) 7.2 mm (0.283 in.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 135 03-15 SERVICE SPECIFICATIONS - ENGINE MECHANICAL 3MZ-FE New V-ribbed belt tension For fan and generator For vane pump 143 to 165 lbf 132 to 154 lbf For fan and generator For vane pump 80 to 132 lbf 55 to 88 lbf Used V-ribbed belt tension Ignition timing w/ Terminals TC and CG of DLC3 connected w/ Terminals TC and CG of DLC3 disconnected Idle speed Compression 8 to 12
BTDC @ idle 7 to 24
BTDC @ idle 650 to 750 rpm Compression pressure Minimum pressure Difference between each cylinder Valve clearance (cold) Intake 0.15 to 0.25 mm (0.006 to 0.010 in.) Exhaust 0.25 to 0.35 mm (0.010 to 0.014 in.) Intake air surge tank Maximum warpage Intake manifold Maximum warpage 1.5 MPa (15.3 kgf/cm2, 218 psi) 1.0 MPa (10.2 kgf/cm2, 145 psi) 100 kPa (1.0 kgf/cm2, 15 psi) 0.10 mm (0.0039 in.) Air intake surge tank side Cylinder head side Exhaust manifold Maximum warpage Camshaft Maximum circle runout Specified cam lobe height Camshaft Journal diameter Specified gear backlash Specified journal thrust clearance Specified journal oil clearance 0.50 mm (0.0196 in.) 0.06 mm (0.0024 in.) Intake 42.980 to 43.232 mm (1.6921 to 1.7020 in.) Exhaust 42.960 to 43.110 mm (1.6874 to 1.6972 in.) 26.959 to 26.975 mm (1.0614 to 1.0620 in.) 0.020 to 0.300 mm (0.0008 to 0.0118 in.) 0.040 to 0.120 mm (0.0016 to 0.0047 in.) 0.025 to 0.100 mm (0.0010 to 0.0039 in.) Cylinder head set bolt Specified outside diameter at tension portion Cylinder head Maximum warpage 0.15 mm (0.0059 in.) 0.08 mm (0.0031 in.) 8.75 to 9.05 mm (0.3445 to 0.3563 in.) Cylinder block side Intake manifold side Exhaust manifold side 0.05 mm (0.0020 in.) 0.10 mm (0.0039 in.) 0.10 mm (0.0039 in.) Intake valve Specified overall length Valve stem diameter Minimum margin thickness 94.95 to 95.45 mm (3.7382 to 3.7579 in.) 5.470 to 5.485 mm (0.2154 to 0.2159 in.) 0.5 to 1.0 mm (0.020 to 0.039 in.) Exhaust valve Specified overall length Valve stem diameter Minimum margin thickness 94.90 to 95.40 mm (3.7362 to 3.7559 in.) 5.465 to 5.480 mm (0.2152 to 0.2157 in.) 0.5 to 1.0 mm (0.020 to 0.039 in.) Inner compression spring Free length Maximum deviation Installed tension at 33.8 mm (1.331 in.) 45.50 mm (1.7913 in.) 2.0 mm (0.079 in.) 186 to 206 N (19.0 to 21.0 kgf, 41.9 to 46.3 lbf) Valve guide bush Bush inside diameter Specified bush oil clearance Cylinder head valve guide bush bore diameter Bush diameter Valve lifter Lifter diameter Lifter bore diameter Specified oil clearance Intake Exhaust STD O/S 0.05 STD O/S 0.05 5.510 to 5.530 mm (0.2169 to 0.2177 in.) 0.025 to 0.080 mm (0.0010 to 0.0031 in.) 0.030 to 0.100 mm (0.0012 to 0.0039 in.) 10.295 to 10.313 mm (0.4053 to 0.4060 in.) 10.345 to 10.363 mm (0.4073 to 0.4080 in.) 10.333 to 10.344 mm (0.4068 to 0.4072 in.) 10.383 to 10.394 mm (0.4088 to 0.4092 in.) 30.966 to 30.976 mm (1.2191 to 1.2195 in.) 31.009 to 31.025 mm (1.2208 to 1.2215 in.) Standard 0.033 to 0.070 mm (0.0013 to 0.0028 in.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 136 03-16 SERVICE SPECIFICATIONS Connecting rod Specified thrust clearance Connecting rod thickness Specified connecting rod oil clearance Connecting rod bearing center wall thickness Crankshaft Crankshaft thrust clearance Thrust washer thickness Specified main journal oil clearance - ENGINE MECHANICAL Mark 1 Mark 2 Mark 3 Mark 4 No. 1 and No. 4 journals No. 2 and No. 3 journals Cylinder block main journal bore diameter (Reference) Mark 00 Mark 01 Mark 02 Mark 03 Mark 04 Mark 05 Mark 06 Mark 07 Mark 08 Mark 09 Mark 10 Mark 11 Mark 12 Mark 13 Mark 14 Mark 15 Mark 16 Main journal diameter Main journal diameter (Reference) Mark 00 Mark 01 Mark 02 Mark 03 Mark 04 Mark 05 Mark 06 Mark 07 Mark 08 Mark 09 Mark 10 Mark 11 Mark 12 Standard main bearing center wall thickness (Reference) Mark 1 Mark 2 Mark 3 Mark 4 Mark 5 Mark 6 Mark 7 Maximum circle runout Main journal taper and out-of-round Crank pin diameter Maximum crank pin taper and out-of-round 0.15 to 0.35 mm (0.0059 to 0.0138 in.) 20.80 to 20.85 mm (0.8189 to 0.8209 in.) 0.038 to 0.080 mm (0.0015 to 0.0031 in.) 1.484 to 1.486 mm (0.0584 to 0.0585 in.) 1.487 to 1.489 mm (0.0585 to 0.0586 in.) 1.490 to 1.492 mm (0.0587 to 0.0587 in.) 1.493 to 1.495 mm (0.0588 to 0.0588 in.) 0.04 to 0.30 mm (0.0016 to 0.0118 in.) 1.93 to 1.98 mm (0.0760 to 0.0780 in.) 0.014 to 0.050 mm (0.0006 to 0.0020 in.) 0.026 to 0.060 mm (0.0010 to 0.0024 in.) 66.000 mm (2.5984 in.) 66.001 mm (2.5985 in.) 66.002 mm (2.5985 in.) 66.003 mm (2.5985 in.) 66.004 mm (2.5986 in.) 66.005 mm (2.5986 in.) 66.006 mm (2.5987 in.) 66.007 mm (2.5987 in.) 66.008 mm (2.5987 in.) 66.009 mm (2.5988 in.) 66.010 mm (2.5988 in.) 66.011 mm (2.5989 in.) 66.012 mm (2.5989 in.) 66.013 mm (2.5989 in.) 66.014 mm (2.5990 in.) 66.015 mm (2.5990 in.) 66.016 mm (2.5990 in.) 61.000 mm (4.1016 in.) 60.999 mm (4.4015 in.) 60.998 mm (4.4015 in.) 60.997 mm (4.4015 in.) 60.996 mm (4.4014 in.) 60.995 mm (4.4014 in.) 60.994 mm (4.4013 in.) 60.993 mm (4.4012 in.) 60.992 mm (4.4012 in.) 60.991 mm (4.4012 in.) 60.990 mm (4.4012 in.) 60.989 mm (4.4011 in.) 60.988 mm (4.4011 in.) 2.486 to 2.489 mm (0.0979 to 0.0980 in.) 2.489 to 2.492 mm (0.0980 to 0.0981 in.) 2.492 to 2.495 mm (0.0981 to 0.0982 in.) 2.495 to 2.498 mm (0.0982 to 0.0983 in.) 2.498 to 2.501 mm (0.0983 to 0.0985 in.) 2.501 to 2.504 mm (0.0985 to 0.0986 in.) 2.504 to 2.507 mm (0.0986 to 0.0987 in.) 0.06 mm (0.0024 in.) 60.988 to 61.000 mm (2.4011 to 2.4016 in.) 0.02 mm (0.0008 in.) 52.992 to 53.000 mm (2.0863 to 2.0866 in.) 0.02 mm (0.0008 in.) Cylinder block Maximum warpage Specified cylinder bore diameter 0.05 mm (0.0020 in.) 92.000 to 92.132 mm (3.6220 to 3.6272 in.) Piston Piston diameter Specified oil clearance 91.953 to 91.967 mm (3.6202 to 3.6207 in.) 0.033 to 0.130 mm (0.0013 to 0.0051 in.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 137 03-17 SERVICE SPECIFICATIONS - ENGINE MECHANICAL Connecting rod Maximum misalignment per 100 mm (3.94 in.) Maximum rod twist per 100 mm (3.94 in.) Bush inside diameter 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) 22.005 to 22.014 mm (0.8663 to 0.8667 in.) Piston pin Piston pin diameter Pecified oil clearance 21.997 to 22.006 mm (0.8660 to 0.8664 in.) 0.005 to 0.050 mm (0.0002 to 0.0020 in.) Piston ring Piston ring groove clearance Specified end gap No. 1 No. 2 Oil No. 1 No. 2 Oil (Side rail) 0.03 to 0.08 mm (0.0012 to 0.0031 in.) 0.02 to 0.06 mm (0.0008 to 0.0024 in.) 0.03 to 0.11 mm (0.0011 to 0.0043 in.) 0.30 to 0.95 mm (0.0118 to 0.0031 in.) 0.50 to 1.05 mm (0.0008 to 0.0024 in.) 0.15 to 1.00 mm (0.0012 to 0.0043 in.) Connecting rod bolt Specified diameter 7.0 to 7.3 mm (0.276 to 0.287 in.) Crankshaft bearing cap set bolt Specified diameter 7.2 to 7.6 mm (0.283 to 0.299 in.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 138 03-18 SERVICE SPECIFICATIONS - ENGINE MECHANICAL 0304Q-06 TORQUE SPECIFICATION 2AZ-FE N⋅m kgf⋅cm ft⋅lbf Engine moving control rod w/bracket x Engine moving control bracket No. 2 Part Tightened 64 653 47 Engine moving control rod bracket RH x Cylinder head 64 653 47 Engine mounting bracket RH x Cylinder head 54 551 40 Engine mounting stay No. 2 RH x Engine mounting control rod bracket No. 2 64 653 47 Engine hanger No.1 x Cylinder head 38 387 28 in.⋅lbf Engine hanger No.2 x Cylinder head 38 387 28 in.⋅lbf Knock sensor x Cylinder block 20 204 15 Engine oil pressure switch assy x Cylinder head 15 153 11 Water by-pass pipe No.1 x Cylinder block 9.0 92 80 in.⋅lbf Drive shaft bearing bracket (2WD) x Cylinder block 64 653 47 V-ribbed belt tensioner assy x Timing chain cover 60 612 44 Ignition coil assy x Cylinder head 9.0 92 80 in.⋅lbf Water inlet x Cylinder block 9.0 92 80 in.⋅lbf Exhaust manifold converter sub-assy x Cylinder head 37 377 27 Exhaust manifold stay x Cylinder block 44 449 32 Exhaust manifold stay x Exhaust manifold converter sub-assy 44 449 32 Manifold converter insulator No. 1 x Exhaust manifold converter 12 122 9 Oil level gauge guide x Water by-pass pipe No. 1 9.0 92 80 in.⋅lbf Intake manifold sub-assy x Cylinder head assy 30 306 22 Drive plate & ring gear x Crankshaft 98 1,000 72 Starter assy x Automatic transaxle assy 39 398 29 Engine mounting bracket RR (4WD) x Transfer for bolt A 34 347 25 Engine mounting bracket RR (4WD) x Cylinder block for bolt B 64 653 47 Engine mounting insulator LH x Automatic transaxle assy 95 969 70 Engine mounting insulator RH x Engine mounting bracket RH 95 969 70 Engine mounting insulator FR x Engine mounting bracket FR 87 887 64 Engine mounting insulator RR x Engine mounting bracket RR (4WD) 75 765 55 Rack & pinion power steering gear assy (4WD) x Front frame assy 70 714 52 Stabilizer bar front (4WD) x Front frame assy 19 194 14 Vane pump assy x Timing chain cover 43 438 31 Frame side plate x Front frame assy for bolt A 86 877 63 Frame side plate x Body for bolt B 32 326 24 Front suspension member brace rear x Front frame assy for bolt C 86 877 63 Front suspension member brace rear x Body for bolt D 32 326 24 35 357 26 Steering intermediate shaft Drive plate & ring gear x Torque converter 41 418 30 Front suspension arm x Lower ball joint 127 1,295 94 Tie rod assy x Steering knuckle 49 500 36 Speed sensor front LH x Steering knuckle 8.0 82 71 Speed sensor front RH x Steering knuckle 8.0 82 71 Front axle hub LH nut x Front drive shaft 294 3,000 217 Front stabilizer link assy x Front suspension 74 755 55 Propeller shaft (4WD) x Intermediate shaft 74 755 55 Return tube x body 20 204 15 Engine mounting bracket No. 2 RH x Timing chain cover 20 204 15 52 21 530 214 38 15 Compressor and magnetic clutch x bracket 25 255 18 Air cleaner assy x Body 5.0 51 44 in.⋅lbf Generator assy x Bracket for bolt A for bolt B 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 139 03-19 SERVICE SPECIFICATIONS - ENGINE MECHANICAL Part Tightened N⋅m kgf⋅cm ft⋅lbf 49 500 36 22 Turn 90
220 Turn 90
15 Turn 90
Stiffening crankcase assy x Cylinder block 33 337 24 W/head taper screw plug No. 1 x Cylinder block 26 265 19 Oil control valve filter x Cylinder block 30 306 22 25 255 18 79 Turn 90
806 Turn 90
58 Turn 90
Camshaft timing gear assy x Camshaft 54 551 40 Camshaft timing gear or sprocket x Camshaft 54 551 40 Camshaft bearing cap No. 1 x Cylinder head 30 306 22 Camshaft bearing cap No. 2 x Cylinder head 30 306 22 Camshaft bearing cap No. 3 x Cylinder head 9.0 92 80 in.⋅lbf Oil pump assy x Stiffening crankcase assy 19 194 14 Chain tensioner plate x Stiffening crankcase assy 12 122 9 Oil pump drive sprocket x Oil pump 30 306 22 Chain vibration damper No. 1 x Cylinder head 9.0 92 80 in.⋅lbf Chain vibration damper No. 1 x Cylinder block 9.0 92 80 in.⋅lbf Chain tensioner slipper x Cylinder block 19 194 14 9.0 92 80 in.⋅lbf 9.0 21 43 9.0 92 214 438 92 80 in.⋅lbf 15 32 80 in.⋅lbf 9.0 92 80 in.⋅lbf Oil pan drain plug x Oil pan 25 255 18 Water pump assy x Cylinder block 9.0 92 80 in.⋅lbf Water pump pulley x Water pump assy 26 265 19 Filler plug (Transfer) Balance shaft housing x Stiffening crankcase assy 1st 2nd Cylinder block water drain cock x Stiffening crankcase assy Cylinder head x Cylinder block 1st 2nd Timing chain guide x Crankshaft bearing cap No. 1 Timing chain cover (see page 14-68 ) for bolt A for bolt B for bolt C for nut Oil pan x Stiffening crankcase assy Crank position sensor x Timing chain cover 9.0 92 80 in.⋅lbf Crankshaft pulley x Crankshaft 180 1,835 133 Chain tensioner assy x Timing chain cover 9.0 92 80 in.⋅lbf Camshaft position sensor x Cylinder head 9.0 92 80 in.⋅lbf 11 14 11 112 143 112 8 10 8 Oil filter union (w/ oil cooler) x Stiffening crankcase assy 30 306 22 Spark plug x Cylinder head 19 194 14 Ventilation valve x Cylinder head cover 19 194 14 5.0 5.0 10 10 51 51 102 102 44 in.⋅lbf 44 in.⋅lbf 7 7 80 816 59 25 Turn 90
250 Turn 90
18 Turn 90
Cylinder head cover x Cylinder head (see page 14-41 ) Stud bolt (see page 14-92 ) for bolt A for bolt B for nut for bolt A for bolt B for bolt C for bolt D Front suspension brace x Body Connecting rod cap x Connecting rod 1st 2nd Camshaft timing oil control valve x Cylinder head Crankshaft bearing cap x Cylinder block Stud bolt (see page 14-105 ) 9.0 92 80 in.⋅lbf 1st 2nd 20 40 204 408 15 30 Stud bolt A Stud bolt B Stud bolt C 5.0 10 5.0 51 102 51 44 in.⋅lbf 7 44 in.⋅lbf 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 140 03-20 SERVICE SPECIFICATIONS - ENGINE MECHANICAL 3MZ-FE N⋅m kgf⋅cm ft⋅lbf Engine hanger No. 2 x Cylinder head Part Tightened 20 204 15 Knock sensor x Cylinder block 20 204 15 Oil pressure switch assy x Cylinder block 15 153 11 Compressor mounting bracket No.1 x Cylinder block 25 255 18 Generator bracket No.1 x Cylinder block 58 591 43 Pump bracket x Cylinder head 32 326 24 Engine mounting bracket RR (2WD) x Cylinder block 64 653 47 Engine mounting bracket RR (2WD) x Front frame assy 64 653 47 Exhaust converter sub-assy x Cylinder head 49 500 36 Exhaust converter sub-assy No. 2 x Cylinder head 49 500 36 Ignition coil assy x Cylinder head cover 8.0 82 71 in.⋅lbf Surge tank stay No. 1 x Cylinder head 20 199 14 Surge tank stay No. 2 x Intake air surge tank 20 199 14 Engine hanger No. 1 x Cylinder head 20 204 15 Engine hanger No. 1 x Intake air surge tank 20 204 15 Manifold stay No. 2 x Exhaust converter sub-assy No. 2 49 500 36 Manifold stay No. 2 x Cylinder block 49 500 36 Manifold stay x Exhaust converter sub-assy 49 500 36 Manifold stay x Cylinder head 49 500 36 34 64 347 653 25 47 Engine mounting insulator RH x Engine mounting bracket 95 969 70 Engine mounting insulator LH x Automatic transaxle assy 95 969 70 Engine mounting insulator FR x Automatic transaxle assy 87 887 64 Engine mounting insulator RR x Transverse engine engine mounting bracket 75 765 55 Rack & pinion power steering gear assy (4WD) x Front frame assy 70 714 52 Stabilizer bar front (4WD) x Front frame assy 29 296 21 Vane pump assy x Pump bracket 43 439 32 Vane pump assy x Engine mounting bracket 43 439 32 Frame side rail plate sub-assembly x Front frame assy (see page 14-149 ) for bolt A for bolt B 85 32 867 326 63 24 for bolt A for bolt B for nut C 85 32 32 867 326 326 63 24 24 Compressor and magnetic clutch x Compressor mounting bracket No.1 (see page 14-149 14 149 ) for bolt for nut 25 26 255 265 18 19 43 18 8.0 438 184 82 32 13 71 in.⋅lbf Generator bracket No. 2 x Transverse engine engine mounting bracket 28 286 21 Intermediate shaft sub-assy 35 357 26 Battery clamp sub-assy x Body 6.0 61 53 in.⋅lbf Exhaust manifold heat insulator No. 2 x Exhaust manifold converter sub-assy No. 2 9.0 92 80 in.⋅lbf Exhaust manifold heat insulator No. 3 x Exhaust manifold converter sub-assy No. 2 9.0 92 80 in.⋅lbf Flywheel housing under cover x Automatic transaxle assy 8.0 82 70 in.⋅lbf Engine mounting bracket (4WD) x Cylinder block (see page 14-149 14 149 ) Front suspension member brace rear x Front frame assy (see page age 14-149 14 149 ) for bolt A for bolt B Generator belt adjusting bar x Cylinder block (see page 14-149 ) for nut A for bolt B for bolt C 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 141 03-21 SERVICE SPECIFICATIONS - ENGINE MECHANICAL Part Tightened N⋅m kgf⋅cm ft⋅lbf Front suspension arm x Lower ball joint 127 1,295 94 Tie rod end x Steering knuckle 49 500 36 Front axle hub nut x Front drive shaft 294 2,998 217 Front stabilizer link assy x Front suspension 74 755 55 Front propeller shaft (4WD) x Intermediate shaft 74 755 55 V-bank cover x Cylinder head cover 8.0 82 70 in.⋅lbf Engine mounting stay No. 2 RH x Engine mounting bracket 64 653 47 64 23 653 235 47 17 Front wheel 103 1,050 76 Camshaft sub-gear x Main gear 5.4 55 48 in.⋅lbf 8.0 82 71 in.⋅lbf 8.0 20 43 82 199 438 71 in.⋅lbf 14 32 Crank position sensor x Oil pump assy 8.0 82 71 in.⋅lbf Oil pan baffle plate x Oil pan sub-assy 8.0 82 71 in.⋅lbf 8.0 20 82 199 71 in.⋅lbf 14 Oil strainer sub-assy x Oil pan sub-assy 8.0 82 71 in.⋅lbf Oil pan sub-assy No. 2 x Oil pan sub-assy 8.0 82 71 in.⋅lbf Oil pan drain plug x Oil pan sub-assy No. 2 45 459 33 Water inlet housing x Cylinder block 8.0 82 71 in.⋅lbf 54 Turn 90
19 551 Turn 90
189 40 Turn 90
14 Oil control valve filter x Cylinder head assy 45 459 33 Cylinder head cover rear x Cylinder head assy 10 102 7 Camshaft timing gear assy (VVT-i) x Camshaft 150 1,530 111 Camshaft bearing cap x Cylinder head assy 16 163 12 Timing belt plate x Oil pump assy 8.0 82 71 in.⋅lbf Water pump assy x Cylinder block assy 8.0 82 71 in.⋅lbf Oil level gage guide x Cylinder block assy 8.0 82 71 in.⋅lbf Oil filter union x Cylinder block assy 30 306 22 Timing belt idler bracket x Cylinder block assy 28 286 21 Timing belt No. 3 cover x Cylinder head assy 9.0 92 80 in.⋅lbf Camshaft timing pulley x Camshaft 125 1,275 92 Timing belt idler sub-assy No. 2 x Timing belt idler bracket 43 438 32 Timing belt idler sub-assy No. 1 x Cylinder block assy 34 348 25 Timing belt tensioner x Oil pump assy 27 280 20 Engine mounting bracket x Cylinder block 28 286 21 Timing belt No. 2 cover x Timing belt No. 3 cover 9.0 92 80 in.⋅lbf Timing belt No. 1 cover x OIl pump assy 9.0 92 80 in.⋅lbf Crankshaft pulley x Crankshaft 220 2,243 162 VVT sensor No. 1 x Cylinder head assy 8.0 82 71 in.⋅lbf Camshaft timing oil control valve assy x Cylinder head assy 8.0 82 71 in.⋅lbf Cylinder head cover x Cylinder head assy 8.0 82 71 in.⋅lbf Spark plug x Cylinder head assy 25 255 18 W/head straight screw plug No. 1 x Cylinder head assy 44 449 32 44 449 32 25 Turn 90
255 Turn 90
18 Turn 90
Engine moving control rod (see page age 14 14-149 149 ) for bolt A for bolt B Engine rear oil seal retainer x Cylinder block Oil pump assy x Cylinder block assy (see page 14-173 ) for bolt A for bolt B for bolt C Oil pan an sub-assy sub assy x Cylinder block (see page age 14-173 14 173 ) Cylinder head assy x Cylinder block assy 10 mm head 12 mm head 12 pointed head 1st 2nd Recessed head W/head straight screw plug No. 2 x Cylinder head assy Connecting rod cap x Connecting rod 1st 2nd 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 142 03-22 SERVICE SPECIFICATIONS - ENGINE MECHANICAL Part Tightened N⋅m kgf⋅cm ft⋅lbf 22 Turn 90
27 224 Turn 90
275 16 Turn 90
20 Cylinder block w/head straight screw No. 1 plug x Cylinder block 30 306 22 Cylinder block w/head straight screw No. 2 plug x Cylinder block 50 510 37 Cylinder block w/head straight screw No. 3 plug x Cylinder block 30 306 22 Water seal plate x Cylinder block 18 184 13 Cylinder block water drain cock sub-assy x Cylinder block 39 398 29 Vane pump assy x Adjusting strut 43 439 32 Generator assy x Generator bracket 58 591 43 Generator assy x Adjusting bar 18 184 13 Intake air surge tank x Intake manifold 28 286 21 Front suspension brace sub-assy upper center x Body 80 816 59 Drive plate & ring gear sub-assy x Crankshaft 83 846 61 Water outlet x Cylinder head 15 153 11 Intake manifold x Cylinder head 15 153 11 Cylinder head cover rear x Cylinder head 10 102 7 Air cleaner case x Body 5.0 51 44 in.⋅lbf crankshaft bearing cap x Cylinder block assy 12 pointed head 1st 2nd 6 pointed head 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 143 03-23 SERVICE SPECIFICATIONS - EXHAUST EXHAUST 0304F-02 SERVICE DATA 2AZ-FE Compression spring Free length Exhaust pipe assy center x Exhaust pipe assy tail 42 mm (1.6535 in.) Compression spring Free length Exhaust pipe assy front x Exhaust manifold converter 43 mm (1.6929 in.) Exhaust pipe assy center x Exhaust pipe assy tail 42 mm (1.6535 in.) Compression spring Free length Exhaust pipe suv-assy front No. 3 x Exhaust pipe assy center 43 mm (1.6929 in.) 3MZ-FE Compression spring Free length 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 144 03-24 SERVICE SPECIFICATIONS - EXHAUST 0304G-02 TORQUE SPECIFICATION 2AZ-FE N⋅m kgf⋅cm ft⋅lbf Front floor heat insulator No. 3 x Body Part Tightened 4.9 50 43 in.⋅lbf Exhaust pipe assy front x Exhaust manifold converter sub-assy 48 489 35 Heated oxyten sensor (Bank 1, sensor 2) x Exhaust pipe assy front 44 449 35 Exhaust pipe assy center x Exhaust pipe assy front 56 571 41 Exhaust pipe assy tail x Exhaust pipe assy center 48 489 35 3MZ-FE N⋅m kgf⋅cm ft⋅lbf Front floor heat insulator No. 3 x Body Part Tightened 4.9 50 43 in.⋅lbf Exhaust pipe support bracket No. 1 x Body 21 214 15 Exhaust pipe assy front x Exhaust manifold converter sub-assy (LH) 56 571 41 Exhaust pipe assy front x Exhaust pipe support bracket No. 1 21 214 15 Heated oxygen sensor (Bank 2, sensor 2) x Exhaust pipe assy front 44 449 35 Exhaust pipe sub-assy front No. 3 x Exhaust pipe assy front 56 571 41 Exhaust pipe sub-assy front No. 3 x Exhaust manifold converter sub-assy (RH) 56 571 41 Heated oxyten sensor (Bank 1, sensor 2) x Exhaust pipe sub-assy front No. 3 44 449 35 Exhaust pipe assy center x Exhaust pipe sub-assy front No. 3 48 489 35 Exhaust pipe assy tail x Exhaust pipe assy center 48 489 35 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 145 03-25 SERVICE SPECIFICATIONS - COOLING COOLING 0304H-04 SERVICE DATA 2AZ-FE Thermostat Valve opening temperature Valve lift at 95
C (203
F) Radiator cap sub-assy Standard opening pressure Minimum opening pressure Cooling fan Standard amperage (80W TYPE) Standard amperage (120W TYPE) 80 to 84
C (176 to 183
F) 10 mm (0.39 in.) or more 93 to 122 kPa (0.95 to 1.25 kgf/cm2, 13.4 to 17.6 psi) 78 kPa (0.8 kgf/cm2, 11.4 psi) at 20
C (68
F) at 20
C (68
F) 5.2 to 8.2 A 8.0 to 11.0 A 3MZ-FE Thermostat Valve opening temperature Valve lift at 95
C (203
F) Radiator cap sub-assy Standard opening pressure Minimum opening pressure Cooling fan Standard amperage 80 to 84
C (176 to 183
F) 10 mm (0.39 in.) or more 93 to 122 kPa (0.95 to 1.25 kgf/cm2, 13.4 to 17.6 psi) 78 kPa (0.8 kgf/cm2, 11.4 psi) at 20
C (68
F) 8.5 to 11.5 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 146 03-26 SERVICE SPECIFICATIONS - COOLING 0304I-04 TORQUE SPECIFICATION 2AZ-FE N⋅m kgf⋅cm ft⋅lbf Water pump x Cylinder block Part Tightened 9.0 92 80 in.⋅lbf Water pump x Water pump pulley 26 265 19 3MZ-FE N⋅m kgf⋅cm ft⋅lbf Water pump assy x Cylinder block Part Tightened 8.0 82 71 in.⋅lbf Idler sub-assy No. 2 x Cylinder block 34 347 25 Engine mounting bracket RH x Cylinder block 54 551 40 Generator bracket No. 2 x Cylinder block 43 438 32 Water inlet x Cylinder block 8.0 82 71 in.⋅lbf Water inlet pipe x Water inlet 20 204 15 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 147 03-27 SERVICE SPECIFICATIONS - LUBRICATION LUBRICATION 0304J-03 SERVICE DATA 2AZ-FE Oil pressure Oil pump Side clearance Tip clearance Body clearance at idle speed at 3,000 rpm Standard Maximum Standard Maximum Standard Maximum 29 kPa (0.3 kgf⋅cm2, 4.3 psi) or more 245 kPa (2.5 kgf⋅cm2, 36 psi) or more 0.030 to 0.085 mm (0.0012 to 0.0033 in.) 0.16 mm (0.0063 in.) 0.080 to 0.160 mm (0.0031 to 0.0063 in.) 0.35 mm (0.0138 in.) 0.100 to 0.170 mm (0.00394 to 0.00669 in.) 0.325 mm (0.01280 in.) 3MZ-FE Oil pressure Oil pump Side clearance Tip clearance Body clearance at idle speed at 3,000 rpm Standard Maximum Standard Maximum Standard Maximum 29 kPa (0.3 kgf⋅cm2, 4.3 psi) or more 245 to 539 kPa (2.5 to 5.5 kgf⋅cm2, 36 to 78 psi) 0.03 to 0.09 mm (0.0012 to 0.0035 in.) 0.15 mm (0.0059 in.) 0.11 to 0.24 mm (0.0043 to 0.0094 in.) 0.35 mm (0.0138 in.) 0.125 to 0.162 mm (0.0050 to 0.0064 in.) 0.30 mm (0.0118 in.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 148 03-28 SERVICE SPECIFICATIONS - LUBRICATION 0304K-03 TORQUE SPECIFICATION 2AZ-FE Part Tightened N⋅m kgf⋅cm ft⋅lbf 15 153 11 Oil pump x Cylinder block 19 194 14 Oil pump x Oil pump cover 8.8 90 79 in.⋅lbf Oil pump x Oil pump strainer 8.8 90 79 in.⋅lbf Oil cooler x Union 79 800 58 Oil cooler x Cylinder block 9.0 92 80 in.⋅lbf Oil filter x Cylinder block Oil pressure switch x Cylinder head 17.5 178 13 Oil draon plug x Oil pan sub-assy 25 255 18 Oil pump driven shaft sprocket x Oil pump assy 30 306 22 Chain tensioner plate x cylinder block 12 122 9.0 Chain vibration danper No. 1 x Cylinder block 9.0 92 80 in.⋅lbf Engine mounting bracket RH x Cylinder block 54 551 40 Engine mounting insulator RH x Engine mounting bracket RH Nut A 95 964 70 Engine mounting insulator RH x Engine mounting bracket RH Nut B 87 887 64 Engine mounting insulator FR x Engine mounting insurator bracket 87 887 64 Oil pan sub-assy x Stiffening crankcace assy 9.0 92 80 in.⋅lbf 3MZ-FE N⋅m kgf⋅cm ft⋅lbf Engine drain plug x Oil pan sub-assy Part Tightened 45 459 33 Oil pressure switch x Cylinder block 15 153 11 Oil pump rotor set x Oil pump assembly 10 105 8.0 Oil pump relif valve x Oil pump housing 49 500 36 OIl pump cover x Oil pump housing 10 102 7.0 8.0 20 43 82 199 438 71 in.⋅lbf 14 32 8.0 82 71 in.⋅lbf 8.0 20 82 204 71 in.⋅lbf 15 8.0 82 71 in.⋅lbf Oil pump assembly x Cylinder block Bolt A Bolt B Bolt C Crank position sensor x Oil pump assembly Oil pan sub-assembly x Cylinder block 10 mm head 12 mm head Oil strainer x Main bearing cap Oil pan sub-assembly No. 2 x Oil pan sub-assembly No. 1 8.0 82 71 in.⋅lbf Transverse engine engine mounting bracket x PS pump bracket Bolt A Nut B Bolt C 54 54 43 551 551 438 40 40 32 Engine mounting insulator RH x Engine mounting bracket Engine mounting insulator RH x Front frame Nut A Nut B 95 87 969 887 70 64 Engine mounting insulator FR x Engine mounting insulator bracket Engine mounting insulator FR x Front frame Bolt A Nut B 87 52 887 530 64 38 Engine moving control rod x body 64 653 47 Compressor mounting bracket No. 1 x Cylinder block 25 255 18 Timing belt idler sub-assembly No. 1 x Cylinder block 34 347 25 Timing belt idler sub-assembly No. 2 x Cylinder block 43 438 32 Compressor and magnetic clutch x Compressor mounting bracket 25 255 18 Transverse engine engine mounting bracket x Cylinder block 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 149 03-29 SERVICE SPECIFICATIONS - IGNITION IGNITION 0304L-03 SERVICE DATA 2AZ-FE Spark plug Recommended spark plug Electrode gap Camshaft position sensor Resistance Crank position sensor Resistance DENSO NGK Standard Maximum SK20R11 IFR6A11 1.0-1.1mm (0.039-0.043 in.) 1.3mm (0.051 in.) at cold at hot 835-1400Ω 1060-1645Ω at cold at hot 985-1600Ω 1265-1890Ω 3MZ-FE Spark plug Recommended spark plug Electrode gap Crank position sensor Resistance Crank position sensor Resistance DENSO NGK Standard Maximum SK20R11 IFR6A11 1.0-1.1mm (0.039-0.043 in.) 1.3mm (0.051 in.) at cold at hot 835-1400Ω 1060-1645Ω at cold at hot 1630-2740Ω 2065-3225Ω 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 150 03-30 SERVICE SPECIFICATIONS - IGNITION 0304M-03 TORQUE SPECIFICATION 2AZ-FE N⋅m kgf⋅cm ft⋅lbf Spark plug x Cylinder head cover Part Tightened 19 194 14 Ignition coil x Cylinder head cover 9.0 92 80 in.⋅lbf 3MZ-FE N⋅m kgf⋅cm ft⋅lbf Spark plug x Cylinder head cover Part Tightened 25 225 18.5 Ignition coil x Cylinder head cover 8.0 82 71 in.⋅lbf 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 151 03-31 SERVICE SPECIFICATIONS - STARTING & CHARGING STARTING & CHARGING 0304N-04 SERVICE DATA 2AZ-FE Starter assy Specified current 90 A or less at 11.5 V Starter relay Specified condition 3-5 3-5 Starter armature assy Depth Standard 3.1 mm (0.122 in.) Maximum 3.8 mm (0.150 in.) Starter commutator end frame assy Brush length Magnetic switch resistance 10 kΩ or higher Below 1 Ω (when battery voltage is applied to terminals 1 and 2) Standard 9.0 mm (0.354 in.) Minimum 4.0 mm (0.158 in.) Terminal 50 - C Terminal 50 - Switch body Below 1 Ω Below 2 Ω Segments Below 1 Ω Commutator - Coil core 1 MΩ or higher Starter armature resistance Voltage regulator Regulating voltage Standard amperage Generator brush holder assy Brush length 13.2 to 14.8 V 10 A or less Standard 10.5 mm (0.413 in.) Minimum 4.5 mm (0.177 in.) Generator rotor assy Open circuit Slip ring diameter Resistance 2.3 to 2.7 Ω at 20
C (68
F) Standard 14.2 to 14.4 mm (0.559 to 0.567 in.) Minimum 14.0 mm (0.551 in.) 3MZ-FE Starter assy Specified current 90 A or less at 11.5 V Starter relay Specified condition 3-5 3-5 Starter armature assy Depth Standard 3.1 mm (0.122 in.) Maximum 3.8 mm (0.150 in.) Starter commutator end frame assy Brush length Magnetic switch resistance 10 kΩ or higher Below 1 Ω (when battery voltage is applied to terminals 1 and 2) Standard 9.0 mm (0.354 in.) Minimum 4.0 mm (0.158 in.) Terminal 50 - C Terminal 50 - Switch body Starter armature resistance Voltage regulator Generator brush holder assy Brush length Generator rotor assy Open circuit Slip ring diameter Below 1 Ω Below 2 Ω Segments Below 1 Ω Commutator - Coil core 1 MΩ or higher Regulating voltage Standard amperage 13.2 to 14.8 V 10 A or less Standard 10.5 mm (0.413 in.) Minimum 4.5 mm (0.177 in.) Resistance 2.3 to 2.7 Ω at 20
C (68
F) Standard 14.2 to 14.4 mm (0.559 to 0.567 in.) Minimum 14.0 mm (0.551 in.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 152 03-32 SERVICE SPECIFICATIONS - STARTING & CHARGING 0304O-04 TORQUE SPECIFICATION 2AZ-FE Part Tightened N⋅m kgf⋅cm ft⋅lbf Starter assy x Engine 37 377 27 Starter wire x Terminal 30 of starter 9.8 100 7.0 Starter drive housing assy x Magnet switch assy 7.5 76 66 in.⋅lbf Starter commutator end frame assy x Starter drive housing assy 6.0 61 53 in.⋅lbf Lead wire of starter yoke x Terminal C of magnet switch assy 10 102 7.0 Battery clamp x Battery clamp bolt 5.5 56 49 in.⋅lbf Cable x Battery terminal 3.5 36 31 in.⋅lbf 21 52 214 530 15 38 Generator wire x Generator assy 9.8 100 7.0 Generator rectifier end frame x Drive end frame assy 5.8 59 51 in.⋅lbf Generator brush holder assy x Generator rectifier end frame 1.8 18 16 in.⋅lbf Generator rear end cover x Generator rectifier end frame 4.6 47 41 in.⋅lbf Starter assy Generator assy (100A) Generator assy x Engine M8 M10 Retainer plate x Drive end frame assy generator 2.3 23 20 in.⋅lbf Generator pulley x Generator rotor assy 110 1,122 81 21 52 214 530 15 38 Generator wire x Generator assy 9.8 100 7.0 Generator rectifier end frame x Drive end frame assy 5.8 59 51 in.⋅lbf Generator brush holder assy x Generator rectifier end frame 1.8 18 16 in.⋅lbf Generator rear end cover x Generator rectifier end frame 4.6 47 41 in.⋅lbf Generator assy (130A) Generator assy x Engine M8 M10 Retainer plate x Drive end frame assy generator 2.3 23 20 in.⋅lbf Generator pulley x Generator rotor assy 110 1,122 81 N⋅m kgf⋅cm ft⋅lbf Starter assy x Engine 37 377 27 Starter wire x Terminal 30 of starter 9.8 100 7.0 Starter drive housing assy x Magnet switch assy 7.5 76 66 in.⋅lbf Starter commutator end frame assy x Starter drive housing assy 6.0 61 53 in.⋅lbf Lead wire of starter yoke x Terminal C of magnet switch assy 10 102 7.0 Battery clamp x Battery clamp bolt 5.5 56 49 in.⋅lbf Cable x Battery terminal 3.5 36 31 in.⋅lbf Generator assy x Generator bracket No. 2 58 592 43 Generator assy x Generator belt adjusting bar 18 184 13 Generator wire x Generator assy 9.8 100 7.0 Generator rectifier end frame x Drive end frame assy 5.8 59 51 in.⋅lbf Generator brush holder assy x Generator rectifier end frame 1.8 18 16 in.⋅lbf Generator rear end cover x Generator rectifier end frame 4.6 47 41 in.⋅lbf Retainer plate x Drive end frame assy generator 2.3 23 20 in.⋅lbf Generator pulley x Generator rotor assy 110 1,122 81 58 592 43 Generator assy x Generator belt adjusting bar 18 184 13 Generator wire x Generator assy 9.8 100 7.0 3MZ-FE Part Tightened Starter assy Generator assy (100A) Generator assy (130A) Generator assy x Generator bracket No. 2 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 153 03-33 SERVICE SPECIFICATIONS Part Tightened - STARTING & CHARGING N⋅m kgf⋅cm ft⋅lbf Generator rectifier end frame x Drive end frame assy 5.8 59 51 in.⋅lbf Generator brush holder assy x Generator rectifier end frame 1.8 18 16 in.⋅lbf Generator rear end cover x Generator rectifier end frame 4.6 47 41 in.⋅lbf Retainer plate x Drive end frame assy generator 2.3 23 20 in.⋅lbf Generator pulley x Generator rotor assy 110 1,122 81 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 154 03-68 SERVICE SPECIFICATIONS - ENGINE HOOD/DOOR ENGINE HOOD/DOOR 03051-03 TORQUE SPECIFICATION N⋅m kgf⋅cm HOOD Part Tightened - - ft⋅lbf - Hood × Hood hinge 13 130 10 Hood lock × Body 62 in.⋅lbf 7.0 71 FRONT DOOR - - - Door hinge × Body 23 235 17 Door hinge × Door panel 27 235 17 Door lock × Door panel for 3 torx screw 5.0 50 45 in.⋅lbf Door lock × Door panel for screw 49 in.⋅lbf 5.5 56 Door lock striker × Body 23 235 17 Handle frame x Door panel 4.0 41 35 in.⋅lbf Outside handle cover x Door panel 4.0 41 35 in.⋅lbf Window regulator × Motor 5.4 55 48 in.⋅lbf Window regulator × Door panel 11 112 8.0 REAR DOOR - - - Door hinge × Body for Lower hinge 26 265 19 Door hinge × Body for Upper hinge 17 23 235 Door hinge × Door panel 26 265 19 Door lock × Door panel 5.0 50 44 in.⋅lbf Door lock × Door panel 5.5 56 49 in.⋅lbf Door lock striker × Body 23 235 17 Handle frame x Door panel 4.0 41 35 in.⋅lbf Outside handle cover x Door panel 4.0 41 35 in.⋅lbf Window regulator × Door panel 11 112 8.0 Window regulator × Motor 5.4 55 48 in.⋅lbf - - - Door lock × Door panel 12.5 128 9.0 Door lock striker × Body 23 235 17 Hinge x Body 19.5 199 14 Lock cylinder x Door panel 5.5 56 49 in.⋅lbf Outside handle x Door panel 5.5 56 49 in.⋅lbf BACK DOOR BACK DOOR STAY - - - Back door Stay × Body 8.0 82 71 in.⋅lbf Back door Stay × Door panel 8.0 82 71 in.⋅lbf 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 189 03-69 SERVICE SPECIFICATIONS - EXTERIOR/INTERIOR TRIM EXTERIOR/INTERIOR TRIM 0304S-02 TORQUE SPECIFICATION Part Tightened N⋅m kgf⋅cm ft⋅lbf Front bumper reinforcement x Body 77 780 57 Front bumper cover x Body 5.5 55 49 in.⋅lbf 3.0 8.0 31 85 27 in.⋅lbf 71 in.⋅lbf Rear bumper reinforcement No. 1 x Body 27 275 20 Rear bumper x Quarter panel mudguard 3.0 31 27 in.⋅lbf Front seat outer belt shoulder anchor × Body 42.0 420 31 Rear No. 1 seat outer belt floor anchor × Body 42.0 420 31 Rear No. 2 seat outer belt shoulder anchor × Body 42.0 420 31 FRONT BUMPER REAR BUMPER Rear bumper cover Bolt Nut ROOF HEADLINING 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 190 03-67 SERVICE SPECIFICATIONS - SLIDING ROOF/CONVERTIBLE SLIDING ROOF/CONVERTIBLE 0304T-02 TORQUE SPECIFICATION N⋅m kgf⋅cm ft⋅lbf Sliding roof housing assembry × Bracket Part Tightened 8.0 82 68 in.⋅lbf Sliding roof housing assembry × Body 5.0 51 43 in.⋅lbf Sliding roof housing assembry × Sliding roof drive gear 5.4 55 49 in.⋅lbf 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 188 03-65 SERVICE SPECIFICATIONS - SEAT SEAT 0305V-03 TORQUE SPECIFICATION Part Tightened N⋅m kgf⋅cm ft⋅lbf 8 82 71 in.⋅lbf Seat Inner belt assy x Seat adjuster assy 42 428 31 Seatback cover bracket x Seat adjuster assy (w/ Side airbag) 5.6 57 49 in.⋅lbf Armrest assy x Seat adjuster assy 37 377 27 36.7 375 27 Seat cushion frame No. 1 x Seat track assy inner 42 428 31 Seat cushion frame No. 2 x Seat track assy outer 42 428 31 Seatback frame lower x Seat cushion frame 42 428 31 Seat track stop plate x Seatback frame lower 18 184 13 Reclining control link x Seat track assy 42 428 31 Seatback frame assembly x Seatback frame lower 42 428 31 Seat belt assy Inner x Seatback frame lower 42 428 31 Fold seat stopper band x Seatback frame assy 9 92 80 in.⋅lbf Seat cushion frame assy x Reclining control link 18 184 13 Seat cushion frame assy x Seatback frame lower 21 214 15 36.7 375 27 9 92 80 in.⋅lbf Seat cushion frame No. 1 x Seat track assy outer 42 428 31 Seat cushion frame No. 2 x Seat track assy inner 42 428 31 Seatback frame lower x Seat cushion frame No. 1 42 428 31 Seatback frame lower x Seat cushion frame No. 2 120 1224 89 Seat track stop plate x Seatback frame lower 18 184 13 FRONT SEAT Airbag sensor x Seat adjuster assy Seat assy x Body REAR NO. 1 SEAT LH (w/o REAR NO. 2 SEAT) Seat assy x Body Fold seat stopper band x Body REAR NO. 1 SEAT RH (w/o REAR NO. 2 SEAT) Reclining control link x Seatback frame lower Bolt 21 214 15 Reclining control link x Seat track assy Nut 42 428 31 Inside Outerside 55 42 561 428 41 31 Seat belt assy Inner x Seatback frame lower 42 428 31 Seat belt assy outer center x Seatback frame assy 42 428 31 Fold seat stopper band x Seatback frame assy 9 92 80 in.⋅lbf Seat cushion frame assy x Reclining control link 18 184 13 Seat cushion frame assy x Seatback frame lower 21 214 15 Armrest assy x Center seatback frame assy 21 214 15 Seatback hinge x Center seatback frame assy 21 214 15 Seat cushion spring No. 2 x Center seatback frame assy 21 214 15 Seatback hinge x Center seatback frame lower 21 214 15 Seat cushion spring No. 2 hinge x Center seatback frame lower 21 214 15 80 in.⋅lbf Seatback frame assy x Seatback frame lower Fold seat stopper band x Seatback frame assy 9 92 36.7 375 27 9 92 80 in.⋅lbf Seat cushion frame No. 1 x Seat track assy outer 42 428 31 Seat cushion frame No. 2 x Seat track assy inner 42 428 31 Seat assy x Body Fold seat stopper band x Body REAR NO. 1 SEAT LH (w/ REAR NO. 2 SEAT) Seatback frame lower x Seat cushion frame No. 1 42 428 31 Seatback frame lower x Seat cushion frame No. 2 120 1224 89 Seat track stop plate x Seatback frame lower 18 184 13 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 186 03-66 SERVICE SPECIFICATIONS - SEAT Part Tightened N⋅m kgf⋅cm ft⋅lbf Reclining control link x Seatback frame lower Bolt 21 214 15 Reclining control link x Seat track assy Nut 42 428 31 Inside Outerside 55 42 561 428 41 31 Seat belt assy Inner x Seatback frame lower 42 428 31 Seat belt assy outer center x Seatback frame assy 42 428 31 Seatback frame assy x Seatback frame lower Fold seat stopper band x Seatback frame assy 9 92 80 in.⋅lbf Seat cushion frame assy x Reclining control link 18 184 13 Seat cushion frame assy x Seatback frame lower 21 214 15 Armrest assy x Center seatback frame assy 21 214 15 Seatback hinge x Center seatback frame assy 21 214 15 Seat cushion spring No. 2 x Center seatback frame assy 21 214 15 Seatback hinge x Center seatback frame lower 21 214 15 Seat cushion spring No. 2 hinge x Center seatback frame lower 21 214 15 Fold seat stopper band x Seatback frame assy 9 92 80 in.⋅lbf 36.7 375 27 9 92 80 in.⋅lbf Seat cushion frame No. 1 x Seat track assy inner 42 428 31 Seat cushion frame No. 2 x Seat track assy outer 42 428 31 Seatback frame lower x Seat cushion frame 42 428 31 Seat track stop plate x Seatback frame lower 18 184 13 Reclining control link x Seat track assy 42 428 31 Seatback frame assembly x Seatback frame lower 42 428 31 Seat belt assy Inner x Seatback frame lower 42 428 31 Fold seat stopper band x Seatback frame assy 9 92 80 in.⋅lbf Seat cushion frame assy x Reclining control link 18 184 13 Seat assy x Body Fold seat stopper band x Body REAR NO. 1 SEAT RH (w/ REAR NO. 2 SEAT) Seat cushion frame assy x Seatback frame lower 21 214 15 36.7 375 27 9 92 80 in.⋅lbf No. 2 seat leg x No.2 seatback frame sub-assy 42 428 31 No. 2 seat leg x No.2 cushion frame sub-assy 21 214 15 No. 2 seat leg x No.2 cushion frame sub-assy 18 184 13 Seat assy x Body 37 377 27 Seat assy x Body Fold seat stopper band x Body REAR NO. 2 SEAT 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 187 03-47 SERVICE SPECIFICATIONS - BRAKE BRAKE 031IB-04 SERVICE DATA Brake pedal height (from asphalt sheet) 150.0 - 160.0 mm (5.906 - 6.299 in.) Brake Pedal free play 2.0 - 3.0 mm (0.079 - 0.118 in.) Stop lamp switch clearance 0.5 - 2.6 mm (0.020 - 0.102 in.) Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110 lbf) More than 80 mm (3.1 in.) Brake booster push rod to piston clearance (w/ SST) 0 mm (0 in.) Front brake pad thickness Standard: 11.0 mm (0.433 in.) Minimum: 1.0 mm (0.039 in.) Front brake disc thickness Standard: 28.0 mm (1.102 in.) Minimum: 26.0 mm (1.024 in.) Front brake disc runout Maximum: 0.05 mm (0.0020 in.) Reae brake pad thickness Standard: 10.0 mm (0.394 in.) Minimum: 1.0 mm (0.039 in.) Rear brake disc thickness Standard: 10.0 mm (0.394 in.) Maximum: 8.5 mm (0.335 in.) Reae brake disc runout Maximum: 0.15 mm (0.0059 in.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 168 03-48 SERVICE SPECIFICATIONS - BRAKE 031IC-04 TORQUE SPECIFICATION Part Tightened N⋅m kgf⋅cm ft⋅lbf Bleeder plug 8.3 85 73 in.⋅lbf Brake booster clevis lock nut 26 265 19 Stop lamp switch assy lock nut 17 173 13 Brake pedal support sub-assy x Brake pedal sub-assy 37 375 27 Brake master cylinder x Brake tube 15 155 11 Brake booster x Body 13 130 9 Brake pedal support sub-assy x Body 13 130 9 Brake pedal support sub-assy x Instrument panel reinforcement 20 204 15 Brake master cylinder x Brake booster 13 127 9 Wheel nut 103 1,050 76 Front brake cylinder mounting x Steering knuckle 104 1,061 77 Front brake cylinder x Front brake cylinder mounting 34 350 25 Front disc brake cylinder x Flexible hose 29 300 21 Rear disc brake cylinder mounting x Rear axle 78 799 58 Rear brake cylinder x Rear brake cylinder mounting 43 440 32 Rear disc brake cylinder x Flexible hose 29 300 21 Front speed sensor x Steering knuckle 8.0 82 71 in.⋅lbf Front speed sensor wire harness clamp x Shock absorber 29 300 22 5.0 51 44 in.⋅lbf 8.0 82 71 in.⋅lbf Rear speed sensor wire harness clamp x Body 5.0 51 44 in.⋅lbf Brake actuator with bracket x Body 19 194 14 Brake actuator assy x Brake tube 15 155 11 Brake actuator x Brake actuator bracket assy 5.4 55 48 in.⋅lbf Yawrate sensor x Body 14 143 10 Front speed sensor wire harness clamp x Body Rear speed sensor x Rear axle 4WD: 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 169 03-44 SERVICE SPECIFICATIONS - TRANSFER TRANSFER 031DF-03 SERVICE DATA Driven pinion preload (For use with SST(s)) New bearig Used bearing 1.1 to 1.6 N⋅m (11 to 16 kgf⋅cm, 9.7 to 14.2 in.⋅lbf) 0.9 to 1.4 N⋅m (9 to 14 kgf⋅cm, 8.0 to 12.4 in.⋅lbf) Total preload (For use with SST(s)) New bearing Used bearing 1.30 to 1.98 N⋅m (13.3 to 20.2 kgf⋅cm, 11.5 to 17.5 in.⋅lbf) 1.07 to 1.68 N⋅m (10.9 to 17.1 kgf⋅cm, 9.5 to 14.9 in.⋅lbf) Ring gear Backlash Ring gear runout Maximum 0.1 mm (0.004 in.) Transfer ring gear mounting case Maximum 0.03 mm (0.0012 in.) Washer thickness LH side Mark AA AB AC BA BB BC CA CB CC DA DB DC EA EB EC FA FB FC GA GB GC HA HB HC JA JB JC KA KB KC LA LB 0.10 to 0.15 mm (0.0039 to 0.0059 in.) 2.07 mm (0.0814 in.) 2.10 mm (0.0826 in.) 2.13 mm (0.0838 in.) 2.16 mm (0.0850 in.) 2.19 mm (0.0862 in.) 2.22 mm (0.0874 in.) 2.25 mm (0.0885 in.) 2.28 mm (0.0897 in.) 2.31 mm (0.0909 in.) 2.34 mm (0.0921 in.) 2.37 mm (0.0933 in.) 2.40 mm (0.0944 in.) 2.43 mm (0.0956 in.) 2.46 mm (0.0968 in.) 2.49 mm (0.0980 in.) 2.52 mm (0.0992 in.) 2.55 mm (0.1003 in.) 2.58 mm (0.1015 in.) 2.61 mm (0.1027 in.) 2.64 mm (0.1039 in.) 2.67 mm (0.1051 in.) 2.70 mm (0.1062 in.) 2.73 mm (0.1074 in.) 2.76 mm (0.1086 in.) 2.79 mm (0.1098 in.) 2.82 mm (0.1110 in.) 2.85 mm (0.1122 in.) 2.88 mm (0.1133 in.) 2.91 mm (0.1145 in.) 2.94 mm (0.1157 in.) 2.97 mm (0.1169 in.) 3.00 mm (0.1181 in.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 165 03-45 SERVICE SPECIFICATIONS Driven pinion bearing waasher thickness front side Washer thickness RH side - TRANSFER Mark AA AC BB CA CC DB EA EC FB GA GC HB JA JC KB LA LC MB NA NC PB QA QC 1.20 mm (0.0472 in.) 1.22 mm (0.0480 in.) 1.24 mm (0.0488 in.) 1.26 mm (0.0496 in.) 1.28 mm (0.0503 in.) 1.30 mm (0.0511 in.) 1.32 mm (0.0519 in.) 1.34 mm (0.0527 in.) 1.36 mm (0.0535 in.) 1.38 mm (0.0543 in.) 1.40 mm (0.0551 in.) 1.42 mm (0.0559 in.) 1.44 mm (0.0566 in.) 1.46 mm (0.0574 in.) 1.48 mm (0.0582 in.) 1.50 mm (0.0590 in.) 1.52 mm (0.0598 in.) 1.54 mm (0.0606 in.) 1.56 mm (0.0614 in.) 1.58 mm (0.0622 in.) 1.60 mm (0.0629 in.) 1.62 mm (0.0637 in.) 1.64 mm (0.0645 in.) Mark AA AB AC BA BB BC CA CB CC DA DB DC EA EB EC FA FB FC GA GB GC HA HB HC JA JB JC KA KB KC LA LB LC MA MB MC NA NB 1.47 mm (0.0578 in.) 1.50 mm (0.0590 in.) 1.53 mm (0.0602 in.) 1.56 mm (0.0614 in.) 1.59 mm (0.0625 in.) 1.62 mm (0.0637 in.) 1.65 mm (0.0649 in.) 1.68 mm (0.0661 in.) 1.71 mm (0.0673 in.) 1.74 mm (0.0685 in.) 1.77 mm (0.0696 in.) 1.80 mm (0.0708 in.) 1.83 mm (0.0720 in.) 1.86 mm (0.0732 in.) 1.89 mm (0.0744 in.) 1.92 mm (0.0755 in.) 1.95 mm (0.0767 in.) 1.98 mm (0.0779 in.) 2.01 mm (0.0790 in.) 2.04 mm (0.0803 in.) 2.07 mm (0.0814 in.) 2.10 mm (0.0826 in.) 2.13 mm (0.0838 in.) 2.16 mm (0.0850 in.) 2.19 mm (0.0862 in.) 2.22 mm (0.0874 in.) 2.25 mm (0.0885 in.) 2.28 mm (0.0897 in.) 2.31 mm (0.0909 in.) 2.34 mm (0.0921 in.) 2.37 mm (0.0933 in.) 2.40 mm (0.0944 in.) 2.43 mm (0.0956 in.) 2.46 mm (0.0968 in.) 2.49 mm (0.0980 in.) 2.52 mm (0.0992 in.) 2.55 mm (0.1003 in.) 2.58 mm (0.1015 in.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 166 03-46 SERVICE SPECIFICATIONS - TRANSFER 031DG-03 TORQUE SPECIFICATION Part Tightened N⋅m kgf⋅cm ft⋅lbf 277 378 2,820 3,855 204 279 Ring gear mount set bolt 78 790 57 Transfer case x Transfer RH bearing retainer sub-assy 28 286 21 Transfer case x Transfer extension housing 26 260 19 Transfer case x Transfer & transaxle setting stud bolt 39 400 29 transfer extension housing x Transfer dynamic damper 26 260 19 Transfer case cover No.1 x Transfer case breather oil deflector 6.5 66 57 in.⋅lbf Transfer case x Transfer case cover No.1 20 200 14 Transaxle assy x Transfer assy 69 700 51 Transfer case No.1 plug x Transfer case 49 500 36 Transfer case No.2 plug x Transfer Case 49 500 36 Transfer drain plug x Transfer case 49 500 36 Transfer gear nut (For use with SST(s)) STD Max. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 167 03-39 SERVICE SPECIFICATIONS - DIFFERENTIAL DIFFERENTIAL 031FB-03 SERVICE DATA Carrier oil seal drive in depth 2.0
0.3 mm (0.079
0.012 in.) Side gear shaft oil seal drive in depth 0
0.5mm (0
0.019 in.) Companion flange vertical runout 0.10 mm (0.0039 in.) or less Companion flange horizontal runout 0.10 mm (0.0039 in.) or less Ring gear runout 0.07 mm (0.0028 in.) or less Side gear backlash 0.05 to 0.20 mm (0.0020 to 0.0079 in.) Drive pinion to ring gear backlash 0.13 to 0.18 mm (0.0051 to 0.0071 in.) Drive pinion preload (at starting) Rear differential New bearing Reused bearing 1.1 to 1.7 N·m (11 to 17 kgf·cm, 9.6 to 14.8 in.·lbf) 0.6 to 0.9 N·m (6 to 9 kgf·cm, 5.2 to 7.8 in.·lbf) Total preload (Drive pinion preload plus) 0.3 to 0.5 N·m (3 to 5 kgf·cm, 2.6 to 4.3 in.·lbf) Side gear thrust washer thickness mm (in.) 0.93 to 0.97 (0.0366 to 0.0382) 0.98 to 1.02 (0.0386 to 0.0402) 1.03 to 1.07 ((0.0406 to 0.0421)) 1.08 to 1.12 (0.0425 to 0.0441) 1.13 to 1.17 (0.0445 to 0.0461) 1.18 to 1.22 (0.0465 to 0.0480) 1 23 to 1.27 1.23 1 27 (0.0484 (0 0484 to 0.0500) 0 0500) 1.28 to 1.32 (0.0504 to 0.0520) 1.33 to 1.37 (0.0524 to 0.0539) 1.38 to 1.42 (0.0543 to 0.0559) mm (in.) 2.26 to 2.28 (0.0890 to 0.0898) 2.29 to 2.31 (0.0902 to 0.0909) 2.32 to 2.34 (0.0913 to 0.0921) 2.35 to 2.37 (0.0925 to 0.0933) 2.38 to 2.40 (0.0937 to 0.0945) 2.41 to 2.43 (0.0949 to 0.0957) 2.44 to 2.46 (0.0961 to 0.0969) 2.47 to 2.49 (0.0972 to 0.0980) 2.50 to 2.52 (0.0984 to 0.0992) 2.53 to 2.55 (0.0996 to 0.1004) 2.56 to 2.58 (0.1008 to 0.1016) 2.59 to 2.61 (0.1020 to 0.1028) 2.62 to 2.64 (0.1031 to 0.1039) 2.65 to 2.67 (0.1043 to 0.1051) 2.68 to 2.70 (0.1055 to 0.1063) Drive pinion plate washer thickness 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 160 03-40 SERVICE SPECIFICATIONS Rear differential Side gear shaft plate washer thickness - DIFFERENTIAL mm (in.) 2.21 to 2.23 (0.0870 to 0.0878) 2.24 to 2.26 (0.0882 to 0.0890) 2.27 to 2.29 (0.0894 to 0.0902) 2.30 to 2.32 (0.0906 to 0.0913) 2.33 to 2.35 (0.0917 to 0.0925) 2.36 to 2.38 (0.0929 to 0.0937) 2.39 to 2.41 (0.0941 to 0.0949) 2.42 to 2.44 (0.0953 to 0.0961) 2.45 to 2.47 (0.0965 to 0.0972) 2.48 to 2.50 (0.0976 to 0.0984) 2.51 to 2.53 (0.0988 to 0.0996) 2.54 to 2.56 (0.1000 to 0.1008) 2.57 to 2.59 (0.1012 to 0.1020) 2.60 to 2.62 (0.1024 to 0.1031) 2.63 to 2.65 (0.1035 to 0.1043) 2.66 to 2.68 (0.1047 to 0.1055) 2.69 to 2.71 (0.1059 to 0.1067) 2.72 to 2.74 (0.1071 to 0.1079) 2.75 to 2.77 (0.1083 to 0.1091) 2.78 to 2.80 (0.1094 to 0.1102) 2.81 to 2.83 (0.1106 to 0.1114) 2.84 to 2.86 (0.1118 to 0.1126) 2.87 to 2.89 (0.1130 to 0.1138) 2.90 to 2.92 (0.1142 to 0.1150) 2.93 to 2.95 (0.1154 to 0.1161) 2.96 to 2.98 (0.1165 to 0.1173) 2.99 to 3.01 (0.1177 to 0.1185) 3.02 to 3.04 (0.1189 to 0.1197) 3.05 to 3.07 (0.1201 to 0.1209) 3.08 to 3.10 (0.1213 to 0.1220) 3.11 to 3.13 (0.1224 to 0.1232) 3.14 to 3.16 (0.1236 to 0.1244) 3.17 to 3.19 (0.1248 to 0.1256) 3.20 to 3.22 (0.1260 to 0.1268) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 161 03-41 SERVICE SPECIFICATIONS - DIFFERENTIAL 031FC-04 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Drain plug 49 500 36 Filler plug 49 500 36 Breather plug 21 210 15 Companion flange x Drive pinion See page 29-11 Companion flange x Propeller shaft 74 750 54 Differential case x Ring gear 97 985 71 Differential carrier x Side bearing cap 79 800 58 Differential carrier x Differential carrier cover 47 475 34 Rear differential support No.1 x Differential carrier assy 103 1,050 76 Rear differential support No.1 x Rear suspension member sub-assy 137 1,400 101 Differential carrier assy x Rear suspension member sub-assy 95 970 70 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 162 03-51 SERVICE SPECIFICATIONS - AUTOMATIC TRANSMISSION / TRANSAXLE AUTOMATIC TRANSMISSION / TRANSAXLE 031I7-02 SERVICE DATA U241E Line pressure (Wheel locked) Engine idling D position R position AT stall (Throttle valve fully opened) D position R position Engine stall revolution D and R positions N → D position N → R position Time lag Engine idle speed (A/C OFF) N position Drive plate runout Torque converter runout Max. Max. Differential oil seal drive in depth LH side RH side Shift schedule D position (Throttle valve fully opened) (Throttle valve fully closed) 2 position (Throttle valve fully opened) L position (Throttle valve fully opened) Lock-up point 3rd gear O/D gear 373 - 412 kPa (3.8 - 4.2 kgf⋅cm2, 54 - 60 psi) 932 - 1,000 kPa (9.5 - 10.5 kgf⋅cm2, 135 - 149 psi) 931 - 1,031kPa (9.5 - 10.5 kgf⋅cm2, 135 - 150 psi) 1,768 - 1,968 kPa (18.0 - 20.0 kgf⋅cm2, 256 - 285 psi) 2,350
150 rpm Less than 1.2 seconds Less than 1.5 seconds 650
50 rpm 0.20 mm (0.0079 in.) 0.30 mm (0.0118 in.) 0
0.5 mm (0
0.020 in.) 0
0.5 mm (0
0.020 in.) 1→2 2→3 3→4 4→3 3→2 2→1 3→4 4→3 56 - 63 km/h (35 - 39 mph) 104 - 112 km/h (65 - 70 mph) 168 - 181 km/h (104 - 112 mph) 159 - 173 km/h (99 - 108 mph) 98 - 106 km/h (61 - 66 mph) 47 - 53 km/h (29 - 33 mph) 42 - 48 km/h (26 - 30 mph) 17 - 23 km/h (11 - 14 mph) 1→2 3→2 2→1 56 - 63 km/h (35 - 39 mph) 104 - 112 km/h (65 - 70 mph) 47 - 53 km/h (29 - 33 mph) 3→2 2→1 104 - 112 km/h (65 - 70 mph) 51 - 58 km/h (32 - 36 mph) Throttle valve opening 5 % Lock-up ON Lock-up OFF Lock-up ON Lock-up OFF 97 - 105 km/h (60 - 65 mph) 95 - 102 km/h (59 - 63 mph) 63 - 70 km/h (39 - 43 mph) 61 - 67 km/h (32 - 42 mph) U140F Line pressure (Wheel locked) Engine idling D position R position AT stall (Throttle valve fully opened) D position R position Engine stall revolution Time lag Engine idle speed (A/C OFF) Drive plate runout Torque converter runout Differential oil seal drive in depth D and R position N → D position N → R position N position Max. Max. LH side RH side 373 - 412 kPa (3.8 - 4.2 kgf⋅cm2, 54 - 60 psi) 932 - 1,000 kPa (9.5 - 10.5 kgf⋅cm2, 135 - 149 psi) 931 - 1,031kPa (9.5 - 10.5 kgf⋅cm2, 135 - 150 psi) 1,768 - 1,968 kPa (18.0 - 20.0 kgf⋅cm2, 256 - 285 psi) 2,650
150 rpm Less than 1.2 seconds Less than 1.2 seconds 700
50 rpm 0.20 mm (0.0079 in.) 0.30 mm (0.0118 in.) 0
0.5 mm (0
0.020 in.) 6
0.5 mm (0.236
0.020 in.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 172 03-52 SERVICE SPECIFICATIONS - AUTOMATIC TRANSMISSION / TRANSAXLE 1.5
0.4 mm (0.059
0.016 in.) Extension housing oil seal drive in depth Shift schedule D position (Throttle valve fully opened) (Throttle valve fully closed) 2 position (Throttle valve fully opened) L position (Throttle valve fully opened) Lock-up point 3rd gear O/D gear 1→2 2→3 3→4 4→3 3→2 2→1 3→4 4→3 55 - 62 km/h (34 - 39 mph) 103 - 111 km/h (64 - 69 mph) 157 - 170 km/h (98 - 106 mph) 148 - 161 km/h (92 - 100 mph) 96 - 103km/h (60 - 64 mph) 43 - 49 km/h (27 - 30 mph) 31 - 37 km/h (19 - 23 mph) 17 - 23 km/h (11 - 14 mph) 1→2 3→2 2→1 55 - 62 km/h (34 - 39 mph) 106 - 113 km/h (66 - 70 mph) 43 - 49 km/h (27 - 30 mph) 3→2 2→1 106 - 113 km/h (66 - 70 mph) 48 - 54 km/h (30 - 34 mph) Throttle valve opening 5 % Lock-up ON Lock-up OFF Lock-up ON Lock-up OFF 157 - 170 km/h (98 - 106 mph) 148 - 161 km/h (92 - 100 mph) 76 - 83 km/h (47 - 52 mph) 71 - 78 km/h (44 - 48 mph) U151E Line pressure (Wheel locked) Engine idling D position R position AT stall (Throttle valve fully opened) D position R position Engine stall revolution Time lag Engine idle speed (A/C OFF) Drive plate runout Torque converter runout Differential oil seal drive in depth D and R positions N → D position N → R position N position Max. Max. LH side RH side 372 to 412 kPa (3.8 to 4.2 kgf⋅cm2, 54 to 60 psi) 672 to 742 kPa (6.9 to 7.6 kgf⋅cm2, 97 to 108 psi) 931 to 1,031 kPa (9.5 to 10.5 kgf⋅cm2, 135 to 150 psi) 1,768 to 1,968 kPa (18.0 to 20.1 kgf⋅cm2, 256 to 285 psi) 2,100
150 rpm Less than 1.2 seconds Less than 1.5 seconds 650
50 rpm 0.20 mm (0.0079 in.) 0.30 mm (0.0118 in.) 0
0.5 mm (0
0.020 in.) 0
0.5 mm (0
0.020 in.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 173 03-53 SERVICE SPECIFICATIONS - AUTOMATIC TRANSMISSION / TRANSAXLE U151E Shift schedule (Shift lever with Multi-mode automatic transmission & Gate shift type) D position (Throttle valve fully opened) 1→2 2→3 3→4 4→5 5→4 4→3 3→2 2→1 (Throttle valve fully closed) 4→5 5→4 Lock-up point D position 5th gear 39 to 48 km/h (24 to 30 mph) 79 to 90 km/h (49 to 56 mph) 129 to 147 km/h (80 to 91 mph) 191 to 213 km/h (119 to 132 mph) 184 to 205 km/h (114 to 127 mph) 125 to 142 km/h (78 to 88 mph) 74 to 84 km/h (46 to 52 mph) 36 to 43 km/h (22 to 27 mph) 45 to 53 km/h (28 to 33 mph) 35 to 42 km/h (22 to 26 mph) Throttle valve opening 5 % Lock-up ON Lock-up OFF Lock-up ON Lock-up OFF Lock-up ON Lock-up OFF 4th gear 3th gear 80 to 90 km/h (50 to 56 mph) 79 to 89 km/h (49 to 55 mph) 98 to 110 km/h (61 to 68 mph) 95 to 107 km/h (59 to 66 mph) 64 to 74 km/h (40 to 46 mph) 61 to 70 km/h (38 to 43 mph) U151F Line pressure (Wheel locked) Engine idling D position R position AT stall (Throttle valve fully opened) D position R position Engine stall revolution D and R positions N → D position N → R position Time lag Engine idle speed (A/C OFF) N position Drive plate runout Torque converter runout Max. Max. Differential oil seal drive in depth LH side RH side Shift schedule (Shift lever with Multi-mode automatic transmission & Gate shift type) D position (Throttle valve fully opened) 1→2 2→3 3→4 4→5 5→4 4→3 3→2 2→1 (Throttle valve fully closed) 4→5 5→4 Lock-up point D position 5th gear 372 to 412 kPa (3.8 to 4.2 kgf⋅cm2, 54 to 60 psi) 672 to 742 kPa (6.9 to 7.6 kgf⋅cm2, 97 to 108 psi) 931 to 1,031 kPa (9.5 to 10.5 kgf⋅cm2, 135 to 150 psi) 1,768 to 1,968 kPa (18.0 to 20.1 kgf⋅cm2, 256 to 285 psi) 2,550
150 rpm Less than 1.2 seconds Less than 1.5 seconds 650
50 rpm 0.20 mm (0.0079 in.) 0.30 mm (0.0118 in.) 0
0.5 mm (0
0.020 in.) 6.0
0.5 mm (0.236
0.020 in.) 42 to 49 km/h (26 to 30 mph) 81 to 88 km/h (50 to 55 mph) 132 to 143 km/h (82 to 89 mph) 195 to 207 km/h (121 to 129 mph) 187 to 200 km/h (116 to 124 mph) 128 to 139 km/h (80 to 86 mph) 76 to 82 km/h (47 to 51 mph) 36 to 42 km/h (22 to 26 mph) 46 to 51 km/h (29 to 32 mph) 35 to 41 km/h (22 to 25 mph) Throttle valve opening 5 % 4th gear 3th gear Lock-up ON Lock-up OFF Lock-up ON Lock-up OFF Lock-up ON Lock-up OFF 83 to 90 km/h (52 to 56 mph) 81 to 87 km/h (50 to 54 mph) 100 to 107 km/h (62 to 66 mph) 97 to 104 km/h (60 to 65 mph) 65 to 72 km/h (40 to 45 mph) 62 to 68 km/h (39 to 42 mph) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 174 03-54 SERVICE SPECIFICATIONS - AUTOMATIC TRANSMISSION / TRANSAXLE 031I8-02 TORQUE SPECIFICATION Part Tightened N⋅m kgf⋅cm ft⋅lbf 6.9 5.4 70 55 61 in.⋅lbf 48 in.⋅lbf Control shaft lever x Control shaft 13 130 9 Shift control cable x Control shaft lever 13 130 9 64 46 37 653 470 377 47 34 27 Torque converter clutch x Drive plate 48 489 35 Flywheel housing under cover x Automatic transaxle 78 7.8 80 69 in.⋅lbf in lbf Engine mounting bracket FR x Transaxle 64 653 47 Oil filler tube x Transaxle 5.5 56 49 in.⋅lbf Control cable bracket No.1 x Transaxle 12 122 9 Control cable bracket No.2 x Transaxle 12 122 9 Oil cooler tube clamp x Control cable bracket 5.4 55 48 in.⋅lbf Oil cooler inlet tube x Transaxle 34 347 25 Oil cooler outlet tube x Transaxle 34 347 25 Starter x Transaxle 37 377 27 Starter wire x Starter 9.8 100 87 in.⋅lbf Wire harness x Transaxle 13 133 10 Wire harness clamp x Transaxle 8.4 86 74 in.⋅lbf Speed sensor (NC) x Transaxle 11 115 8 Speed sensor (NT) x Transaxle 11 112 8 Air cleaner x Air cleaner hose 5.0 51 44 in.⋅lbf Drain plug x Oil pan 49 500 36 Transmission wire x Transaxle 5.4 55 48 in.⋅lbf ATF temperature sensor x Valve body 6.6 67 58 in.⋅lbf Oil pan x Transaxle 7.8 80 69 in.⋅lbf 11 6.6 110 67 8 58 in.⋅lbf Valve body x Transaxle 11 110 8 Oil strainer x Valve body 11 110 8 Floor shift assy x Body 12 120 9 Control cable x Body 4.9 50 43 in.⋅lbf Transfer x Transaxle (U151F) 78 800 58 Trasfer x Transfer stiffener plate RH (U151F) 34 350 25 34 350 25 70 7.0 71 62 in.⋅lbf in lbf Park/neutral position osition switch Transaxle housing x Engine block Solenoid valve x Valve body Nut Bolt A bolt B bolt C bolt A B bolt C D bolt Engine mount bracket RR x Transfer stiffener, plate RH Oil cooler assy x Body Nut bolt 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 175 03-42 SERVICE SPECIFICATIONS - DRIVE SHAFT / PROPELLER SHAFT / AXLE DRIVE SHAFT / PROPELLER SHAFT / AXLE 031I9-02 SERVICE DATA Propeller shaft assy swing Maximum: 0.8 mm (0.031 in.) Propeller shaft assy rear swing Maximum: 0.8 mm (0.031 in.) Intermediate shaft runout Maximum: 0.8 mm (0.031 in.) Intermediate shaft front flange runout Maximum: 0.1 mm (0.004 in.) Intermediate shaft rear flange runout (horizontal direction) Maximum: 0.1 mm (0.004 in.) Intermediate shaft rear flange runout (vertical direction) Maximum: 0.1 mm (0.004 in.) Front axle hub bearing backlash Maximum: 0.05 mm (0.0020 in.) Front axle hub bearing deviation Maximum: 0.05 mm (0.0020 in.) Rear axle hub bearing backlash Maximum: 0.05 mm (0.0020 in.) Rear axle hub bearing deviation Maximum: 0.08 mm (0.0031 in.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 163 03-43 SERVICE SPECIFICATIONS - DRIVE SHAFT / PROPELLER SHAFT / AXLE 031IA-02 TORQUE SPECIFICATION Part Tightened N⋅m kgf⋅cm ft⋅lbf 182 1,850 134 2nd 69 700 51 1st 182 1,850 134 69 700 51 Propeller shaft assy x Front flange 74 750 54 Propeller shaft assy rear x Rear differential 74 750 54 Intermediate shaft rear flange x Propeller shaft assy rear 29 296 21 Center support bearing assy No. 1 (front) x Body 37 375 27 Center support bearing assy No. 1 (rear) x Body 37 375 27 Front wheel set nut 103 1,050 76 Lower ball joint x Lower suspension arm 127 1,300 94 Tie rod end x Steering knuckle 49 500 36 Axle hub x Front drive shaft 294 3,000 217 Front disc brake caliper assy x Steering knuckle 104 1,060 77 Intermediate shaft x Center support bearing assy No. 1 (front) 1st Loosen nut Intermediate shaft x Center support bearing assy No. 1 (rear) Loosen nut 2nd Front drive shaft center bearing set bolt 32 330 24 Front speed sensor set bolt 2WD 8.0 82 71 in.⋅lbf Flexible hose and speed sensor wire harness x Shock absorber 19 192 14 Rear wheel set nut 103 1,050 76 Speed sensor x Rear axle carrier 4WD 8.0 82 71 in.⋅lbf Axle hub x Rear drive shaft 4WD 294 3,000 217 Rear axle carrier sub-assy x Rear disc brake caliper 78 800 58 Front stabilizer Link assy x Shock absorber 74 755 55 Shock absorber x Steering knuckle 230 2,350 170 Front axle carrier x Lower ball joint 123 1,250 91 Rear axle carrier sub-assy x Rear axle hub & bearing 75 765 55 Transfer extension housing x Transfer dynamic damper 26 260 19 Rear shock absorber x Flexible hose 19 192 14 Rear axle carrier sub-assy x Strut rod assy rear 80 816 59 Rear axle carrier sub-assy x Rear suspension arm assy No.1 LH 112 1,140 83 Rear axle carrier sub-assy x Rear suspension arm assy No.2 LH 112 1,140 83 Disc brake dust cover front x Steering knuckle 8.3 85 74 in.⋅lbf Rear shock absorber x Rear axle carrier 180 1,840 133 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 164 03-36 SERVICE SPECIFICATIONS - REAR SUSPENSION REAR SUSPENSION 031WC-01 SERVICE DATA Toe-in (total) Rear wheel align alignment No.2 lower suspension arm length difference: FF 4WD Camber FF 4WD Right-left error Rear Suspension 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 Stabilizer link ball joint turning torque -1 °20’ ± 45’ (-1.33° ± 0.75°) -0 °45’ ± 45’ (-0.75° ± 0.75°) 45’ (0.75°) or less 1.0 N⋅m (10 kgf⋅cm, 9 in.⋅lbf) or less 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 157 03-37 SERVICE SPECIFICATIONS - REAR SUSPENSION 031WD-01 TORQUE SPECIFICATION Part Tightened N⋅m kgf⋅cm ft⋅lbf Hub nut 103 1,050 76 Tie rod adjusting tube set nut 56 570 41 Shock absorber with coil spring x Rear axle carrier 180 1,840 133 Shock absorber with coil spring x Body 58 590 43 Support assy rear suspension x Shock absorber piston rod 49 500 36 Flexible hose set bolt 19 192 14 Skid control sensor wire set bolt 5.0 51 44 in.⋅lbf Speed sensor set bolt 8.0 82 71 in.⋅lbf Speed sensor wire set bolt 5.0 51 44 in.⋅lbf Strut rod x Body 80 816 59 Strut rod x Rear axle carrier 80 816 59 Parking brake cable set bolt 39 400 29 Parking brake cable set nut 6.0 61 53 in.⋅lbf Front side Rear side 115 181 1,170 1,850 85 134 Rear suspension arm assy No.1 x Rear suspension member FF 4WD 120 80 1,220 816 89 59 Rear suspension arm assy No.1 x Rear axle carrier FF 4WD 112 112 1,140 1,140 83 83 Rear suspension arm assy No.2 x Rear suspension member FF 4WD 120 100 1,220 1,020 89 74 Rear suspension arm assy No.2 x Rear axle carrier FF 4WD 112 112 1,140 1,140 83 83 Stabilizer link set nut 39 400 29 Stabilizer bar bracket set bolt (FF) 19 194 14 54 19 550 194 40 14 Rear suspension member (4WD) set nut Stabilizer bar set bolt (4WD) Left side Right side 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 158 03-64 SERVICE SPECIFICATIONS - INSTRUMENT PANEL/METER INSTRUMENT PANEL/METER 031V3-01 TORQUE SPECIFICATION Part Tightened Instrument Panel Reinforcement × Passenger Airbag N⋅m kgf⋅cm ft⋅lbf 20 204 15 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 185 03-59 SERVICE SPECIFICATIONS - HEATER & AIR CONDITIONER HEATER & AIR CONDITIONER 031WE-01 SERVICE DATA Standard: 650
50 g (22.93
1.76 oz.) Refrigerant charge volume V(cooler compressor to crankshaft pulley) belt No.. 1 tension New belt: Used belt: 160 to 180 lbf 115 to 135 lbf 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 180 03-60 SERVICE SPECIFICATIONS - HEATER & AIR CONDITIONER 031WF-01 TORQUE SPECIFICATION Part Tightened N⋅m kgf⋅cm ft⋅lbf 58 18 591 183 43 13 V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 Generator installation bolt Bolt A Bolt B AIR CONDITIONING RADIATOR ASSY Air conditioner tube assy x Cooler evaporator sub-assy No. 1 5.4 55 48 in.⋅lbf Air conditioner unit assy x Body 9.8 100 87 in.⋅lbf Instrument panel reinforcement assy x Body 29 300 21 Skid control ECU assy x Reinforcement assy 5.0 50 43 in.⋅lbf Instrument panel junction block assy x Reinforcement assy 8.4 86 74 in.⋅lbf ECM x Reinforcement assy 5.5 56 49 in.⋅lbf Instrument panel brace sub-assy No. 2 x Reinforcement assy 29 300 21 Instrument panel brace sub-assy No. 1 x Reinforcement assy 29 300 21 Floor shift assy x Instrument panel brace sub-assy 12 122 9 Shift cable x Instrument panel brace sub-assy No. 2 20 200 14 Steering column assy x Reinforcement assy 21 210 15 Blower assy x Body 9.8 100 87 in.⋅lbf ECM x Reinforcement assy 5.5 56 49 in.⋅lbf Magnetic clutch x Cooler compressor assy 18 183 13 Compressor and magnetic clutch x Engine 25 250 18 25 250 18 18 BLOWER ASSY COOLER COMPRESSOR ASSY (3MZ-FE) Cooler compressor bracket x Compressor and magnetic clutch Nut Cooler compressor bracket x Compressor and magnetic clutch Bolt (A) 25 250 Cooler compressor bracket x Compressor and magnetic clutch Bolt (B) 18 184 13 Cooler refrigerant discharge hose No. 1 x Cooler compressor assy 9.8 100 87 in.⋅lbf Cooler refrigerant suction hose No. 1 x Cooler compressor assy 9.8 100 87 in.⋅lbf Magnetic clutch x Cooler compressor assy 18 183 13 Compressor and magnetic clutch x Engine 24.5 250 18 Cooler refrigerant discharge hose No. 1 x Cooler compressor assy 9.8 100 87 in.⋅lbf Cooler refrigerant suction hose No. 1 x Cooler compressor assy 9.8 100 87 in.⋅lbf Radiator support x Cooler condenser assy 9.8 100 87 in.⋅lbf Radiator upper support x Cross member 9.8 100 87 in.⋅lbf Cooler refrigerant liquid pipe A x Cooler condenser assy 5.4 55 47 in.⋅lbf Cooler refrigerant discharge pipe A x Cooler condenser assy 5.4 55 47 in.⋅lbf Rear heater blower fan sub-assy x Rear heater blower motor sub-assy 4.0 41 35 in.⋅lbf Rear heater assy x Body 9.8 100 87 in.⋅lbf 9.8 100 87 in.⋅lbf COOLER COMPRESSOR ASSY (2AZ-FE) COOLER CONDENSER ASSY REAR HEATER ASSY Plate x Rear heater assy Bolt (A) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 181 03-62 SERVICE SPECIFICATIONS - SEAT BELT SEAT BELT 031W7-01 TORQUE SPECIFICATION Part Tightened N⋅m kgf⋅cm ft⋅lbf Front seat outer belt assy RH (For upper bolt) x Body 7.5 77 66 in.⋅lbf FRONT SEAT BELT (From August, 2003) Front seat outer belt assy RH (For lower bolt) x Body 42 428 31 Front seat outer belt (floor anchor) x Body 42 428 31 Front seat outer belt (shoulder anchor) x Body 42 428 31 Front seat inner belt assy RH x Front seat 42 428 31 REAR NO. 1 SEAT BELT (From August, 2003) Rear seat outer belt assy x Body (RH and LH) 42 428 31 Front seat outer belt assy (For upper bolt) x Seatback frame (Center) 7.5 77 66 in.⋅lbf Rear seat outer belt assy (For lower bolt) x Seatback frame (Center) 42 428 31 Rear seat outer belt assy (floor anchor) x Body (RH and LH) 42 428 31 Rear seat outer belt assy (floor anchor) x Seatback frame (Center) 42 428 31 Rear seat inner belt assy RH x Seat cushion frame 42 428 31 Rear seat inner belt assy LH x Seat cushion frame 42 428 31 Rear seat inner belt assy x Body 42 428 31 REAR NO. 2 SEAT BELT (From August, 2003) Rear seat outer belt assy (For upper bolt) x Body 7.5 77 66 in.⋅lbf Rear seat outer belt assy (For lower bolt) x Body 42 428 31 Rear seat inner belt assy x Body 42 428 31 Rear seat lap type belt assy RH x Seat cushion frame 42 428 31 Rear seat lap type belt assy LH x Seat cushion frame 42 428 31 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 183 03-63 SERVICE SPECIFICATIONS - WIPER & WASHER WIPER & WASHER 031WA-01 TORQUE SPECIFICATION N⋅m kgf⋅cm ft⋅lbf Windshield wiper motor assy x Windshield wiper link assy Part Tightened 5.39 55 48 in.⋅lbf Windshield wiper link assy x Body 7.0 71 61 in.⋅lbf FR wiper arm & blade assy RH x Windshield wiper link assy 24 245 18 FR wiper arm & blade assy LH x Windshield wiper link assy 24 245 18 Rear wiper motor assy x Body 5.5 56 48 in.⋅lbf RR wiper arm & blade assy x Rear wiper motor assy 5.5 56 48 in.⋅lbf 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 184 05-1643 DIAGNOSTICS - AUDIO SYSTEM 05IRM-01 STEERING PAD SWITCH CIRCUIT CIRCUIT DESCRIPTION This circuit sends an operation signal from the steering pad switch to the radio receiver assy. If there is an open in the circuit, the audio system cannot be operated by the steering pad switch. If there is a short in the circuit, the same condition as that when the switch is continuously depressed occurs. Therefore, the radio receiver assy cannot be operated by the steering pad switch, and also the radio receiver assy itself does not function. WIRING DIAGRAM C16 Steering Pad SW LH AU1 AU2 EAU A Spiral Cable Sub-assy 12 12 11 11 10 10 AU1 AU2 EAU AU1 AU2 EAU Radio Receiver Assy 12 GR 3 IL1 R 11 B 4 IL1 LG 10 L 5 IL1 GR 7 R23 SW1 8 R23 SW2 6 R23 GMD I39166 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1833 05-1644 DIAGNOSTICS - AUDIO SYSTEM INSPECTION PROCEDURE 1 INSPECT RADIO RECEIVER ASSY (a) (b) R23 SW1 GMD SW2 I40203 Disconnect the connectors from the radio receiver assy. Measure the resistance according to the values in the table below. Standard: Tester connection Condition Specified condition SW1 - GMD Do not switch position Approx. 100 kΩ SW1 - GMD SEEK+ switch: push Approx. 0 Ω SW1 - GMD SEEK- switch: push Approx. 0.3 kΩ SW1 - GMD VOL+ switch: push Approx. 1 kΩ SW1 - GMD VOL- switch: push Approx. 3.2 kΩ SW2 - GMD Do not switch position Approx. 100 kΩ SW2 - GMD MODE switch: push Approx. 0 Ω NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1632 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1834 05-1645 DIAGNOSTICS 2 - AUDIO SYSTEM INSPECT STEERING PAD SWITCH LH(AU1,AU2,EAU) C16 AU1 AU2 EAU I39169 (a) (b) Disconnect the steering pad switch LH connector. Measure the resistance according to the values in the table below. Standard: Tester connection Condition Specified condition AU1 - EAU Do not switch position Approx. 100 kΩ AU1 - EAU SEEK+ switch: push Approx. 0 Ω AU1 - EAU SEEK- switch: push Approx. 0.3 kΩ AU1 - EAU VOL+ switch: push Approx. 1 kΩ AU1 - EAU VOL- switch: push Approx. 3.2 kΩ AU2 - EAU Do not switch position Approx. 100 kΩ AU2 - EAU MODE switch: push Approx. 0 Ω NG REPLACE STEERING PAD SWITCH LH (SEE PAGE 67-28 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1835 05-1646 DIAGNOSTICS 3 - AUDIO SYSTEM CHECK HARNESS AND CONNECTOR(SPIRAL CABLE SUB-ASSY - RADIO RECEIVER ASSY) (a) Radio Receiver Assy: R23 (b) GMD SW1 Disconnect the connectors from the spiral cable subassy and radio receiver assy R23. Measure the resistance according to the values in the table below. Standard: SW2 I40203 Spiral Cable Side: A NG EAU AU2 AU1 I36955 Tester connection Specified condition SW1 - AU1 Below 1 Ω SW2 - AU2 Below 1 Ω GMD - EAU Below 1 Ω SW1 - Body ground 10 kΩ or higher SW2 - Body ground 10 kΩ or higher GMD - Body ground 10 kΩ or higher REPAIR OR CONNECTOR REPLACE HARNESS OR I38235 OK REPLACE SPIRAL CABLE SUB-ASSY (SEE PAGE 60-26 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1836 05-1651 DIAGNOSTICS - AUDIO SYSTEM 05IRO-01 AMP MUTE SIGNAL CIRCUIT (FROM RADIO RECEIVER ASSY) CIRCUIT DESCRIPTION This circuit sends the signal to the stereo component amplifier to mute the noise. Because of that, the noise produced by changing the sound source ceases. In addition, this circuit is used to mute the sound when the navigation system performs voice guide. If the vehicle is equipped with a navigation system, normal audio sound will cease, and only voice guidance will be heard from the driver’s side speaker when voice guides are given. If there is an open in the circuit, noise can be heard from the speaker when changing the sound source. If there is a short in the circuit, even though the stereo component amplifier assy is normal, no sound or only extremely small sound can be produced. WIRING DIAGRAM Radio Receiver Assy Stereo Component Amplifier Assy 12 MUTE S22 BR 5 IR2 BR 7 R4 MUTE I36622 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1841 05-1652 DIAGNOSTICS - AUDIO SYSTEM INSPECTION PROCEDURE 1 INSPECT STEREO COMPONENT AMPLIFIER ASSY (a) S22 Measure the voltage according to the value in the table below. Standard: Tester connection Condition Specification MUTE - Body ground Turn ignition switch to ACC, Audio system is playing → Changing Above 3.5 V → Below 1 V NG MUTE Go to step 2 I39177 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1632 ) 2 CHECK HARNESS AND CONNECTOR(RADIO RECEIVER ASSY - STEREO COMPONENT AMPLIFIER ASSY) (a) Radio Receiver Assy: (b) R4 MUTE Disconnect the connectors from the radio receiver assy and stereo component amplifier assy. Measure the resistance according to the values in the table below. Standard: Tester connection Condition Specified condition MUTE - MUTE Always Below 1 Ω MUTE - Body ground Always 10 kΩ or higher Stereo Component Amplifier Assy: S22 I39175 I39178 MUTE NG I40341 REPAIR OR CONNECTOR REPLACE HARNESS OR OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1842 05-1653 DIAGNOSTICS 3 (a) - AUDIO SYSTEM REPLACE RADIO RECEIVER ASSY (SEE PAGE 67-6 ) Replace the radio receiver assy and check if it operates normally. OK: The radio receiver assy operates normally OK NORMAL OPERATION NG REPLACE STEREO COMPONENT AMPLIFIER ASSY (SEE PAGE 67-20 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1843 05-1657 DIAGNOSTICS - AUDIO SYSTEM 05IRQ-01 SPEAKER CIRCUIT CIRCUIT DESCRIPTION
When the vehicle has a built-in type amplifier, a sound signal is sent from the radio receiver assy to the speakers via the ”standard type” circuit.
When the vehicle has a separate type amplifier, a sound signal from the radio receiver assy is amplified by the stereo component amplifier and then transmitted to the speaker via the ”JBL type”. If there is a short in this circuit, the stereo component amplifier assy detects it and stops output to the speaker. Thus sound can not be heard from the speaker even if there is no malfunction in the stereo component amplifier assy or speaker. JBL Type: When a short in the speaker circuit is detected, all sound output is stopped. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1847 05-1658 DIAGNOSTICS - AUDIO SYSTEM WIRING DIAGRAM Standard type: R F10 Front No.1 Speaker Assy LH 1 2 W Y F11 Front No.1 Speaker Assy RH R9 Rear Speaker Assy LH R10 Rear Speaker Assy RH 1 2 B 2 V 6 IB1 T12 Front No.2 Speaker Assy RH 7 3 1 LG IN1 2 4 P 10 IF3 P G 20 IF3 V 6 R3 FL- Y 1 IL1 LG 1 R3 FR+ L 6 IN1 R 10 IL1 L 5 R3 FR- 5 BB1 L 1 BH1 Y 10 IR1 B 2 R2 RL+ W 10 BB1 Y 10 BH1 R-Y 20 IR1 Y 6 R2 RL- R 5 BC1 LG 1 IR1 R 1 R2 RR+ W 10 BC1 L 11 IR1 W 3 R2 RR- 1 2 4 Radio Receiver Assy 2 R3 FL+ R 1 2 T11 Front No.2 Speaker Assy LH 7 1 3 P IB1 I30205 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1848 05-1659 DIAGNOSTICS - AUDIO SYSTEM JBL type: Stereo Component Amplifier Assy T11 Front No.2 Speaker Assy LH 7 R P P IB1 1 1 3 F10 Front No.1 Speaker Assy LH SLD 9 S23 FL- LG 1 S23 FR+ 10 IL1 B 11 IR1 L 8 S23 FR- 6 IB1 B (*1) L 6 IN1 R 5 BB1 L 1 BH1 GR 4 S23 RL+ W 10 BB1 Y 10 BH1 LG 11 S23 RL- R 5 BC1 R 3 S23 RR+ W 10 BC1 G 10 S23 RR- 2 1 R 1 2 MUTE R-Y 1 IR1 R10 Rear Speaker Assy RH RR+ 20 IR1 G 2 RL+ 2 S23 FL+ 1 IL1 R9 Rear Speaker Assy LH FR+ Y T12 Front No.2 Speaker Assy RH 7 LG Y Y IN1 1 1 3 2 4 FL+ 10 IR1 20 IF3 V W 4 2 B R4 Radio Receiver Assy G (*1) G 2 F11 Front No.1 Speaker Assy RH 10 IF3 (Shielded) (Shielded) B 3 IR2 W 4 IR2 W R 13 IR2 R 9 8 19 12 IR2 5 IR2 16 IR2 G 18 BR 7 10 B G BR 5 S22 F.L 6 S22 F.R 13 S22 R.L 14 S22 R.R 12 S22 MUTE *1: w/o Navigation System I39172 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1849 05-1660 DIAGNOSTICS - AUDIO SYSTEM INSPECTION PROCEDURE 1 CHECK TYPE HINT: If the radio receiver assy is JBL type, ”JBL” is indicated on its surface. (a) Choose type to be inspected. Type Go to step Standard type A JBL type B B Go to step 6 A 2 CHECK HARNESS AND CONNECTOR(RADIO RECEIVER ASSY - SPEAKER ASSY) (a) Radio Receiver Assy: (b) R3 R2 FR+ RL+ FL+ RR+ FLFR- RL- RR- Wire Harness Side: (Front No.1 Speaker Assy) (Rear Speaker Assy) Disconnect the connectors from the radio receiver assy and speakers. Measure the resistance according to the value(s) in the table below. Standard: I40177 F10 F11 R9 R10 I38233 Wire Harness Side: (Front No.2 Speaker Assy) T11 Tester connection Specified condition FL+ - 1 (Front No.1 speaker assy LH) Below 1 Ω FL- - 2 (Front No.1 speaker assy LH) Below 1 Ω FR+ - 1 (Front No.1 speaker assy RH) Below 1 Ω FR- - 2 (Front No.1 speaker assy RH) Below 1 Ω FL+ - 1 (Front No.2 speaker assy LH) Below 1 Ω FL- - 2 (Front No.2 speaker assy LH) Below 1 Ω FR+ - 1 (Front No.2 speaker assy RH) Below 1 Ω FR- - 2 (Front No.2 speaker assy RH) Below 1 Ω RL+ - 1 (Rear speaker assy LH) Below 1 Ω RL- - 2 (Rear speaker assy LH) Below 1 Ω RR+ - 1 (Rear speaker assy RH) Below 1 Ω RR- - 2 (Rear speaker assy RH) Below 1 Ω FL+ - Body ground 10 kΩ or higher FL- - Body ground 10 kΩ or higher FR+ - Body ground 10 kΩ or higher FR- - Body ground 10 kΩ or higher RL+ - Body ground 10 kΩ or higher RL- - Body ground 10 kΩ or higher RR+ - Body ground 10 kΩ or higher RR- - Body ground 10 kΩ or higher T12 NG I38999 REPAIR OR CONNECTOR REPLACE HARNESS OR OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1850 05-1661 DIAGNOSTICS 3 - AUDIO SYSTEM INSPECT FRONT NO. 1 SPEAKER ASSY (a) Resistance check (1) Measure the resistance between the terminals of the speaker. NOTICE: The speaker should not be removed for checking. Standard: 4 Ω NG REPLACE FRONT NO. 1 SPEAKER ASSY (SEE PAGE 67-10 ) OK 4 (a) INSPECT FRONT NO. 2 SPEAKER ASSY Check that malfunction disappears when another speaker in a good condition is installed. OK: Malfunction disappears. HINT:

Connect all the connectors to the speakers. When there is a possibility that either right or left front speaker is defective, inspect by interchanging the right one and the left one. OK REPLACE FRONT NO. 2 SPEAKER ASSY (SEE PAGE 67-1 1) NG 5 INSPECT REAR SPEAKER ASSY (a) Resistance check (1) Measure the resistance between the terminals of the speaker. NOTICE: The speaker should not be removed for checking. Standard: 8 Ω NG REPLACE REAR SPEAKER ASSY (SEE PAGE 67-12 ) OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1632 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1851 05-1662 DIAGNOSTICS 6 - AUDIO SYSTEM CHECK HARNESS AND CONNECTOR(STEREO COMPONENT AMPLIFIER ASSY SPEAKER ASSY) (a) Stereo Component Amplifier Assy: (b) S23 RR+ Disconnect the connectors from the stereo component amplifier assy and speakers. Measure the resistance according to the values in the table below. Standard: FL+ RL+ Tester connection Specified condition FL+ - 1 (Front No.1 speaker assy LH) Below 1 Ω FR+ FRRL- RR- FL- I39179 Front No.1 Speaker Assy: Rear Speaker Assy: F10 F11 R9 R10 FL- - 2 (Front No.1 speaker assy LH) Below 1 Ω FR+ - 1 (Front No.1 speaker assy RH) Below 1 Ω FR- - 2 (Front No.1 speaker assy RH) Below 1 Ω FL+ - 1 (Front No.2 speaker assy LH) Below 1 Ω FL- - 2 (Front No.2 speaker assy LH) Below 1 Ω FR+ - 1 (Front No.2 speaker assy RH) Below 1 Ω FR- - 2 (Front No.2 speaker assy RH) Below 1 Ω RL+ - 1 (Rear speaker assy LH) Below 1 Ω RL- - 2 (Rear speaker assy LH) Below 1 Ω RR+ - 1 (Rear speaker assy RH) Below 1 Ω RR- - 2 (Rear speaker assy RH) Below 1 Ω FL+ - Body ground 10 kΩ or higher FL- - Body ground 10 kΩ or higher FR+ - Body ground 10 kΩ or higher FR- - Body ground 10 kΩ or higher RL+ - Body ground 10 kΩ or higher I38233 Front No.2 Speaker Assy: T11 T12 NG I38999 RL- - Body ground 10 kΩ or higher RR+ - Body ground 10 kΩ or higher RR- - Body ground 10 kΩ or higher REPAIR OR CONNECTOR REPLACE HARNESS AND OK 7 INSPECT FRONT NO. 1 SPEAKER ASSY (a) Resistance check (1) Measure the resistance between the terminals of the speaker. NOTICE: The speaker should not be removed for checking. Standard: 2 Ω NG REPLACE FRONT NO. 1 SPEAKER ASSY (SEE PAGE 67-10 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1852 05-1663 DIAGNOSTICS 8 (a) - AUDIO SYSTEM INSPECT FRONT NO. 2 SPEAKER ASSY Check that malfunction disappears when another speaker in a good condition is installed. OK: Malfunction disappears. HINT:

Connect the connector to the speaker. When there is a possibility that either right or left front speaker is defective, inspect by interchanging the right one and the left one. OK REPLACE FRONT NO. 2 SPEAKER ASSY (SEE PAGE 67-1 1) NG 9 INSPECT REAR SPEAKER ASSY (a) Resistance check (1) Measure the resistance between the terminals of the speaker. NOTICE: The speaker should not be removed for checking. Standard: 2 Ω NG REPLACE REAR SPEAKER ASSY (SEE PAGE 67-12 ) OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1632 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1853 05-1669 DIAGNOSTICS - AUDIO SYSTEM 05CL5-04 AMP SOUND SIGNAL CIRCUIT (RADIO RECEIVER ASSY - AMP) CIRCUIT DESCRIPTION The radio receiver assy sends a sound signal to the stereo component amplifier assy through this circuit. The sound signal that has been sent is amplified by the stereo component amplifier assy, and then is sent to the speaker. If there is an open or short in the circuit, sound can not be heard from the speaker even if there is no malfunction in the stereo component amplifier assy or speaker. WIRING DIAGRAM Stereo Component Amplifier Assy (Shielded) R.R 14 S22 R.L 13 S22 6 F.R S22 5 F.L S22 G (*1) R (*1) W (*1) B (*1) Radio Receiver Assy 16 IR2 (Shielded) 12 IR2 G (*1) 13 IR2 R (*1) 4 IR2 W (*1) 3 IR2 B (*1) 10 R4 SLD 18 R4 RR+ 19 R4 RL+ 8 R4 FR+ 9 R4 *1: w/ Rear Seat Entertainment System FL+ I39182 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1859 05-1670 DIAGNOSTICS - AUDIO SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(RADIO RECEIVER ASSY - STEREO COMPONENT AMPLIFIER ASSY) (a) Radio Receiver Assy: (b) R4 FR+ FL+ Disconnect the connectors from the radio receiver assy and stereo component amplifier assy. Measure the resistance according to the values in the table below. Standard: SLD RL+ RR+ I39175 Stereo Component Amplifier Assy: S22 Tester connection Specified condition FL+ - F.L Below 1 Ω FR+ - F.R Below 1 Ω RL+ - R.L Below 1 Ω RR+ - R.R Below 1 Ω FL+ - Body ground 10 kΩ or higher FR+ - Body ground 10 kΩ or higher RL+ - Body ground 10 kΩ or higher RR+ - Body ground 10 kΩ or higher F.L F.R NG R.R R.L REPAIR OR CONNECTOR REPLACE HARNESS OR I39178 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1632 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1860 05-1671 DIAGNOSTICS - AUDIO SYSTEM 05IRS-03 RSE SOUND SIGNAL CIRCUIT (MULTI-DISPLA Y CONTROLLER SUB-ASSY - RADIO RECEIVER ASSY) CIRCUIT DESCRIPTION The multi-display controller sub-assy sends a sound signal to the radio receiver assy through this circuit. The sound signal that has been sent is amplified by the stereo component amplifier assy, and then is sent to the speaker. If there is an open or short in the circuit, sound can not be heard from the speaker even if there is no malfunction in the stereo component amplifier assy or speaker. WIRING DIAGRAM Radio Receiver Assy Multi-display Controller Sub-Assy 11 SG1 R29 7 L- R29 8 L+ R29 9 R- R29 10 R+ R29 (Shielded) G (*1) R (*1) W (*1) B (*1) 8 IP1 (Shielded) 7 IP1 5 R22 L- G (*1) 6 IP1 4 R22 L+ R (*1) 5 IP1 3 R22 R- W (*1) 4 IP1 2 R22 R+ B (*1) *1: w/ Rear Seat Entertainment System I40722 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1861 05-1672 DIAGNOSTICS - AUDIO SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(MULTI-DISPLA Y CONTROLLER SUB-ASSY - RADIO RECEIVER ASSY) (a) Radio Receiver Assy: (b) R4 R+ Disconnect the connectors from the radio receiver assy and multi-display controller sub-assy. Measure the resistance according to the values in the table below. Standard: L- RL+ I39175 Multi-display Controller Sub-Assy: R29 NG SG1 R+ Tester connection Specified condition R+ - R+ Below 1 Ω R- - R- Below 1 Ω L+ - L+ Below 1 Ω L- - L- Below 1 Ω R+ - Body ground 10 kΩ or higher R- - Body ground 10 kΩ or higher L+ - Body ground 10 kΩ or higher L- - Body ground 10 kΩ or higher REPAIR OR CONNECTOR REPLACE HARNESS OR LR- L+ I34639 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1632 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1862 05-1654 DIAGNOSTICS - AUDIO SYSTEM 05IRP-03 MUTE SIGNAL CIRCUIT (FROM MULTI-DISPLA Y CONTROLLER SUB-ASSY) CIRCUIT DESCRIPTION The radio receiver assy controls the volume according to the LMUT signal from the multi-display controller sub-assy . The LMUT signal is send to reduce noise and pop sound when switching mode, etc. WIRING DIAGRAM Multi-display Controller Sub-Assy Radio Receiver Assy 6 MUTE R22 P (*1) 20 IP1 V (*1) 12 R29 LMUT *1: w/ Rear Seat Entertainment System I34950 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1844 05-1655 DIAGNOSTICS - AUDIO SYSTEM INSPECTION PROCEDURE 1 INSPECT RADIO RECEIVER ASSY (a) R4 Measure the voltage according to the value in the table below. Standard: Tester connection Condition Specification MUTE - Body ground Turn ignition switch to ACC, RSE system is playing → Changing Above 3.5 V → Below 1 V MUTE NG Go to step 2 I39180 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1632 ) 2 CHECK HARNESS AND CONNECTOR(RADIO RECEIVER ASSY - MULTI-DISPLA Y CONTROLLER SUB-ASSY) Radio Receiver Assy: (a) R4 (b) MUTE Disconnect the connectors from the radio receiver assy and multi-display controller sub-assy. Measure the resistance according to the values in the table below. Standard: Tester connection Condition Specified condition MUTE - LMUT Always Below 1 Ω MUTE - Body ground Always 10 kΩ or higher I39175 Multi-display Controller Sub-assy: R29 LMUT NG I34639 REPAIR OR CONNECTOR REPLACE HARNESS OR OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1845 05-1656 DIAGNOSTICS 3 - AUDIO SYSTEM INSPECT MULTI-DISPLA Y CONTROLLER SUB-ASSY (a) (b) R29 LMUT I34639 Disconnect the connectors from the multi-display controller sub-assy. Measure the resistance according to the values in the table below. Standard: Tester connection Condition Specified condition LMUT - Body ground Turn ignition switch to ACC Above 3.5 V NG REPLACE RADIO RECEIVER ASSY (SEE PAGE 67-6 ) OK REPLACE MULTI-DISPLA Y CONTROLLER SUB-ASSY (SEE PAGE 67-23 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1846 05-1638 DIAGNOSTICS - AUDIO SYSTEM 05IRK-01 POWER SOURCE CIRCUIT (STEREO COMPONENT AMPLIFIER ASSY) CIRCUIT DESCRIPTION This circuit provides the power to the stereo component amplifier assy. WIRING DIAGRAM Radio Receiver Assy 3 AMP+ R4 Stereo Component Amplifier Assy 1 P S22 AMP+ J18 J/C 2 G G S22 ACC A A 6 IR2 V Passenger Side J/B Y 2 4E L-B 4 3C 8 4D W 14 IO1 5 3C R-Y 1 IR2 Center J/B 2 IL1 20 IK3 LG L-Y 4 2C Engine Room J/B RAD No.1 D.C.C B RAD No.2 2 1C 1 1A AM1 6 1C 1 1 2I I15 Ignition SW Instrument Panel J/B 1 1H 7 S23 +B R-Y L 3 ACC AM1 2 W 2 F7 Fusible Link Block ALT 2 W 3 W-B W FL MAIN A 1 W-B A Battery 12 S23 GND J19 J/C A W-B BB BF I39185 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1828 05-1639 DIAGNOSTICS - AUDIO SYSTEM INSPECTION PROCEDURE 1 INSPECT RADIO RECEIVER ASSY (a) R4 AMP+ Measure the voltage according to the value in the table below. Standard: Tester connection Condition Specified condition AMP+ - Body ground Radio receiver assy ON 10 to 14 V NG REPLACE RADIO RECEIVER ASSY (SEE PAGE 67-6 ) I39180 OK 2 CHECK HARNESS AND CONNECTOR(RADIO RECEIVER ASSY - STEREO COMPONENT AMPLIFIER ASSY) Radio Receiver Assy: (a) R4 (b) AMP+ Disconnect the connectors from the radio receiver assy and stereo component amplifier assy. Measure the resistance according to the values in the table below. Standard: Tester connection Condition Specified condition AMP+ - AMP+ Always Below 1 Ω AMP+ - Body ground Always 10 kΩ or higher I39175 Stereo Component Amplifier Assy: S22 AMP+ NG I39178 REPAIR OR CONNECTOR REPLACE HARNESS OR OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1829 05-1640 DIAGNOSTICS 3 - AUDIO SYSTEM INSPECT STEREO COMPONENT AMPLIFIER ASSY(+B, ACC, GND) (a) (b) S23 S22 ACC +B GND (c) I39176 Disconnect the connectors from the stereo component amplifier assy. Measure the resistance according to the values in the table below. Standard: Tester connection Condition Specified condition GND - Body ground Always Below 1 Ω Measure the voltage according to the values in the table below. Standard: Tester connection Condition Specified condition +B - GND Always 10 to 14 V ACC - GND Ignition SW ACC 10 to 14 V NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1632 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1830 05-1680 DIAGNOSTICS - AUDIO SYSTEM 05ASI-06 CD CANNOT BE EJECTED INSPECTION PROCEDURE 1 PRESS ”EJECT” AND CHECK OPERATION (a) Press ”EJECT”and check the operation. (1) Press the CD EJECT switch of the radio receiver assembly for 2 seconds or more to see if the CD is ejected. OK: CD is ejected. Reference: If the CD is not ejected, bring the vehicle in for repair. Do not attempt to remove it by force. NG REPLACE RADIO RECEIVER ASSY (SEE PAGE 67-6 ) OK 2 (a) CHECK IF A PROPER CD IS INSERTED Check that a normal audio CD is inserted. (1) Check in what conditions the sound skipping occurs. OK: Driving on a bad road. NG REPLACE RADIO RECEIVER ASSY (SEE PAGE 67-6 ) OK 3 (a) REPLACE CD WITH ANOTHER AND RECHECK Replace the CD with another and recheck. (1) Check the installation condition of the radio receiver assembly. OK: Installed properly. NG REPLACE RADIO RECEIVER ASSY (SEE PAGE 67-6 ) OK CD FAULTY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1870 05-1678 DIAGNOSTICS - AUDIO SYSTEM 05ASH-07 CD CANNOT BE INSERTED OR IS EJECTED RIGHT AFTER INSERTION INSPECTION PROCEDURE 1 CHECK IF A NORMAL CD IS INSERTED (a) Check if a normal CD is inserted. (1) Make sure that the CD is a normal audio CD, and that there is no deformation, flaw, stain, burr or other defects on the CD. OK: Normal audio CD. Reference:
Translucent or oddly-shaped CD cannot be played.
Computer CD-ROMs (even those with music) and CD-R discs cannot be played.
Playing an 8 cm CD does not require an adapter. NG CD FAULTY OK 2 (a) CHECK IF A CD IS INSERTED PROPERLY Check if a CD is inserted properly. (1) Check whether or not the CD is inserted upside down. OK: Not upside down. NG SET DISC CORRECTLY OK 3 DISC CLEANING (a) Disc cleaning (1) If the disc gets dirty, clean the disc by wiping the surface from the center to outside in the radial directions with a soft cloth. NOTICE: Do not use a conventional record cleaner or anti-static preservative. OK: Malfunction disappears. E50013 OK DISC DIRTY NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1868 05-1679 DIAGNOSTICS 4 (a) - AUDIO SYSTEM REPLACE CD WITH ANOTHER AND RECHECK Replace the CD with another and recheck. (1) Replace the CD with another normal one to see if the same trouble occurs again. OK: Malfunction disappears. NG REPLACE RADIO RECEIVER ASSY (SEE PAGE 67-6 ) OK CD FAULTY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1869 05-1682 DIAGNOSTICS - AUDIO SYSTEM 055M0-11 CD SOUND SKIPS INSPECTION PROCEDURE 1 DISC CLEANING (a) Disc cleaning (1) If the disc gets dirty, clean the disc by wiping the surface from the center to outside in a radial direction with a soft cloth. NOTICE: Do not use a conventional record cleaner or anti-static preservative. OK: Malfunction disappears. E50013 OK DISC DIRTY NG 2 (a) REPLACE CD WITH ANOTHER AND RECHECK Replace the CD with another and recheck. (1) Replace the CD with another normal one to see if the same trouble occurs again. OK: Malfunction disappears. OK CD FAULTY NG 3 (a) CHECK WHEN THIS HAPPENS Check when this happens. (1) Check under what conditions (places) noise occurs. OK: Driving on a bumpy road. OK Go to step 5 NG 4 (a) COMPARE IT WITH ANOTHER CAR OF SAME MODEL Compare it with another vehicle of the same model. (1) Compare it with the vehicle of the same type which does not have a trouble to see if there is any difference in the CD sound. OK: No difference found. OK SETTING NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1872 05-1683 DIAGNOSTICS 5 (a) - AUDIO SYSTEM CHECK OF RADIO RECEIVER ASSEMBLY INSTALLATION Check the radio receiver assembly installation condition. (1) Check that the radio receiver assembly is installed properly. OK: Installed properly. NG INSTALL THE RADIO RECEIVER ASSEMBLY PROPERLY OK 6 DID TEMPERATURE IN CABIN CHANGE RAPIDLY? (a) Did the temperature in the cabin change rapidly? (1) Check whether or not the rapid temperature change occurred in the cabin. OK: The rapid temperature change occurred. Reference: The rapid temperature change creates condensation inside the CD player, which may prevent the CD from being played. NG REPLACE RADIO RECEIVER ASSY (SEE PAGE 67-6 ) OK CONDENSATION DUE TO TEMPERATURE CHANGE (LEAVE IT AS IT IS FOR A WHILE BEFORE USING) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1873 05-1647 DIAGNOSTICS - AUDIO SYSTEM 05IRN-01 ILLUMINATION CIRCUIT CIRCUIT DESCRIPTION When the light control switch is in the TAIL or HEAD position, the TAILLIGHT relay activates and supplies power to illuminate the radio receiver assy panel. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1837 05-1648 DIAGNOSTICS - AUDIO SYSTEM WIRING DIAGRAM C11 Combination Meter Assy ILL 5 3F 2 3G W 3 3D 9 3F LG 10 13 3F 8 3I B 7 12 V 22 W-B 12 IK3 Radio Receiver Assy Center J/B V 3E 12 3A Passenger Side J/B 6 11 4H 4D V 12 5 R4 R2 ILL(*1) (*2) W-B 2 R4 G 10 R3 ILL+ (*1) (*2) 11 IL2 Engine Room J/B 3 2A R DOME 1 2I D.C.C W Instrument Panel J/B 7 1K 4 1J O Taillight System PANEL TAILLIGHT Relay 1 1A 3 5 2 B 1 F7 Fusible Link Block W 1 ALT 2 3 FL MAIN Battery IB *1:JBL Type *2:Standard Type I40214 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1838 05-1649 DIAGNOSTICS - AUDIO SYSTEM INSPECTION PROCEDURE 1 (a) CHECK SYSTEM Turn the light control switch to the TAIL or HEAD position. Check if other displays or indicators such as the A/C indicator come on. OK: Other displays or indicators come on. NG GO TO COMBINATION METER SYSTEM (SEE PAGE 05-1868 ) OK 2 INSPECT RADIO RECEIVER ASSY(ILL+) (a) (b) Standard Type: R3 Disconnect the connector from the radio receiver assy. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition ILL+ - Body ground Light SW TAIL or HEAD 10 to 14 V ILL+ I39174 JBL Type: R4 ILL+ NG I39175 REPAIR OR CONNECTOR REPLACE HARNESS OR OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1839 05-1650 DIAGNOSTICS 3 - AUDIO SYSTEM CHECK HARNESS AND CONNECTOR(COMBINATION METER ASSY - RADIO RECEIVER ASSY) (a) Combination Meter Assy: (b) C11 Disconnect the connectors from the combination meter assy and radio receiver assy. Measure the resistance according to the values in the table below. Standard: ILL Tester connection Specified condition ILL - ILL- Below 1 Ω ILL - Body ground 10 kΩ or higher I40182 Radio Receiver Assy Standard Type: R2 ILL- I40213 Radio Receiver Assy: JBL Type: R4 ILL- NG I39175 REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1632 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1840 05-1688 DIAGNOSTICS - AUDIO SYSTEM 05IRU-02 AVC-LAN CIRCUIT (MULTI-DISPLA Y CONTROLLER SUB-ASSY RADIO RECEIVER ASSY CIRCUIT DESCRIPTION Each unit of the radio receiver system connected to AVC-LAN (communication bus) communicates by transferring the signals from each switch. When +B short and GND short occur in this AVC-LAN, radio receiver system will not function normally as communication is discontinued. In AVC-LAN, radio receiver assy becomes the communication master, and the radio receiver assy has enough resistance necessary for transmitting the communication. WIRING DIAGRAM Multi-display Controller Sub-assy 31 TX+ R29 30 TX- R29 Radio Receiver Assy LG (*1) GR (*1) 9 IP1 19 IP1 Y (*1) L (*1) 9 R23 TX1+ 10 R23 TX1- *1: w/ Rear Seat Entertainment System I39199 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1878 05-1689 DIAGNOSTICS - AUDIO SYSTEM INSPECTION PROCEDURE 1 INSPECT RADIO RECEIVER ASSY (a) R23 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition TX1+ - TX1- Always 60 to 80 Ω TX1TX1+ I40222 NG REPLACE RADIO RECEIVER ASSY (SEE PAGE 67-6 ) OK 2 CHECK HARNESS AND CONNECTOR(MULTI-DISPLA Y CONTROLLER SUB-ASSY - RADIO RECEIVER ASSY) (a) Multi-display Controller Sub-assy: (b) R29 TX+ TXI34639 Disconnect the connectors from the multi-display controller sub-assy R29 and radio receiver assy R23. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition TX+ - TX1+ Always Below 1 Ω TX- - TX1- Always Below 1 Ω TX+ - Body ground Always 10 kΩ or higher TX- - Body ground Always 10 kΩ or higher Radio Receive Assy: R23 TX1+ TX1- NG I40203 REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1632 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1879 05-1664 DIAGNOSTICS - AUDIO SYSTEM 05IRR-02 SPEAKER CIRCUIT (DRIVER SIDE SPEAKER) CIRCUIT DESCRIPTION When the vehicle is equipped with the navigation system, a sound signal for the driver’s side is sent from the stereo component amplifier to the driver’s side speaker via the navigation ECU. WIRING DIAGRAM Stereo Component Amplifier Assy Navigation ECU 2 FL+ S23 9 S23 FL- F10 Front No.1 Speaker Assy LH Y 10 IR1 LG (*1) R-Y 20 IR1 R (*1) P 7 IB1 P 10 IF3 2 V 6 IB1 G 20 IF3 R 1 3 2 W 4 1 1 N3 10 N3 AUI- 2 N3 AUO+ G (*1) B (*1) AUI+ 11 N3 AUO- T11 Front No.2 speaker Assy LH *1: w/ Navigation System I40199 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1854 05-1665 DIAGNOSTICS - AUDIO SYSTEM INSPECTION PROCEDURE 1 (a) CHECK NAVIGATION VOICE GUIDANCE Check if navigation voice guidance is heard from the speaker on the driver side. OK: Voice guidance is heard. OK Go to step 8 NG 2 (a) CHECK SETTING(THE VOLUME OF THE NAVIGATION VOICE SOUND) Check that ”OFF” is not selected. OK: OFF is not selected. NG USING VOICE ADJUSTMENT SWITCH, TURN THE VOICE GUIDANCE VOLUME UP OK 3 (a) INSPECT SYSTEM Check the system. (1) Check if sound is heard from speakers. Symptom Proceed to No sound is heard from both speakers A No sound is heard from front No.1 speaker assy B No sound is heard from front No.2 speaker assy Replace front No.2 speaker assy (see page 67-11) B Go to step 6 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1855 05-1666 DIAGNOSTICS 4 - AUDIO SYSTEM CHECK HARNESS AND CONNECTOR(NAVIGATION ECU - FRONT NO. 2 SPEAKER ASSY) (a) Navigation ECU: (b) N3 AUO+ AUO- Disconnect the connectors from the navigation ECU and speaker. Measure the resistance according to the values in the table below. Standard: Tester connection Condition Specified condition AUO+ - 1 Always Below 1 Ω AUO- - 2 Always Below 1 Ω AUO+ - Body ground Always 10 kΩ or higher AUO- - Body ground Always 10 kΩ or higher Wire Harness Side: Front No.2 Speaker Assy NG I40178 I38999 I40553 REPAIR OR CONNECTOR REPLACE HARNESS OR OK 5 (a) INSPECT FRONT NO. 2 SPEAKER ASSY Check that malfunction disappears when another speaker in a good condition is installed. OK: Malfunction disappears. HINT:

Connect all the connectors to the speakers. When there is a possibility that either right or left front speaker is defective, inspect by interchanging the right one and the left one. OK REPLACE FRONT NO. 2 SPEAKER ASSY (SEE PAGE 67-1 1) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1856 05-1667 DIAGNOSTICS 6 AUDIO SYSTEM CHECK HARNESS AND CONNECTOR(FRONT NO. 2 SPEAKER ASSY - FRONT NO. 1 SPEAKER ASSY) (a) Wire Harness Side: Front No.2 Speaker Assy (b) Wire Harness Side: Front No.1 Speaker Assy I38999 I38233 - Disconnect the connectors from the front No.2 speaker assy and front No.1 speaker assy. Measure the resistance according to the values in the table below. Tester connection Condition Specified condition 3 (Front No.2 speaker Assy) - 1 (Front No.1 speaker Assy) Always Below 1 Ω 4 (Front No.2 speaker Assy) - 2 (Front No.1 speaker Assy) Always Below 1 Ω 3 (Front No.2 speaker Assy) - Body ground Always 10 kΩ or higher 4 (Front No.2 speaker Assy) - Body ground Always 10 kΩ or higher NG I40554 REPAIR OR CONNECTOR REPLACE HARNESS OR OK 7 INSPECT FRONT NO. 1 SPEAKER ASSY (a) Resistance check (1) Measure the resistance between the terminals of the speaker. NOTICE: The speaker should not be removed for checking. Standard: 4 Ω NG REPLACE FRONT NO. 1 SPEAKER ASSY (SEE PAGE 67-10 ) OK REPLACE NAVIGATION ECU (SEE PAGE 67-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1857 05-1668 DIAGNOSTICS 8 - AUDIO SYSTEM CHECK HARNESS AND CONNECTOR(NAVIGATION ECU - STEREO COMPONENT AMPLIFIER ASSY) (a) Navigation ECU: (b) N3 AUI+ AUIStereo Component Amplifier Assy: S23 I40178 I39179 FL- FL+ Disconnect the connectors from the navigation ECU and stereo component amplifier assy. Measure the resistance according to the values in the table below. Standard: Tester connection Condition Specified condition AUI+ - FL+ Always Below 1 Ω AUI- - FL- Always Below 1 Ω AUI+ - Body ground Always 10 kΩ or higher AUI- - Body ground Always 10 kΩ or higher NG I40555 REPAIR OR CONNECTOR REPLACE HARNESS OR OK 9 INSPECT NAVIGATION ECU (a) (b) N3 AUO+ AUO- AUI+ AUII40178 Disconnect the connector from the navigation ECU. Measure the resistance according to the values in the table below. Standard: Tester connection Condition Specified condition AUI+ - AUO+ Always Below 1 Ω AUI- - AUO- Always Below 1 Ω NG REPLACE NAVIGATION ECU (SEE PAGE 67-9 ) OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1632 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1858 05-1674 DIAGNOSTICS - AUDIO SYSTEM 055M1-10 NOISE OCCURS INSPECTION PROCEDURE 1 (a) CHECK OF SPEAKER INSTALLATION Check the speaker installation condition. (1) Check that each speaker is securely installed. OK: Malfunction disappears. HINT: The radio is equipped with a noise prevention system that blocks only excessively loud noise. If loud noise occurs, check whether or not the ground on the antenna installation part and the proper noise-prevention equipment are all installed, and whether or not there is improper wiring. Condition in which noise occurs Noise type Depressing the acceleration pedal increases the noise, and stopping the engine stops the noise immediately. Alternator noise Noise occurs during A/C or the heater operation. Blower motor noise Rapid acceleration during the drive on an unpaved road or after the ignition switch is turned on makes noise. Fuel pump noise Pressing and then releasing the horn switch, and keeping pressing the horn switch makes noise. Horn noise Quiet noise is heard while the engine is running, but stops with the engine. Ignition noise Noise occurs in turn with the blink of the turn signal flash. Flasher noise Noise occurs during window washer operation. Washer noise Noise occurs while the engine is running, and it continues even after the engine is stopped. Water temperature sensor noise Noise occurs during wiper operation. Wiper noise Noise occurs when the brake pedal is depressed. Stop light switch noise Others Static electricity on the vehicle HINT:


Identify the condition in which the noise occurs, and check the noise filter on the related part. Make sure first that there is no noise from outside. Failing to do so makes the noise occurrence source detection difficult and leads to misdiagnosis. The noise should be removed in descending order of loudness. NG INSTALL IT PROPERLY OK IDENTIFICATION OF NOISE SOURCE 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1864 05-1634 DIAGNOSTICS - AUDIO SYSTEM 05IRJ-01 POWER SOURCE CIRCUIT (RADIO RECEIVER ASSY) CIRCUIT DESCRIPTION This circuit provides the power to the radio receiver assy. WIRING DIAGRAM Standard type: Engine Room J/B Radio Receiver Assy 1 D.C.C RAD No.1 4 2C 2I 20 IK3 L-Y LG 2 IL1 L-B 4 R3 BU+B 3 R3 ACC+B Center J/B 13 3A V GR Instrument Panel J/B I15 Ignition SW 2 AM1 9 3I 2 1C L ACC 3 6 1C W RAD No. 2 3 1K AM1 1 1A 2 1 W 3 FL MAIN Battery W ALT 1 2 B BR F7 Fusible Link Block 7 R3 GND IB I30203 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1824 05-1635 DIAGNOSTICS - AUDIO SYSTEM JBL type: Center J/B 13 3A 4 3C V 20 IK3 L-Y 2 IL1 LG L-B 9 3I 10 3K GR L-B Radio Receiver Assy 11 R4 ACC 1 R4 B Engine Room J/B 4 2C RAD No.1 D.C.C 1 2I W I15 Ignition SW Instrument Panel J/B 3 1K RAD No.2 6 1C AM1 1 1A B 1 2 1C L BR 3 ACC AM1 2 20 R4 GND W 2 F7 Fusible Link Block ALT 2 3 W 1 FL MAIN IB Battery I39184 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1825 05-1636 DIAGNOSTICS - AUDIO SYSTEM INSPECTION PROCEDURE 1 CHECK TYPE HINT: If the radio receiver assy is JBL type, ”JBL” is indicated on its surface. (a) Choose type to be inspected. Type Go to step Standard type A JBL type B B Go to step 3 A 2 INSPECT RADIO RECEIVER ASSY(BU+B, ACC+B, GND) (a) (b) R3 ACC+B (c) BU+B GND I39174 Disconnect the connectors from the radio receiver assy. Measure the resistance according to the value in the table below. Standard: Tester connection Condition Specified condition GND - Body ground Always Below 1 Ω Measure the voltage according to the values in the table below. Standard: Tester connection Condition Specified condition BU+B - GND Always 10 to 14 V ACC+B - GND Ignition SW ACC 10 to 14 V NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1632 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1826 05-1637 DIAGNOSTICS 3 AUDIO SYSTEM INSPECT RADIO RECEIVER ASSY(B, ACC, GND) (a) (b) R4 B (c) GND - ACC I39175 Disconnect the connectors from the radio receiver assy. Measure the resistance according to the value in the table below. Standard: Tester connection Condition Specified condition GND - Body ground Always Below 1 Ω Measure the voltage according to the values in the table below. Standard: Tester connection Condition Specified condition B - GND Always 10 to 14 V ACC - GND Ignition SW ACC 10 to 14 V NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1632 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1827 05-1675 DIAGNOSTICS - AUDIO SYSTEM 05IRT-01 RADIO BROADCAST CANNOT BE RECEIVED(BAD RECEPTION) INSPECTION PROCEDURE 1 (a) CHECK IF RADIO AUTO-SEARCH FUNCTIONS PROPERLY Check if the radio auto-search functions properly. (1) Perform the auto-search of the radio and check that it functions normally. OK: The radio auto-search functions properly. OK REPLACE RADIO RECEIVER ASSY (SEE PAGE 67-6 ) NG 2 (a) CHECK OPTIONAL COMPONENT Check optional component (sun shade film, telephone antenna etc.). (1) Check whether or not any optional component such as the sun shade film and the telephone antenna is installed. OK: Optional component is installed. OK EFFECT FROM OPTIONAL COMPONENT NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1865 05-1676 DIAGNOSTICS 3 - AUDIO SYSTEM INSPECT RADIO RECEIVER ASSY(ANTENNA) (a) Preparation for Check (1) Remove the antenna plug of the radio receiver assembly. Noise Check (1) With the radio receiver assy connector connected, turn the ignition switch to the ACC position. (2) Turn on the radio and choose the AM mode. (3) Place a flat-head screwdriver or a piece of metal such as thin wire on an antenna jack of the radio receiver assy and check that the noise is heard from the speaker. OK: Noise occurs. (b) E50367 NG REPLACE RADIO RECEIVER ASSY (SEE PAGE 67-6 ) OK 4 (a) CHECK ANTENNA TYPE Choose type to be inspected. Type Go to step Glass printed type antenna A Fender type antenna B B Go to step 7 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1866 05-1677 DIAGNOSTICS 5 - AUDIO SYSTEM CHECK ANTENNA ASSY Tester Probe Tin Foil Antenna Wire BE4029 (a) Check for continuity of the antenna. HINT: Inspect the continuity, at the center of each antenna wire, as shown in the illustration. NOTICE: When cleaning the glass, use a soft dry cloth, and wipe the glass in the direction of the wire. Take care not to damage the wires. Do not use detergents or glass cleaners with abrasive ingredients. When measuring voltage, wind a piece of tin foil around the top of the negative probe and press the foil against the wire with your finger, as shown in the illustration. OK: There is continuity in the antenna. NG REPAIR ANTENNA ASSY (SEE PAGE 67-33 ) E32576 OK 6 (a) REPLACE AMPLIFIER ANTENNA ASSY (SEE PAGE 67-15 OR 67-16 ) Replace the amplifier antenna assy and check if it operates normally. OK: The amplifier antenna assy operates normally. OK NORMAL OPERATION NG REPLACE RADIO RECEIVER ASSY (SEE PAGE 67-6 ) 7 (a) CHECK ANTENNA ASSY Check that the antenna is securely installed. OK: The antenna is installed properly. OK Go to step 6 NG INSTALL THE ANTENNA ASSY PROPERLY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1867 05-1641 DIAGNOSTICS - AUDIO SYSTEM 05IRL-02 POWER SOURCE CIRCUIT(MULTI-DISPLA Y CONTROLLER SUB-ASSY) CIRCUIT DESCRIPTION This circuit provides the power to the multi-display controller sub-assy. WIRING DIAGRAM J17 J/C Engine Room R/B CRT W (*1) 1 16 IK2 V (*1) 2 2 2 V (*1) A Passenger Side J/B 2 4E 8 4D G B A A 1 1H RAD No.2 1 1A AM1 1 F7 Fusible Link Block Y (*1) 2 1C 6 1C I15 Ignition SW L 3 ACC AM1 2 W 2 W-B 2 ALT C W 1 3 16 R29 +B1 32 R29 ACC G (*1) Instrument Panel J/B Y 21 IO2 V A (*1) J18 J/C 14 IO1 W Multi-display Controller Sub-assy J18 J/C C W-B 7 R31 SELD 29 R29 GND C W-B FL MAIN BF Battery *1: w/ Rear Seat Entertainment System I37210 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1831 05-1642 DIAGNOSTICS - AUDIO SYSTEM INSPECTION PROCEDURE 1 INSPECT MULTI-DISPLA Y CONTROLLER SUB-ASSY(+B1, ACC, GND, SELD) R29 (a) R31 (b) +B1 ACC GND SELD I37211 (c) Disconnect the connectors from the multi-display controller sub-assy. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition GND - Body ground Always Below 1 Ω SELD - Body ground Always Below 1 Ω Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition +B1 - GND Always 10 - 14 V ACC - GND Ignition SW ACC 10 - 14 V NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1632 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1832 05-1681 DIAGNOSTICS - AUDIO SYSTEM 055LZ-10 SOUND QUALITY IS BAD ONLY WHEN CD IS PLAYED (VOLUME IS TOO LOW) INSPECTION PROCEDURE 1 (a) REPLACE CD WITH ANOTHER AND RECHECK Replace the CD with another one and recheck. (1) Check the installation condition of the radio receiver assembly. OK: Malfunction disappears. NG REPLACE RADIO RECEIVER ASSY (SEE PAGE 67-6 ) OK CD FAULTY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1871 05-1686 DIAGNOSTICS - AUDIO SYSTEM 055LU-12 SOUND QUALITY IS BAD ONLY WHEN PLAYING TAPE INSPECTION PROCEDURE 1 (a) REPLACE CASSETTE TAPE WITH ANOTHER AND RECHECK Replace the cassette tape with another one and recheck. (1) Replace the cassette tape with another normal one to see if the same trouble occurs again. OK: Malfunction disappears. OK CASSETTE TAPE FAULTY NG 2 (a) CHECK FOR ANY FOREIGN OBJECT Check for foreign objects. (1) Check that no foreign objects or defects are detected in the cassette tape player. OK: No foreign objects or defects are detected. NG REMOVE FOREIGN OBJECT OK 3 CLEAN HEAD AND CHECK OPERATION (a) Head Pinch Roller Capstan Head cleaning (1) Raise the cassette door with your finger. Using a pencil or similar object, push in the guide. (2) Using a cleaning pen or cotton applicator soaked in cleaner, clean the head surface, pinch rollers and capstans. (3) Check if the same trouble occurs again. OK: Malfunction disappears. N17398 NG REPLACE RADIO RECEIVER ASSY (SEE PAGE 67-6 ) OK HEAD DIRTY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1876 05-1673 DIAGNOSTICS - AUDIO SYSTEM 05CL8-04 SOUND QUALITY IS BAD IN ALL MODES (VOLUME IS TOO LOW) INSPECTION PROCEDURE 1 (a) ADJUST SOUND QUALITY Adjust the sound quality. (1) Operate the radio receiver assy to adjust the sound quality. OK: Malfunction disappears. OK BAD SOUND QUALITY NG 2 (a) COMPARE IT WITH ANOTHER VEHICLE OF SAME MODEL Compare it with another vehicle of the same model. (1) Compare it with the vehicle of the same type which does not have a trouble to see if there is any difference in the sound quality. OK: No difference is found. OK SETTING NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1632 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1863 05-1685 DIAGNOSTICS - AUDIO SYSTEM 05ASK-06 CASSETTE TAPE CANNOT BE EJECTED INSPECTION PROCEDURE 1 (a) PRESS ”EJECT” AND CHECK OPERATION Press ”EJECT” and check the operation. (1) Press the cassette tape EJECT switch of the radio receiver assembly for 2 seconds or more and check that the cassette tape is ejected. OK: The cassette tape is ejected. NG REPLACE RADIO RECEIVER ASSY (SEE PAGE 67-6 ) OK 2 (a) CHECK CASSETTE TAPE Check the cassette tape. (1) Check that the ejected cassette tape does not have a peeled label, a cassette body deformation or any other defects. OK: No fault on the cassette tape. NG CASSETTE TAPE FAULTY OK 3 (a) REPLACE CASSETTE TAPE WITH ANOTHER AND RECHECK Replace the cassette tape with another and recheck. (1) Replace the cassette tape with another normal one to see if the same trouble occurs again. OK: Malfunction disappears. NG REPLACE RADIO RECEIVER ASSY (SEE PAGE 67-6 ) OK CASSETTE TAPE FAULTY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1875 05-1684 DIAGNOSTICS - AUDIO SYSTEM 05ASJ-06 CASSETTE TAPE CANNOT BE INSERTED OR PLAYED INSPECTION PROCEDURE 1 (a) CHECK FOR ANY FOREIGN OBJECT Check for any foreign objects. (1) Check that no foreign objects or defects are detected in the cassette tape player of the radio receiver assembly. OK: No foreign objects or defects are detected. NG REMOVE FOREIGN OBJECT OK 2 (a) CHECK CASSETTE TAPE Check the cassette tape. (1) Check that the cassette tape is a normal tape with music or voice recorded. OK: Proper cassette tape with music or voice recorded. NG CASSETTE TAPE FAULTY OK 3 (a) REPLACE CASSETTE TAPE WITH ANOTHER AND RECHECK Replace the cassette tape with another one and recheck. (1) Replace the cassette tape with another normal one to see if the same trouble occurs again. OK: The function returns to be normal. NG REPLACE RADIO RECEIVER ASSY (SEE PAGE 67-6 ) OK CASSETTE TAPE FAULTY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1874 05-1687 DIAGNOSTICS - AUDIO SYSTEM 055LV-12 TAPE IS TANGLED DUE TO INCORRECT TAPE SPEED OR AUTO-REVERSE MALFUNCTION INSPECTION PROCEDURE 1 (a) CHECK FOR ANY FOREIGN OBJECT Check for any foreign objects. (1) Check that no foreign objects or defects are detected in the cassette tape player of the radio receiver assy. OK: No foreign objects or defects are detected. NG REMOVE FOREIGN OBJECT OK 2 (a) REPLACE CASSETTE TAPE WITH ANOTHER AND RECHECK(BELOW 90 MIN.) Replace the cassette tape with another one and recheck. (1) Replace the cassette tape with another normal one (90 minutes. or less) to see if the same trouble occurs again. OK: Malfunction disappears. OK CASSETTE TAPE FAULTY NG 3 CLEAN HEAD AND CHECK OPERATION (a) Head Pinch Roller Capstan Head cleaning (1) Raise the cassette door with your finger. Using a pencil or similar object, push in the guide. (2) Using a cleaning pen or cotton applicator soaked in cleaner, clean the head surface, pinch rollers and capstans. (3) Check if the same trouble occurs again. OK: Malfunction disappears. NG N17398 REPLACE RADIO RECEIVER ASSY (SEE PAGE 67-6 ) OK HEAD DIRTY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1877 05-1617 DIAGNOSTICS - AUDIO SYSTEM 0569B-11 CUSTOMER PROBLEM ANALYSIS CHECK AUDIO SYSTEM Check Sheet Inspector’s name: VIN Production Date Customer’s Name Licence Plate No. Date of Vehicle Brought in / / / Date of First Occurrence Frequency of Problem Occurrence km mile Odometer Reading
Constant /
Intermittent ( Times a day) Problem Symptom
Switch
Radio
CD
Noise Parts name DTC (2nd time) DTC (1st time) DTC Check Radio receiver assy Stereo component amplifier assy Others I32867 I35110 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1807 05-161 1 DIAGNOSTICS - AUDIO SYSTEM AUDIO SYSTEM 05IRH-01 DESCRIPTION 1. RADIO WAVE BAND The radio wave bands used in radio broadcasting are as follows: Frequency 30 kHz Designation 300 kHz 3 MHz LF MF Modulation 300 MHz HF AM Radio wave 30 MHz VHF FM Amplitude modulation Frequency modulation LF: Low Frequency MF: Medium Frequency HF: High Frequency VHF: Very High Frequency 2. (a) FM (Stereo) FM (Monaural) SERVICE AREA There is a great difference in the size of the service areas for AM and FM broadcasting. Sometimes an FM stereo broadcast cannot be received even though AM can be received very clearly. FM stereo has the smaller service area, it also picks up static and other types of interference (”noise”) easily. AM BE2818 3. RECEPTION PROBLEMS HINT: Besides the problem of static, there are other problems, such as ”phasing”, ”multipath” and ”fade out”. These problems are caused not by electrical noise but by the nature of the radio waves themselves. Phasing (a) Ionosphere Phasing Besides electrical interference, AM broadcasts are also susceptible to other types of interference, especially at night. This is because AM radio waves bounce off the ionosphere at night. These radio waves then interfere with the signals that reach the vehicle’s antenna directly from the same transmitter. This type of interference is called ”phasing”. BE2819 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1801 05-1612 DIAGNOSTICS Multipath - AUDIO SYSTEM (b) Multipath Interference caused by reflection of radio waves against obstructions is called ”Multipath”. Multipath occurs when radio signals emitted from the broadcast transmitter antenna are reflected against tall buildings or mountains and interferes with other signals which are to be received directly. (c) Fade Out FM radio wave tends to be reflected against obstructions such as tall buildings or mountains because FM frequency is higher than that of AM. For this reason, FM signals often seem to gradually disappear or fade away as the vehicle goes behind those obstructions. This phenomenon is called ”fade out”. BE2820 Fade Out BE2821 4. (a) NOISE PROBLEMS It is very important for technicians to understand a customer’s claim about noise clearly. Use the following table to diagnose the phenomena. Radio wave AM FM Condition in which noise occurs Probable cause Noise occurs at a specific place. Strong possibility of foreign noise. Noise occurs when listening to faint broadcasting. The same program may be broadcasted from some local stations. If the program is the same, one of those may be tuned in. Noise occurs only at night. Strong possibility of beat from a distant broadcasting. Noise occurs at a specific place during driving. Strong possibility of multipath noise and phasing noise caused by changes of FM frequency. HINT: If the condition when the noise occurs does not meet any of the above, find out the cause based on ”Reception Problems”. Refer to the description about Multipath and Phasing mentioned previously. 5. COMPACT DISC PLAYER (a) Compact Disc (hereafter called ”CD”) Players use a laser beam pick-up to read the digital signals recorded on the CD and reproduce analog signals of the music, etc. 4.7 in. (12 cm) and 3.2 in. (8 cm) discs are available for the CD player. HINT: Never disassemble or apply oil to any part of the player unit. Do not insert any object other than a disc, into the CD player. NOTICE: CD players use an invisible laser beam which could cause hazardous radiation exposure. Be sure to operate the player correctly as instructed. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1802 05-1613 DIAGNOSTICS 6. Example: Head Capstan (a) (b) Pinch Roller - AUDIO SYSTEM MAINTENANCE Tape Player/Head Cleaning: Raise the cassette door with your finger. Using a pencil or similar object, push in the guide. Using a cleaning pen or cotton applicator soaked in cleaner, clean the head surface, pinch rollers and capstans. N17398 7. MAINTENANCE CD Player/Disc Cleaning: If the disc gets dirty, clean the disc by wiping the surface from the center to outside in the radial directions with a soft cloth. NOTICE: Do not use a conventional record cleaner or anti-static preservative. BE4331 8. (a) AVC-LAN Description What is AVC-LAN? AVC-LAN, an abbreviation for ”Audio Visual Communication Local Area Network”, is a united standard developed by the manufacturers in affiliation with Toyota Motor Corporation. This standard pertains to audio and visual signals as well as switch and communication signals. Example: Radio Receiver Assy (Resister 60 to 80 Ω) AVC-LAN Multi-display controller Sub-assy I39082 (b) Purpose: Recently, car audio systems have rapidly developed and the functions vastly changed. The conventional car audio system is being integrated with multi-media interfaces similar to those in navigation systems. At the same time, customers are demanding higher quality from their audio systems. This is merely an overview of the standardization background. The specific purposes are as follows. (1) To solve sound problems, etc. caused by using components of different manufacturers through signal standardization. (2) To allow each manufacturer to concentrate on developing products they do best. From this, reasonably priced products can be produced. HINT:
If a +B or GND short is detected in the AVC-LAN circuit, communication is interrupted and the audio system will stop functioning. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1803 05-1614 DIAGNOSTICS



9. (a) (b) (c) 10. (a) (b) - AUDIO SYSTEM If an audio system is equipped with a navigation system, the multi-display unit acts as the master unit. If the navigation system is not equipped, the audio head unit acts as the master unit instead. If the radio and navigation assy is equipped, it is the master unit. The radio receiver assy provides resistance to make communication possible. The car audio system with an AVC-LAN circuit has a diagnostic function. Each component has a specified number (3-digit) called a physical address. Each function has a number (2-digit) called a logical address. Communication system outline Components of the audio system communicate with each other via the AVC-LAN. Radio receiver assy has enough resistance (60 to 80 Ω) necessary for transmitting the communication. This is essential for communication. If a short circuit or open circuit occurs in the AVC-LAN circuit, communication is interrupted and the audio system will stop functioning. Diagnostic function outline The audio system has a diagnostic function (the result is indicated on the master unit). A 3-digit hexadecimal component code (physical address) is allocated to each component on the AVC-LAN. Using this code, the component in the diagnostic function can be displayed. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1804 05-1624 DIAGNOSTICS - AUDIO SYSTEM 055LJ-12 DIAGNOSTIC TROUBLE CODE CHART Terms Meaning Three-digit code (shown in hexadecimal) which is given to each component comprising the AVC-LAN. Corresponding to the function, individual symbols are specified. Physical address Logical address Two-digit code (shown in hexadecimal) which is given to each function comprising the inner system of the AVC-LAN. HINT: Titles for each unit are stated in the following order: physical address(parts name). 1. 190 (RADIO RECEIVER ASSY) HINT:
*1: Even if no failure is detected, trouble codes may be stored depending on the battery condition or voltage for starting the engine.
*2: The code is stored 180 seconds after the power supply connector is disconnected after engine start.
*3: The code may be stored when the engine key is turned 1 minute after engine start.
*4: The code may be stored when the engine key is turned again after engine start. (a) Logical address: 01 (Communication control) DTC Diagnosis item Diagnosis content Countermeasure and inspected parts 21 ROM Error Abnormal condition of ROM is detected. Replace radio receiver assy. 22 RAM Error Abnormal condition of RAM is detected. Replace radio receiver assy. Absence of Master Component in which this code is recorded was disconnected from system or master component with ignition switch in ACC or ON.
Check harness for power supply system of radio receiver assy.
Check harness for communication system of radio receiver assy. No Response to Connection Check Component shown by sub code is or was disconnected from system after engine start.
Check harness for power supply system of component shown by sub code.
Check harness for communication system of component shown by sub code. Last Mode Error Audio or visual component operated before engine stop is or was disconnected with ignition switch in ACC or ON.
Check harness for power supply system of component shown by sub code.
Check harness for communication system of component shown by sub code. No Response to ON/OFF Instruction No response is identified when changing mode (audio and visual mode change). Sound and picture does not change by button operation.
Check harness for power supply system of component shown by sub code.
Check harness for communication system of component shown by sub code.
If error occurs again, replace component shown by sub code. Mode Status Error Dual alarm is detected.
Check harness for power supply system of component shown by sub code.
Check harness for communication system of component shown by sub code. D6 *1 D8 *2 D9 *1 DA DB *1 DC *3 DD *4 Transmission Error Master Reset (Momentary Interruption) Transmission to component shown by auxiliary code has been failed. (Detecting this DTC does not necessarily mean actual failure.) After the engine was started, master component was disconnected from system. If same sub code is recorded in other component, check harness for power supply and communication system of all components shown by code. (If not, delete DTC and recheck.)
Check harness for power supply system of radio receiver assy.
Check harness for communication system of radio receiver assy.
If this error occurs frequently, replace radio receiver assy. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1814 05-1625 DIAGNOSTICS DTC Diagnosis item - AUDIO SYSTEM Diagnosis content Countermeasure and inspected parts
Check harness for power supply of component shown by sub code.
Check harness for communication system of component shown by sub code. DE *4 Slave Reset (Momentary Interruption) After the engine was started, component shown by sub code was disconnected from system. DF *4 Master Error Due to defective cognition of component with a display, master function is switched to audio equipment. Error occurs in communication between sub-master (audio) and master component. E0 *1 Registration Completion Instruction Error ”Registration Completion Instruction” command from master cannot be received. Since this DTC is provided for engineering purposes, it may be detected when no actual failure exists. Voice Processing Device ON Error When the AMP device records that the AMP output does not function even while the source device operates.
Check harness for power supply of radio receiver assy.
Check harness for communication system of radio receiver assy. ON/OFF Instruction Parameter Error Error occurs in ON/OFF controlling command from master component. E1 *1 E2 (b) Replace radio receiver assy. Registration Request Transmission Registration Request command is output from component shown by sub code. Receiving Connection Check Instruction, Registration Request command is output from sub-master component. Since this DTC is provided for engineering purposes, it may be detected when no actual failure exists. Multiple Frame Abort Multiple frame transmission is aborted. Since this DTC is provided for engineering purposes, it may be detected when no actual failure exists. E3 *1 E4 *1
Check harness for power supply of radio receiver assy.
Check harness for communication system of radio receiver assy.
Check harness for communication system between radio receiver assy and sub-master component. Logical address: 60 (Radio unit) DTC Diagnosis item Diagnosis content Countermeasure and inspected parts 43 AM Tuner Error Abnormal condition of AM tuner is detected. Replace radio receiver assy. 44 FM Tuner Error Abnormal condition of FM tuner is detected. Replace radio receiver assy. (c) Logical address: 61 (Cassette unit) DTC Diagnosis item Diagnosis content Countermeasure and inspected parts Malfunction due to mechanical failure is identified. Either that, or cassette tape is cut or entangled.
Inspect cassette tape.
Replace radio receiver assy. 40 Mechanical Error of Media 41 EJECT Error Malfunction due to mechanical failure. Replace radio receiver assy. 42 Tape caught in the radio receiver assy Hub lock etc. Inspect cassette tape. (d) DTC Logical address: 62 (CD player) Diagnosis item 47 Detection of high temperature 48 Detection of excess current (e) DTC Diagnosis content Countermeasure and inspected parts High temperature is detected in CD player. With ignition switch off, leave vehicle in cool shaded place for a while and recheck. After deleting the DTC memory, if same code detected, replace radio receiver assy. Excess current flows into CD player. Replace radio receiver assy. Logical address: 63 (In-dash CD changer) Diagnosis item Diagnosis content Countermeasure and inspected parts 51 CD changer elevator error Mechanical error occurred during elevator operation Replace radio receiver assy. 52 CD changer clump error Failure in disc clamping or clamp error Replace radio receiver assy. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1815 05-1626 DIAGNOSTICS - AUDIO SYSTEM 2. 1F6,16C,16D (MULTI-DISPLA Y CONTROLLER SUB-ASSY) HINT:
*1: Even if no failure is detected, this code may be stored depending on the battery condition or voltage for starting the engine.
*2: The code is stored 180 seconds after the power supply connector is disconnected after engine start.
*3: The code may be stored when the engine key is turned 1 minute after engine start.
*4: The code may be stored when the engine key is turned again after engine start.
*5: If the device is reported as not existing during verification, check the power source circuit and AVCLAN circuit for the device. (a) Logical address: 01 (Communication control) DTC Diagnosis item Condition Countermeasure and inspected parts Absence of Master Component in which this code is recorded was disconnected from system with ignition switch in ACC or ON. Either that, or multidisplay controller sub-assy was disconnected when this code was recorded.
Check harness for power supply system of radio receiver assy.
Check harness for communication system of radio receiver assy.
Check harness for communication system between radio receiver assy and multi-display controller sub-assy. D7 *2 Connection Check Error Component in which this code is recorded was disconnected from system after engine start. Either that, or multi-display controller sub-assy was disconnected when this code was recorded.
Check harness for power supply system of radio receiver assy.
Check harness for communication system of radio receiver assy.
Check harness for power supply of multidisplay controller sub-assy.
Check harness for communication system of multi-display controller sub-assy. DC *2 *5 Transmission Error Transmission to component shown by subcode failed. (This code does not necessarily mean actual failure.) If same sub-code is recorded in other component(s), check harness for power supply and communication system of all components shown by code. DD *3 Master Reset (Momentary Interruption) Master component was disconnected after engine start.
Check harness for power supply system of radio receiver assy.
Check harness for communication system of radio receiver assy.
Check harness for power supply of multidisplay controller sub-assy.
Check harness for communication system of multi-display controller sub-assy.
If error occurs frequently, replace radio receiver assy. DF *4 Master Error Due to defective condition of component with a display, master function is switched to audio equipment. Error occurs in communication between sub-master (audio) and master component.
Check harness for power supply of radio receiver assy.
Check harness for communication system of radio receiver assy.
Check harness for communication system between multi-display controller sub-assy and radio receiver assy. E0 *1 Registration Completion Instruction Error ”Registration Completion Instruction” command from master cannot be received. Since this DTC is provided for engineering, it may be detected when no actual failure exists. E2 ON/OFF Instruction Parameter Error Error occurs in ON/OFF controlling command from radio receiver assy. D6 *1 Replace radio receiver assy. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1816 05-1627 DIAGNOSTICS DTC Diagnosis item - AUDIO SYSTEM Condition Countermeasure and inspected parts E3 *1 Registration Request Transmission
Registration Request command is output from slave component.
Registration Request command is output from sub-master component. Since this DTC is provided for engineering, it may be detected when no actual failure exists. E4 Multiple Frame Abort Multiple frame transmission is aborted. Since this DTC is provided for engineering purpose, it may be detected when no actual failure exists. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1817 05-1615 DIAGNOSTICS - AUDIO SYSTEM 055LG-12 HOW TO PROCEED WITH TROUBLESHOOTING 1 VEHICLE BROUGHT TO WORKSHOP 2 CUSTOMER PROBLEM ANALYSIS (SEE PAGE 05-1617 ) 3 BASIC INSPECTION (a) Basic inspection. (1) Check the battery voltage. Standard: 11 to 14 V Check the power supply to the radio receiver assy. (1) Turn the ignition switch to the ACC position. (2) Check whether or not the display appears on the radio receiver assy. (b) DISPLAY DOES NOT APPEAR (PROCEED TO PROBLEM SYMPTOM TABLE) (SEE PAGE 05-1632 ) DISPLAY APPEARS (GO TO STEP 4) 4 DTC CHECK (SEE PAGE 05-1618 ) HINT: If the audio system is equipped with a multi-display, check DTCs in the NAVIGATION SYSTEM section(see page 05-1757 ). DTC IS OUTPUT (GO TO STEP 9) DTC IS NOT OUTPUT (GO TO STEP 10) 5 DTC CHART (SEE PAGE 05-1624 ) GO TO STEP 12 6 PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1632 ) 7 CIRCUIT INSPECTION AND PART INSPECTION (SEE PAGE 05-1634 - 05-1688 ) 8 IDENTIFICATION OF PROBLEM 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1805 05-1616 DIAGNOSTICS 9 - AUDIO SYSTEM CONFIRMATION TEST END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1806 05-1628 DIAGNOSTICS - AUDIO SYSTEM 055LK-11 LOCATION Fusible Link Block Engine Room J/B
DOME Fuse
RAD No. 1 Fuse
ALT Fuse Steering Pad SW LH Instrument Panel J/B
RAD No. 2 Fuse
AM1 Fuse
PANEL Fuse
TAILLIGHT Relay Antenna Amplifier Fix Antenna Front No.2 Speaker Assy RH Radio Receiver Assy Ignition Switch Front No.2 Speaker Assy LH Front No.1 Speaker Assy RH Antenna Amplifier Spiral Cable Sub-assy Glass Printed Antenna (AM, FM) Front No.1 Speaker Assy LH Rear Speaker Assy LH Glass Printed Antenna (FM Sub Antenna) Stereo Component Amplifier Assy *1 Rear Speaker Assy RH *1: JBL type I39163 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1818 05-1618 DIAGNOSTICS - AUDIO SYSTEM 055LI-10 SEEK TRACK 1 PRE-CHECK 6 1. (a) DISC I40723 (b) DIAGNOSTIC CHECK Starting Diagnostic Mode (All elements come on during the SW check mode.) (1) Turn off the audio system and turn the ignition switch to the ACC position. While pressing the preset switches ”1” and ”6” at the same time, press the ”DISC” 3 times. (2) Reference:
When the system enters the Diagnosis Mode, beep sound is emitted 3 times and all the elements come on during the SW check mode.
It takes about 40 seconds to complete the check.
Turn all the elements in the LCD on.
When pressing the switch, confirm beep sound is emitted.
Press the ”SEEK TRACK UP” switch to enter the ”Service Check Screen”. Service Check Screen (1) Reference: In the service check mode, the system check and the diagnostic memory check are performed, and the check results are displayed in ascending order of the component codes (physical address). Terms Meaning Component code (Physical address) Three-digit code (in hexadecimal) given to each device comprising AVC-LAN. Corresponding to its function, individual symbol is provided. Logical address Two-digit code (in hexadecimal) given to each function and device unit in each device comprising AVC-LAN. Code No. (physical address) List Code No. (physical address) 190 1F6, 16C (c) Equipment name Radio receiver assy (Audio head unit) Multi-display Controller Sub-assy Finishing Diagnostic Mode (1) Press the ”DISC” switch for 2 seconds or more, or turn the ignition switch off. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1808 05-1619 DIAGNOSTICS (d) - AUDIO SYSTEM Service Check Mode Result Display (for checking the current and the past system conditions). (1) Press the ”SEEK TRACK” switch to see the check result of each component. P---indicates physical address. 190---physical address good---”The component is normal”. P---indicates physical address. 360---physical address CHEC---”Check needed”. : SEEK TRACK UP : SEEK TRACK DOWN The illustration shows the case that the system has 2 components with codes 190 and 360, and one component (code 360) requires a check. The check result is displayed in ascending order of component code. The component device code is displayed first, and then the check result follows. I34696 (2) Display good NCON ECHN CHEC Check Result Display. Original Language Meaning Action to be taken Good (normal) No DTCs are detected in both ”System Check Mode” and ”Diagnostic Memory Mode”. - No connection The system recognized the component when it was registered, but the component gives no response to the ”Diagnostic Mode ON Request”. Check the power source circuit and the communication circuit of the component indicated by the component code (physical address). Exchange One or more DTCs for ”Exchange” are detected in either ”System Check Mode” or ”Diagnostic Memory Mode”. Go to the detailed information mode to check the trouble area referring to the DTC list. Check When no DTCs are detected for ”Exchange”, one or more DTCs for ”Check” are detected in either ”System Check Mode” or ”Diagnostic Memory Mode”. Go to the detailed information mode to check the trouble area referring to the DTC list. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1809 05-1620 DIAGNOSTICS - AUDIO SYSTEM Display Original Language Meaning Action to be taken OLD Old version Old DTC application is identified and DTC is detected in either ”System Check Mode” or ”Diagnostic Memory Mode”. - No response The device gives no response to any one of ”System Check Mode ON Request”, ”System Check Result Request” and ”Diagnostic Memory Request”. Check the power source circuit and the communication circuit of the component indicated by the component code (physical address). NRES (3) (e) To perform the Service Check again, press the preset switch ”1”. Detailed Information Mode (when displaying the DTC for a trouble component) (1) With ”CHEC” or ”ECHN” being displayed, press the preset switch ”2” to go to the detailed information mode. (2) Press the ”SEEK TRACK” switch to display the ”System Check Result (SYS)” and ”Diagnostic Memory Response (CODE)”. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1810 05-1621 DIAGNOSTICS - AUDIO SYSTEM Service Check Mode PRESET SWITCH ”3” Detailed Information Mode PRESET SWITCH ”2” P---indicates physical address. 190---physical address *1 SYS---system check result 1---the first code 62---logical address Detailed information of the first code is displayed. 47---DTC Continue to display detailed information when more than one DTC are detected. CODE---diagnosis memory response result 2---the second code 01---logical address DC---DTC P---indicates physical address. 360---sub code Detail information of the second code is displayed. (*2) 6F---connection check number 05---the number of times of occurrence (in decimal) Continue to display detailed information when more than one DTC are detected. : SEEK TRACK UP : SEEK TRACK DOWN From *1 To *1 The illustration shows the case that the component with code 190 has DTC ”47” and ”dC” as a result of the system check and the diagnostic memory response. The detailed information mode shows the system check result first, then the diagnostic memory response result follows. (*2): As for the DTCs that do not have any sub code, sub code is not displayed. I34695 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1811 05-1622 DIAGNOSTICS (3) - AUDIO SYSTEM Displayed Items in Detailed Information Mode Division Code for DTC display Meaning The order of detailed information displayed when the ”TUNE UP” switch is pressed (The order is reversed when the ”TUNE DOWN” switch is pressed.) SYS System check result is displayed. Logical address → DTC Diagnostic memory check result is displayed. Logical address→ DTC→ Sub code→ Connection confirmation number→ The number of times of occurrence CODE (4) (5) (f) Check the trouble area referring to the DTC list. To return to the service check mode, press the preset switch ”3”. Clearing Individual DTC Memory (when clearing the memory of the DTC detected in the past individually) (1) Press the preset switch ”5” for 2 seconds or more while the ”ECHN” is displayed in the service check mode or during the detailed information mode. HINT:


(g) A beep sound is emitted once when the DTC memory is completely cleared. When the DTC memory is cleared, only the component code (physical address) is displayed for the target component. To check DTCs, press the preset switch ”1” and perform the service check again. Clearance of all the DTC memory (when clearing all the memory of the DTCs detected in the past) (1) Start the diagnostic mode after repairing the trouble area. (2) Press the preset switch ”5” for 2 seconds or more. (”CLR” is displayed at this time.) HINT:

A beep sound is emitted once when the DTC memory is completely cleared. When the DTC memory for all the component is cleared, only the component codes (physical address) are displayed. (3) Press the preset switch ”1” to perform the service check again, and check that no DTCs are displayed for all the component codes (physical address). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1812 05-1623 DIAGNOSTICS 2. (a) - AUDIO SYSTEM IDENTIFICATION OF NOISE SOURCE Identify the condition in which the noise occurs, and check the noise filter on the related part. Condition in which noise occurs Noise Source Depressing the acceleration pedal increases the noise, and stopping the engine stops the noise immediately. Generator Noise occurs during A/C or the heater operation. Blower motor Rapid acceleration while driving on an unpaved road or after the ignition switch is turned on makes noise. Fuel pump Pressing and then releasing the horn switch, and keeping pressing the horn switch makes unusual noise. Horn Quiet noise is heard while the engine is running, but stops with the engine. Ignition Noise occurs synchronously with the turn signal flash. Flasher Noise occurs during the window washer operation. Washer Noise occurs during the engine running, and it continues even after the engine stops. Engine coolant temperature sensor Noise occurs during the wiper operation. Wiper Noise occurs when the brake pedal is depressed. Stop light switch Others Static electricity stored on the vehicle (b) Reference:
Make sure first that there is no noise from outside. Failing to do so makes the noise source detection difficult and leads to misunderstanding.
The noise should be removed in descending order of loudness.
Turning the radio so that no station is received makes the noise more noticeable, making the recognition of the phenomenon easier. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1813 05-1632 DIAGNOSTICS - AUDIO SYSTEM 055LM-12 PROBLEM SYMPTOMS TABLE RADIO RECEIVER ASSY Symptom Suspect Area See page Pressing power switch does not start system. 5. Power source circuit (radio receiver assy) 6. Radio receiver assy 05-1634 67-6 All switches do not respond. 1. Steering pad switch circuit 2. Radio receiver assy 05-1643 67-6 Turning on light switch does not light up night time illumination of radio receiver. 1. Illumination circuit 2. Radio receiver assy 05-1647 67-6 05-1634 05-1638 All sound can not be heard. 1. Power source circuit (radio receiver assy) 2. Power source circuit (stereo component amplifier assy) *1 3. AMP sound signal circuit (radio receiver assy - AMP) *1 4. Speaker circuit 5. AMP mute signal circuit (from radio receiver assy) *1 6. Stereo component amplifier assy *1 7. Radio receiver assy 1. Power source circuit (radio receiver assy) 2. Power source circuit (stereo component amplifier assy) *1 3. Speaker circuit (driver side speaker) *2 4. AMP sound signal circuit (radio receiver assy - AMP) *1 5. Stereo component amplifier assy *1 6. Radio receiver assy 05-1634 05-1638 1. Power source circuit (radio receiver assy) 2. Power source circuit (stereo component amplifier assy) *1 3. Speaker circuit 4. AMP sound signal circuit (radio receiver assy - AMP) *1 5. Sound quality is bad in all modes (volume is too low) 6. Stereo component amplifier assy *1 7. Radio receiver assy 05-1634 05-1638 Front speaker (driver side) only is not heard. (volume is too low) Sound quality is bad in all modes. (volume is too low) Sound quality is bad or sound is not heard. (RSE sound) 05-1669 05-1657 05-1651 67-20 67-6 05-1664 05-1669 67-20 67-6 1. Power source circuit (radio receiver assy) 2. Power source circuit (multi-display controller sub-assy) 3. AVC-LAN circuit (multi-display controller sub-assy radio receiver assy) 4. RSE sound signal circuit (multi-display controller subassy - radio receiver assy) 5. Mute signal circuit (from multi-display controller subassy) 6. Radio receiver assy 7. Multi-display controller sub-assy 05-1657 05-1669 05-1673 67-20 67-6 05-1634 05-1641 05-1688 05-1671 05-1654 67-6 67-23 Noise occurs. - 05-1674 Radio broadcast cannot be received. (bad reception) - 05-1675 CD cannot be inserted or is ejected right after insertion. 1. Power source circuit (radio receiver assy) 2. CD cannot be inserted or is ejected right after insertion 05-1634 05-1678 CD cannot be ejected. 1. Power source circuit (radio receiver assy) 2. CD cannot be ejected 05-1634 05-1680 Sound quality is bad only when playing CD. (volume is too low) - 05-1681 CD sound skips. - 05-1682 Cassette tape cannot be inserted or played. 1. Power source circuit (radio receiver assy) 2. Cassette tape cannot be inserted or played 05-1634 05-1684 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1822 05-1633 DIAGNOSTICS - AUDIO SYSTEM Cassette tape cannot be ejected. 1. Power source circuit (radio receiver assy) 2. Cassette tape cannot be ejected 05-1634 05-1685 Sound quality is bad only when playing tape. - 05-1686 Tape is tangled due to incorrect tape speed or auto-reverse malfunction. - 05-1687 *1: JBL type *2: w/ Navigation System STEERING PAD SWITCH Symptom A audio system cannot be operated with steering pad switch Suspect Area See page 1. Steering pad switch circuit 2. Radio receiver assy 05-1643 67-6 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1823 05-1629 DIAGNOSTICS - AUDIO SYSTEM 05IRI-01 TERMINALS OF ECU 1. RADIO RECEIVER ASSY (STANDARD TYPE) R3 R2 I40196 Symbols (Terminal No.) Wiring Color Terminal Description R - BR Sound signal (Rear Right) Audio system is sounding - RL+ (R2-2) - GND (R3-7) B - BR Sound signal (Rear Left) Audio system is sounding - RR- (R2-3) - GND (R3-7) W - BR Sound signal (Rear Right) Audio system is sounding - Illumination (rheostat) signal Light control switch TAIL or HEAD Sound signal (Real Left) Audio system is sounding - Sound signal (Front Right) Audio system is sounding - Sound signal (Front Left) Audio system is sounding - RR+ (R2-1) - GND (R3-7) ILL- (R2-5) - Body ground W - Body ground RL- (R2-6) - GND (R3-7) Y - BR FR+ (R3-1) - GND (R3-7) LG - BR FL+ (R3-2) - GND (R3-7) P - BR Condition ACC+B (R3-3) - GND (R3-7) GR - BR Accessory (ON) Turn Ignition switch OFF → ACC or ON BU+B (R3-4) - GND (R3-7) L-B - BR Specification 10 to 14 V Below 1V → 10 to 14 V Battery Always FR- (R3-5) - GND (R3-7) L - BR Sound signal (Front Right) Audio system is sounding - FL- (R3-6) - GND (R3-7) V - BR Sound signal (Front Left) Audio system is sounding - GND (R3-7) - Body ground BR Body ground Ground Always Below 1 Ω ILL+ (R3-10) - GND (R3-7) G - BR Illumination (rheostat) signal Light control switch TAIL or HEAD 10 to 14 V 2. 10 to 14 V RADIO RECEIVER ASSY (JBL TYPE) R4 R22 R23 I40207 Symbols (Terminal No.) B (R4-1) - GND (R4-20) Wiring Color L-B - BR Terminal Description Condition Specification Battery Always 10 to 14 V Light control switch TAIL or HEAD 10 to 14 V ILL+ (R4-2) - GND (R4-20) G - BR Illumination (rheostat) signal AMP+ (R4-3) - GND (R4-20) V - BR Stereo component amplifier assy control signal Turn Ignition switch OFF → ACC or ON Below 1V → 10 to 14 V MUTE (R4-7) - GND (R4-20) BR - BR MUTE signal Audio system is sounding → changing Above 3.5 V → Below 1 V FR+ (R4-8) - GND (R4-20) W - BR Sound signal (Front Right) Audio system is sounding - FL+ (R4-9) - GND (R4-20) B - BR Sound signal (Front Left) Audio system is sounding - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1819 05-1630 DIAGNOSTICS SLD (R4-10) - Body ground Shielded Body ground - AUDIO SYSTEM Below 1 Ω Shield ground Always Accessory Turn Ignition switch OFF → ACC or ON Below 1V → 10 to 14 V ACC (R4-11) - GND (R4-20) GR - BR ILL- (R4-12) - GND (R4-20) W - BR Illumination (rheostat) signal Light control switch TAIL or HEAD ANT+ (R4-13) - GND (R4-20) O - BR Power source of antenna See ”Service Check Mode” S.GND (R4-16) - Body ground Y - Body ground Shield ground Always BEEP (R4-17) - GND (R4-20) L - BR Beep sound signal Audio system is sounding - RR+ (R4-18) - GND (R4-20) G - BR Sound signal (Rear Right) Audio system is sounding - RL+ (R4-19) - GND (R4-20) R - BR Sound signal (Rear Left) Audio system is sounding - GND (R4-20) - Body ground BR Body ground Ground Always 10 to 14 V Below 1 Ω Below 1 Ω R+ (R22-2) - GND (R4-20) B - BR Sound signal (Right) RSE system is sounding - R- (R22-3) - GND (R4-20) W - BR Sound signal (Right) RSE system is sounding - L+ (R22-4) - GND (R4-20) R - BR Sound signal (Left) RSE system is sounding - L- (R22-5) - GND (R4-20) G - BR Sound signal (Left) RSE system is sounding - MUTE (R22-6) - GND (R4-20) P - BR MUTE signal RSE system is sounding → changing TX1+ (R23-9) - GND (R4-20) Y - BR AVC - LAN communication signal Turn Ignition switch to ACC 2 to 3 V TX1- (R23-10) - GND (R4-20) L - BR AVC - LAN communication signal Turn Ignition switch to ACC 2 to 3 V 3. Above 3.5 V → Below 1 V STEREO COMPONENT AMPLIFIER ASSY (JBL TYPE) S23 S22 I30200 Symbols (Terminal No.) Wiring Color Terminal Description AMP+ (S22-1) GND (S23-12) P - W-B Stereo component amplifier assy control signal Radio switch is ON 10 to 14 V ACC (S22-2) - GND (S23-12) G - W-B Accessory (ON) Turn Ignition switch OFF → ACC or ON Below 1V → 10 to 14 V BEEP (S22-4) GND (S23-12) L - W-B Beep sound signal Audio system is sounding - F.L (S22-5) - GND (S23-12) B - W-B Sound signal (Front Left) Audio system is sounding - F.R (S22-6) - GND (S23-12) W - W-B Sound signal (Front Right) Audio system is sounding Y - Body ground Shield ground Always BR - W-B MUTE signal Audio system is sounding → changing SGND (S22-11) - Body ground MUTE (S22-12) GND (S23-12) Condition Specification Below 1 Ω Above 3.5 V → Below 1 V R.L (S22-13) - GND (S23-12) R - W-B Sound signal (Rear Left) Audio system is sounding - R.R (S22-14) - GND (S23-12) G - W-B Sound signal (Rear Right) Audio system is sounding - FR+ (S23-1) - GND (S23-12) LG - W-B Sound signal (Front Right) Audio system is sounding - FL+ (S23-2) - GND (S23-12) Y - W-B Sound signal (Front Left) Audio system is sounding - RR+ (S23-3) - GND (S23-12) R - W-B Sound signal (Rear Right) Audio system is sounding - RL+ (S23-4) - GND (S23-12) GR - W-B Sound signal (Rear Left) Audio system is sounding +B (S23-7) - GND (S23-12) R-Y - W-B Battery Always 10 to 14 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1820 05-1631 DIAGNOSTICS FR- (S23-8) - GND (S23-12) L - W-B FL- (S23-9) - GND (S23-12) - AUDIO SYSTEM Sound signal (Front Right) Audio system is sounding - R-Y - W-B Sound signal (Front Left) Audio system is sounding - RR- (S23-10) - GND (S23-12) G - W-B Sound signal (Rear Right) Audio system is sounding - RL- (S23-11) - GND (S23-12) LG - W-B Sound signal (Rear Left) Audio system is sounding - GND (S23-12) - Body ground W-B Body ground Ground Always 4. Below 1 Ω MULTI-DISPLA Y CONTROLLER SUB-ASSY R31 R29 I40208 Symbols (Terminal No.) L- (R29-7) - GND (R29-29) Wiring Color Terminal Description Condition Specification G - W-B Sound signal (Left) RSE system is sounding - L+ (R29-8) - GND (R29-29) R - W-B Sound signal (Left) RSE system is sounding - R- (R29-9) - GND (R29-29) W - W-B Sound signal (Right) RSE system is sounding - R+ (R29-10) - GND (R29-29) B - W-B Sound signal (Right) RSE system is sounding - SG1 (R29-11) - Body ground Shielded Body ground Shield ground Always LMUT (R29-12) - GND (R29-29) V - W-B MUTE signal RSE system is sounding → changing +B1 (R29-16) - GND (R29-29) Y - W-B Battery Always 10 to 14 V GND (R29-29) - Body ground W-B Body ground Ground Always Below 1 Ω Below 1 Ω Above 3.5 V → Below 1 V TX- (R29-30) - GND (R29-29) GR - W-B AVC - LAN communication signal Turn Ignition switch to ACC 2 to 3 V TX+ (R29-31) - GND (R29-29) LG - W-B AVC - LAN communication signal Turn Ignition switch to ACC 2 to 3 V ACC (R29-32) - GND (R29-29) G - W-B Accessory (ON) Turn Ignition switch OFF → ACC or ON Ground Always SELD (R31-7) - Body ground W-B Body ground Below 1V → 10 to 14 V Below 1 Ω 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1821 05-1 130 DIAGNOSTICS DTC - AIR CONDITIONING SYSTEM 05ITS-01 B1411/11 ROOM TEMPERATURE SENSOR CIRCUIT CIRCUIT DESCRIPTION This sensor detects the temperature inside the cabin and sends the appropriate signals to the A/C amplifier assy. DTC No. B1411/11 Detection item Trouble Area Open or short in room temperature sensor circuit
Cooler (room temperature sensor) thermistor
Harness or connector between cooler (room temperature sensor) thermistor and A/C amplifier assy
A/C amplifier assy WIRING DIAGRAM A/C Amplifier assy Y 3 A11 SG-3 1 R6 Cooler (Room Temperature Sensor)Thermistor 2 4 W A11 TR I18376 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1320 05-1 131 DIAGNOSTICS - AIR CONDITIONING SYSTEM INSPECTION PROCEDURE HINT: In case of using the hand-held tester, start the inspection step 1 and in case of not using the hand-held tester, start from step 2. 1 READ VALUE OF HAND-HELD TESTER (a) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the hand-held tester main switch ON. (c) Select the items below in the DATA LIST,and read the displays on the hand-held tester. A C: Item Measurement Item/Display (Range) Normal Condition Diagnostic Note ROOM TEMP Room temperature sensor /min.: -6.5C (20.3F) max.: 57.25C (135.05F) Actual room temperature - Result: NG A OK (Checking from the DTC) B OK (Checking from the PROBLEM SYMPTOM TABLE) C B REPLACE AIRCONDITIONER AMPLIFIER ASSY C PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1 129) A 2 INSPECT AIRCONDITIONER AMPLIFIER ASSY(TR, SG-3) (a) A/C Amplifier Connector Wire Harness View: (b) (c) A11 TR (+) SG-3 (-) I30331 Remove A/C amplifier assy with connectors still connected. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A11-3 (SG-3) A11-4 (TR) at 25C (77F) 1.8 to 2.2 V A11-3 (SG-3) A11-4 (TR) at 40C (104F) 1.2 to 1.6 V HINT: As the temperature increases, the voltage decreases. OK REPLACE AIRCONDITIONER AMPLIFIER ASSY NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1321 05-1 132 DIAGNOSTICS 3 - AIR CONDITIONING SYSTEM INSPECT COOLER (ROOM TEMP. SENSOR) THERMISTOR (a) (b) Cooler Thermistor Connector Front View: R6 I30111 Remove cooler (room temperature sensor) thermistor. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition R6-1 - R6-2 10°C (50°F) 3.00 to 3.73 kΩ R6-1 - R6-2 15°C (59°F) 2.45 to 2.88 kΩ R6-1 - R6-2 20°F (68°F) 1.95 to 2.30 kΩ R6-1 - R6-2 25°C (77°F) 1.60 to 1.80 kΩ R6-1 - R6-2 30°C (86°F) 1.28 to 1.47 kΩ R6-1 - R6-2 35°C (95°F) 1.00 to 1.22 kΩ R6-1 - R6-2 40°C (104°F) 0.80 to 1.00 kΩ R6-1 - R6-2 45°C (113°F) 0.65 to 0.85 kΩ R6-1 - R6-2 50°C (122°F) 0.50 to 0.70 kΩ R6-1 - R6-2 55°C (131°F) 0.44 to 0.60 kΩ R6-1 - R6-2 60°C (140°F) 0.36 to 0.50 kΩ NOTICE:
Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor.
When measuring the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the chart below). 4.0 3.5 3.0 2.5 Resistance (kΩ) Maximum permissible value line 2.0 1.5 1.0 0.5 Minimum permissible value line 0.0 0 32 20 68 40 104 Temperature 60 (°C) 140 (°F) I38777 I40673 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1322 05-1 133 DIAGNOSTICS - NG AIR CONDITIONING SYSTEM REPLACE COOLER (ROOM TEMP. SENSOR) THERMISTOR OK 4 CHECK HARNESS AND CONNECTOR(COOLER (ROOM TEMPERATURE SENSOR) THERMISTOR - A/C AMPLIFIER ASSY) (a) Cooler (Room Temperature Sensor) Thermistor Connector Front View: R6 A/C Amplifier Connector Wire Harness View: Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A11-4 (TR) - R6-2 Always Below 1 Ω A11-3 (SG-3) - R6-1 Always Below 1 Ω A11-4 (TR) Body ground Always 10 kΩ or higher A11-3 (SG-3) Body ground Always 10 kΩ or higher A11 TR SG-3 NG I41011 REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE AIRCONDITIONER AMPLIFIER ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1323 05-1 134 DIAGNOSTICS DTC - AIR CONDITIONING SYSTEM 05ITT-01 B1412/12 AMBIENT TEMPERATURE SENSOR CIRCUIT CIRCUIT DESCRIPTION The ECM and A/C amplifier communicate via BEAN. This sensor detects the temperature outside the cabin and sends the appropriate signals to the A/C amplifier assy. DTC No. B1412/12 Detection item Trouble Area
Cooler (ambient temperature sensor) thermistor
Harness or connector between cooler (ambient temperature sensor) thermistor and ECM
ECM
A/C amplifier assy Open or short in ambient temperature sensor circuit WIRING DIAGRAM ECM A/C Amplifier assy 2 MPX+ A11 BEAN signal 9 MPX- A10 6 EB2 BR BR Short Connector 5 5 S28 S29 BR 18 E6 MPX1 29 E6 MPX2 28 E7 E2 32 E6 TAM 1 A1 Cooler (Ambient Temperature Sensor) Thermistor 2 5 IK3 B B-R I38775 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1324 05-1 135 DIAGNOSTICS - AIR CONDITIONING SYSTEM INSPECTION PROCEDURE HINT: In case of using the hand-held tester, start the inspection step 1 and in case of not using the hand-held tester, start from step 2. 1 READ VALUE OF HAND-HELD TESTER (a) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the hand-held tester main switch ON. (c) Select the items below in the DATA LIST, and read the displays on the hand-held tester. A C: Item Measurement Item/Display (Range) Normal Condition Diagnostic Note 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 - Result: NG A OK (Checking from the DTC) B OK (Checking from the PROBLEM SYMPTOM TABLE) C B REPLACE ECM C PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE(SEE PAGE 05-1 129) A 2 INSPECT ECM(TAM, E2) (a) (b) (c) ECM Connector Wire Harness View: E7 E6 E2 (-) TAM (+) I38774 Remove ECM with connectors still connected. Turn ignition switch ON. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition E6-32 (TAM) E7-28 (E2) at 25C (77F) 1.4 to 1.8 V E6-32 (TAM) E7-28 (E2) at 40C (104F) 0.8 to 1.2 V HINT: As the temperature increases, the voltage decreases. OK REPLACE ECM NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1325 05-1 136 DIAGNOSTICS 3 - AIR CONDITIONING SYSTEM INSPECT COOLER (AMBIENT TEMP. SENSOR) THERMISTOR (a) (b) Ambient Temperature Sensor Connector Front View: A1 1 2 I30487 Remove cooler (ambient temperature sensor) thermistor. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A1-1 - A1-2 10°C (50°F) 3.00 to 3.73 kΩ A1-1 - A1-2 15°C (59°F) 2.45 to 2.88 kΩ A1-1 - A1-2 20°F (68°F) 1.95 to 2.30 kΩ A1-1 - A1-2 25°C (77°F) 1.60 to 1.80 kΩ A1-1 - A1-2 30°C (86°F) 1.28 to 1.47 kΩ A1-1 - A1-2 35°C (95°F) 1.00 to 1.22 kΩ A1-1 - A1-2 40°C (104°F) 0.80 to 1.00 kΩ A1-1 - A1-2 45°C (113°F) 0.65 to 0.85 kΩ A1-1 - A1-2 50°C (122°F) 0.50 to 0.70 kΩ A1-1 - A1-2 55°C (131°F) 0.44 to 0.60 kΩ A1-1 - A1-2 60°C (140°F) 0.36 to 0.50 kΩ NOTICE:
Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor.
When measuring the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the chart below). 4.0 3.5 3.0 2.5 Resistance (kΩ) Maximum permissible value line 2.0 1.5 1.0 0.5 Minimum permissible value line 0.0 0 32 20 68 40 104 Temperature 60 (°C) 140 (°F) I38777 I40673 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1326 05-1 137 DIAGNOSTICS NG - AIR CONDITIONING SYSTEM REPLACE COOLER (AMBIENT TEMP. SENSOR) THERMISTOR OK 4 CHECK HARNESS AND CONNECTOR(COOLER (AMBIENT TEMPERATURE SENSOR) THERMISTOR - ECM) (a) Ambient Temperature Sensor Connector Front View: A1 1 2 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition E7-28 (E2) - A1-1 Always Below 1 Ω E6-32 (TAM) - A1-2 Always Below 1 Ω E7-28 (E2) Body ground Always 10 kΩ or higher E6-32 (TAM) Body ground Always 10 kΩ or higher ECM Connector Wire Harness View: E7 E2 ECM Connector Wire Harness View: E6 NG TAM I41016 REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE ECM 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1327 05-1 138 DIAGNOSTICS DTC - AIR CONDITIONING SYSTEM 05ITU-01 B1413/13 EVAPORATOR TEMPERATURE SENSOR CIRCUIT CIRCUIT DESCRIPTION This sensor detects the temperature inside the cooling unit and sends the appropriate signals to the A/C amplifier assy. DTC No. B1413/13 Detection Item Trouble Area
Cooler thermistor No. 1 ((Evaporator temperature sensor))
Harness or connector between cooler thermistor No. 1 and A/C amplifier assy. assy
A/C amplifier assy. Open or short in evaporator temperature sensor circuit. WIRING DIAGRAM A/C Amplifier Assy G-Y 6 IJ1 LG 5 A11 TE LG-R 3 IJ1 P 12 A11 SG-1 2 E12 Cooler Thermistor No. 1 (Evaporator Temperature sensor) 1 I30339 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1328 05-1 139 DIAGNOSTICS - AIR CONDITIONING SYSTEM INSPECTION PROCEDURE HINT: In case of using the hand-held tester, start the inspection step 1 and in case of not using the hand-held tester, start from step 2. 1 READ VALUE OF HAND-HELD TESTER (a) Connect the hand-held tester to DLC3. (b) Turn the ignition switch ON and push the hand-held tester main switch ON. (c) Select the items below in the DATA LIST, and read the displays on the hand-held tester. A C: Item Measurement Item/Display (Range) Normal Condition Diagnostic Note EVAP TEMP Evaporator temperature sensor /min.: -29.7C (-21.46F) max.: 59.55C (139.19F) Actual evaporator temperature - Result: NG A OK (Checking from the DTC) B OK (Checking from the PROBLEM SYMPTOM TABLE) C B REPLACE AIRCONDITIONER AMPLIFIER ASSY C PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE(SEE PAGE 05-1 129) A 2 INSPECT AIRCONDITIONER AMPLIFIER ASSY(TE, SG-1) (a) A/C Amplifier Connector Wire Harness View: (b) (c) A11 TE (+) SG-1 (-) I30331 Remove A/C amplifier assy with connectors still connected. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A11-5 (TE) A11-12 (SG-1) at 0C (32F) 2.0 to 2.4 V A11-5 (TE) A11-12 (SG-1) at 15C (59F) 1.4 to 1.8 V OK REPLACE AIRCONDITIONER AMPLIFIER ASSY NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1329 05-1 140 DIAGNOSTICS 3 - AIR CONDITIONING SYSTEM INSPECT COOLER THERMISTOR NO.1(EVAPORATOR TEMPERATURE SENSOR) (a) (b) Cooler Thermistor No.1 Connector Front View: E12 E50650 Remove cooler thermistor No. 1. Check resistance between terminals 1 and 2 of cooler thermistor No. 1 at each temperature, as shown in the chart. Standard: Tester connection Condition Specified condition E12-1 - E12-2 -10 °C (14°F) 7.40 to 9.20 kΩ E12-1 - E12-2 -5 °C (23°F) 5.65 to 7.00 kΩ E12-1 - E12-2 0°C (32°F) 4.35 to 5.40 kΩ E12-1 - E12-2 5°C (41°F) 3.40 to 4.20 kΩ E12-1 - E12-2 10°C (50°F) 2.68 to 3.30 kΩ E12-1 - E12-2 15°C (59°F) 2.10 to 2.60 kΩ E12-1 - E12-2 20°F (68°F) 1.66 to 2.10 kΩ E12-1 - E12-2 25°C (77°F) 1.32 to 1.66 kΩ E12-1 - E12-2 30°C (86°F) 1.05 to 1.35 kΩ NOTICE:
Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor.
When measuring the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decrease (see the graph below). 10.0 9.0 8.0 7.0 Maximum permissible value line 6.0 Resistance (kΩ) 5.0 4.0 3.0 2.0 Minimum permissible value line 1.0 0.0 -20 -4 0 32 40 (°C) 104 (°F) 20 68 Temperature I38756 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1330 05-1 141 DIAGNOSTICS - NG AIR CONDITIONING SYSTEM REPLACE COOLER THERMISTOR NO.1(EVAPORATOR TEMPERATURE SENSOR) OK 4 CHECK HARNESS AND CONNECTOR(COOLER THERMISTER NO.1 (EVAPORATOR TEMPERATURE SENSOR) - A/C AMPLIFIER ASSY) (a) Cooler Thermistor No.1 Connector Wire Harness View: E12 A/C Amplifier Connector Wire Harness View: Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A11-5 (TE) - E12-2 Always Below 1 Ω A11-12 (SG-1) - E12-1 Always Below 1 Ω A11-5 (TE) Body ground Always 10 kΩ or higher A11-12 (SG-1) Body ground Always 10 kΩ or higher A11 TE SG-1 NG I41012 REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE AIRCONDITIONER AMPLIFIER ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1331 05-1 142 DIAGNOSTICS DTC - AIR CONDITIONING SYSTEM 05ITV-01 B1421/21 SOLAR SENSOR CIRCUIT (PASSENGER SIDE) CIRCUIT DESCRIPTION Resistance of photodiode High A photo diode in the solar sensor detects solar radiation and sends signals to the A/C amplifier assy. Low Weak Strong Strength of solar radiation DTC No. B1421/21 Detection Item Trouble Area Open or short in solar sensor circuit circuit. dis lay of DTC B1421/21 is not abnormal (Please note that display when the sensor is not receiving solar radiation.)
Cooler (solar ( sensor)) thermistor
Harness or connector between Cooler (solar sensor) Thermistor and A/C amplifier assy
A/C amplifier assy WIRING DIAGRAM A/C Amplifier Assy L 16 A11 TS W 15 A11 S5-3 2 A12 Cooler (Solar sensor) Thermistor 1 I30340 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1332 05-1 143 DIAGNOSTICS - AIR CONDITIONING SYSTEM INSPECTION PROCEDURE HINT: In case of using the hand-held tester, start the inspection step 1 and in case of not using the hand-held tester, start from step 2. 1 READ VALUE OF HAND-HELD TESTER (a) Connect the hand-held tester to DLC3. (b) Turn the ignition switch ON and push the hand-held tester main switch ON. (c) Select the items below in the DATA LIST, and read the displays on the hand-held tester. A C: Item Measurement Item/Display (Range) Normal Condition Diagnostic Note SOLAR SENS-P Solar sensor (Passenger side) /min.: 0 max.: 255 Changes depending on brightness (Passenger side) - Result: NG A OK (Checking from the DTC) B OK (Checking from the PROBLEM SYMPTOM TABLE) C B REPLACE AIRCONDITIONER AMPLIFIER ASSY C PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE(SEE PAGE 05-1 129) A 2 INSPECT AIRCONDITIONER AMPLIFIER ASSY(TS, S5-3) (a) A/C Amplifier Connector Wire Harness View: (b) (c) A11 TS (+) S5-3 (-) I30331 Remove A/C amplifier assy with connectors still connected. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A11-16 (TS) A11-15 (S5-3) Sensor subject to electric light Below 4.0 V A11-16 (TS) A11-15 (S5-3) Sensor is covered by a cloth 4.0 to 4.5 V HINT: As the inspection light is moved away from the sensor, the voltage increases. Use an incandescent lamp for inspection. Bring it within 30 cm (11.8 in.) of the solar sensor. OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE(SEE PAGE 05-1 129) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1333 05-1 144 DIAGNOSTICS 3 - AIR CONDITIONING SYSTEM INSPECT COOLER (SOLAR SENSOR) THERMISTOR (a) (b) Solar Sensor Connector Front View: (c) A12 2 1 I30886 Remove the cooler (solar sensor) thermistor. Measure the resistance according to the value(s) in the table below. Connect the negative (-) lead from the ohmmeter to terminal 1 and positive (+) lead to terminal 2 of the A/C solar sensor. Standard: Tester connection Condition Specified condition A12-1 - A12-2 Sensor is subject to electric light Except ∞ Ω A12-1 - A12-2 Sensor is covered with a cloth ∞ Ω (No continuity) NOTICE: The connection procedure for using a digital tester such as an electrical tester is shown above. When using an analog tester, connect the negative (-) lead to terminal 2 and positive (+) lead to terminal 1 of the A/C solar sensor. HINT:
As the inspection light is moved away from the sensor, the resistance increases.
Use an incandescent lamp for inspection. Bring it within 30 cm (11.8 in.) of the cooler (solar sensor) thermistor. NG REPLACE COOLER THERMISTOR (SOLAR SENSOR) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1334 05-1 145 DIAGNOSTICS 4 - AIR CONDITIONING SYSTEM CHECK HARNESS AND CONNECTOR(COOLER (SOLAR SENSOR) THERMISTOR - A/C AMPLIFIER ASSY) (a) Cooler (Solar Sensor) Thermistor Connector Wire Harness View: A12 A/C Amplifier Connector Wire Harness View: Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A11-15 (S5-3) - A12-1 Always Below 1 Ω A11-16 (TS) - A12-2 Always Below 1 Ω A11-15 (S5-3) Body ground Always 10 kΩ or higher A11-16 (TS) Body ground Always 10 kΩ or higher A11 TS S5-3 I41013 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE AIRCONDITIONER AMPLIFIER ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1335 05-1 146 DIAGNOSTICS DTC - AIR CONDITIONING SYSTEM 05ITW-01 B1422/22 COMPRESSOR LOCK SENSOR CIRCUIT CIRCUIT DESCRIPTION The ECM and A/C amplifier communicate via BEAN. This sensor sends 4 pulses per engine revolution to the ECM. If the number ratio of the compressor speed divided by the engine speed is smaller than a predetermined value, the ECM turns the compressor OFF. And the indicator flashes at about 1 second intervals. DTC No. Detection Item All conditions below are detected for 3 secs. secs or more (c) Engine speed: 450 rpm or more (d) Ratio between engine and compressor speed deviates 20 % or more in comparison to normal operation. operation B1422/22 Trouble Area
Cooler compressor assy (A/C magnetic clutch and lock sensor)
Cooler com compressor ressor assy drive belt
Cooler compressor assy lock sensor
Harness and connector between cooler compressor assy and ECM
Multiplex communication circuit
ECM
A/C amplifier assy WIRING DIAGRAM ECM 23 W-L 1 E9 LCK1 A2 Cooler Compressor Assy 2 BR A J7 J/C A BR (*2) EE BR (*1) ED *1: 3MZ-FE *2: 2AZ-FE I38769 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1336 05-1 147 DIAGNOSTICS - AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 INSPECT ECM(LCK1) (a) (b) ECM Connector Wire Harness View: E9 Remove the ECM with connectors still connected. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition E9-23 (LCK1) - Body ground Start engine A/C, switch AUTO Pulse generation LCK1 I38774 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE(SEE PAGE 05-1 129) NG 2 INSPECT COOLER COMPRESSOR ASSY Cooler Compressor Assy Connector Front View: A2 le 3 2 (a) (b) Disconnect the cooler compressor assy connector. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A2-1 - A2-2 at 20°C (68°F) 165 to 205 Ω E05280 NG REPLACE COOLER COMPRESSOR ASSY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1337 05-1 148 DIAGNOSTICS 3 - AIR CONDITIONING SYSTEM CHECK HARNESS AND CONNECTOR(ECM - COOLER COMPRESSOR ASSY) (a) Cooler Compressor Assy Connector Front view: A2 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition E9-23(LCK1) - A2-1 Always Below 1 Ω E9-23 (LCK1) - Body ground Always 10 kΩ or higher A2-2 - Body ground Always Below 1 Ω NG REPLACE ECM Connector Wire Harness View: E9 LCK1 I41017 REPAIR OR CONNECTOR HARNESS AND OK REPLACE ECM 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1338 05-1 149 DIAGNOSTICS DTC - AIR CONDITIONING SYSTEM 05ITX-02 B1423/23 PRESSURE SWITCH CIRCUIT CIRCUIT DESCRIPTION Low pressure side High pressure side ON (Below 1.0 Ω) 196 KPa 3,140 KPa (2.0 kgf⋅cm2, 28 psi) (32.0 kgf⋅cm2, 455 psi) OFF OFF (10 kΩ or higher) (10 kΩ or higher) I40666 DTC No. B1423/23 The ECM and A/C amplifier communicate via BEAN. The pressure switch sends the appropriate signals to the A/C amplifier when the A/C refrigerant pressure drops too low or rises too high. When the A/C amplifier receives these signals, it outputs signals through the A/C amplifier to turn the magnet clutch relay off and turns the magnetic clutch off. Detection Item Trouble Area
Pressure switch
Harness or connector between cooler refrigerant liquid pipe A (pressure switch) and ECM
Multiplex communication circuit
Refrigerant pipe line
ECM
A/C amplifier assy
Open in pressure sensor circuit.
Abnormal refrigerant pressure. below 196 kPa (2.0 kg/cm2, 28 psi) over 3,140 kPa (32.0 kgf/cm2, 455 psi) WIRING DIAGRAM A3 Pressure Switch W-B 4 Dual G 1 2 IK3 L 1 ECM E6 HP A J2 J/C EH I41168 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1339 05-1 150 DIAGNOSTICS - AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 (a) (b) INSPECT REFRIGERANT PRESSURE Set the manifold gauge. Read the manifold gauge pressure when these conditions are established. Test conditions:
Temperature at the air inlet with the switch set at RECIRC is 30 to 35°C (86 to 95°F)
Engine running at 1,500 rpm
Blower speed control switch at ”HI” position
Temperature control dial at ”COOL” position
Air conditioning switch ON
Fully open doors Standard: Pressure on high pressure side: 1.37 to 1.57 MPa (13.9 to 16.0 kgf⋅cm2, 198 to 228 psi) HINT: If the refrigerant pressure is below 196 KPa (2.0 kgf⋅cm2, 28 psi), the refrigerant amount in the air conditioning cycle may have decreased significantly for reasons such as a gas leakage. NG INSPECT AND REPAIR AIR CONDITIONING CYCLE OK 2 CHECK AIR CONDITIONING OPERATION (a) (b) Pressure Switch Connector Wire Harness View: A3 (c) (d) (e) I40669 Disconnect the pressure switch connector. Connect terminals 1 and 4 of the connector of the pressure switch on the vehicle wire harness side using a service wire. Start the engine. Turn the air conditioning switch on and check that the magnet clutch is turned on. Check that the magnet clutch is turned off when disconnecting terminals 1 and 4 (that are connected in the prior step). OK: Terminals 1 and 4 connected: magnet clutch is on Terminals 1 and 4 disconnected: magnet clutch is off NG Go to step 3 OK REPLACE PRESSURE SWITCH 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1340 05-1 151 DIAGNOSTICS 3 - AIR CONDITIONING SYSTEM CHECK HARNESS AND CONNECTOR(PRESSURE SWITCH - ECM) (a) Pressure Switch Connector Front View: A3 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition E6-1 (HP) - A3-1 Always Below 1 Ω A3-4 - Body ground Always Below 1 Ω E6-1 (HP) - Body ground Always 10 kΩ or higher A3-1 - Body ground Always 10 kΩ or higher Result: ECM Connector Wire Harness View: E6 NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C HP I41169 B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIRCONDITIONER AMPLIFIER ASSY A REPAIR OR REPLACE HARNESS OR CONNECTOR 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1341 05-1 152 DIAGNOSTICS DTC - AIR CONDITIONING SYSTEM 05ITY-01 B1431/31 AIR MIX DAMPER POSITION SENSOR CIRCUIT (PASSENGER SIDE) CIRCUIT DESCRIPTION This sensor detects the position of the air mix damper servo sub-assy and sends the appropriate signals to the A/C amplifier assy. The position sensor is built into the air mix servo subassy. TP terminal voltage (V) 4 1 0 Damper opening angle 100% DTC No. Detection Item Trouble Area B1431/31 Short to ground or power source circuit in air mix damper position sensor circuit.
Air mix damper position sensor.
Harness or connector between air mix damper servo subassy and A/C amplifier assy.
A/C amplifier assy WIRING DIAGRAM A14 Air Mix Damper Servo Sub-assy A/C Amplifier Assy 2 LG-R 3 IJ1 P 12 A11 SG-1 1 P-L 4 IJ1 O 11 A11 S5-1 3 O 5 IJ1 SB 5 Y-G 1 IJ1 B 14 A11 AMH 4 Y 2 IJ1 GR 13 A11 AMC 10 A11 TP I30342 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1342 05-1 153 DIAGNOSTICS - AIR CONDITIONING SYSTEM INSPECTION PROCEDURE HINT: In case of using the hand-held tester, start the inspection step 1 and in case of not using the hand-held tester, start from step 2. 1 READ VALUE OF HAND-HELD TESTER (a) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the hand-held tester main switch ON. (c) Select the items below in the DATA LIST, and read the displays on the hand-held tester. A C: Item Measurement Item/Display (Range) Normal Condition Diagnostic Note A/M DAMP POS-P Air mix damper position (Passenger side) /min.:-5% max.:105% Changes depending on the set temperature (Passenger side) - A/M DAMP TARG-P Air mix damper target position (Passenger side) /min.:-5% max.:105% Changes depending on the set temperature (Passenger side) - Result: NG A OK (Checking from the DTC) B OK (Checking from the PROBLEM SYMPTOM TABLE) C B REPLACE AIRCONDITIONER AMPLIFIER ASSY C PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1 129) A 2 INSPECT AIRCONDITIONER AMPLIFIER ASSY(TP, SG-1) (a) A/C Amplifier Connector Wire Harness View: (b) (c) A11 SG-1 (-) TP (+) I30331 Remove the A/C amplifier assy with connectors still connected. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A11-10 (TP) A11-12 (SG-1) MAX. COOL 3.5 to 4.5 V A11-10 (TP) A11-12 (SG-1) MAX. WARM 0.5 to 1.8 V HINT: As the set temperature increases, the voltage decreases gradually without interruption. OK REPLACE AIRCONDITIONER AMPLIFIER ASSY NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1343 05-1 154 DIAGNOSTICS 3 - AIR CONDITIONING SYSTEM INSPECT AIRMIX DAMPER SERVO SUB-ASSY (a) (b) Air Mix Damper Servo Sub-assy Connector Wire Harness View: A14 (c) I30157 MAX. WARM MAX. COOL Remove the air mix damper servo sub-assy. Measure resistance between terminals 1 and 2 of air mix damper servo sub-assy connector. Standard: Tester connection Condition Specified condition A14-1 - A14-2 Always 4.2 to 7.8 kΩ While operating air mix damper servo sub-assy as shown in the procedure on page 05-1 160, measure resistance between terminals 1 and 3 of air mix damper servo subassy. Standard: Tester connection Condition Specified condition A14-1 - A14-3 MAX. COOL 3.4 to 6.2 kΩ A14-1 - A14-3 MAX. WARM 0.8 to 1.6 kΩ HINT: As the air mix damper servo sub-assy moves from cool side to warm side, the resistance decreases gradually without interruption. I30332 Resistance (kΩ) 3.4 - 6.2 Arm position 0.8 - 1.6 MAX. COOL MAX. WARM I30161 NG REPLACE AIRMIX DAMPER SERVO SUB-ASSY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1344 05-1 155 DIAGNOSTICS 4 - AIR CONDITIONING SYSTEM CHECK HARNESS AND CONNECTOR(AIR MIX DAMPER SERVO SUB-ASSY - A/C AMPLIFIER ASSY) (a) Air Mix Damper Servo Sub-assy Wire Harness View: A14 A/C Amplifier Connector Wire Harness View: A11 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A11-1 1 (S5-1) - A14-1 Always Below 1 Ω A11-12 (SG-1) - A14-2 Always Below 1 Ω A11-10 (TP) - A14-3 Always Below 1 Ω A11-1 1 (S5-1) Body ground Always 10 kΩ or higher A11-12 (SG-1) Body ground Always 10 kΩ or higher A11-10 (TP) Body ground Always 10 kΩ or higher TP SG-1 S5-1 NG I41014 REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE AIRCONDITIONER AMPLIFIER ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1345 05-1 156 DIAGNOSTICS DTC - AIR CONDITIONING SYSTEM 05ITZ-02 B1433/33 AIR OUTLET DAMPER POSITION SENSOR CIRCUIT CIRCUIT DESCRIPTION This sensor detects the position of the mode damper servo sub-assy and sends the appropriate signals to the A/C amplifier assy. The position sensor is built into the mode damper servo sub-assy . TPO terminal voltage (V) 4 1 0 100% Damper opening angle DTC No. B1433/33 Detection Item Trouble Area Short to ground or power source circuit in air outlet damper position sensor circuit.
Mode damper position sensor (Air outlet damper position sensor)
Harness or connector between mode damper servo subassy and A/C amplifier assy
A/C amplifier assy WIRING DIAGRAM A15 Mode Damper Servo Sub-assy (Air Outlet Damper Position Sensor) A/C Amplifier Assy 1 W 13 IL2 B 1 A11 SG-4 2 B 3 IL2 BR 9 A11 S5-4 3 G 14 IL2 R 6 A11 TPO 5 LG 15 IL2 V 8 A11 AOF 4 L 4 IL2 G 7 A11 AOD I30342 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1346 05-1 157 DIAGNOSTICS - AIR CONDITIONING SYSTEM INSPECTION PROCEDURE HINT: In case of using the hand-held tester, start the inspection step 1 and in case of not using the hand-held tester, start from step 2. 1 READ VALUE OF HAND-HELD TESTER (a) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the hand-held tester main switch ON. (c) Select the items below in the DATA LIST, and read the displays on the hand-held tester. A C: Item Measurement Item/Display (Range) Normal Condition Diagnostic Note A/O DAMP POS Air outlet damper position /min.:-14% max.:113.5% Changes depending on air outlet power position - A/O DAMP TARG Air outlet damper target position /min.:-14% max.:113.5% Changes depending on air outlet power position - Result: NG A OK (Checking from the DTC) B OK (Checking from the PROBLEM SYMPTOM TABLE) C B REPLACE AIRCONDITIONER AMPLIFIER ASSY C PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1 129) A 2 INSPECT AIRCONDITIONER AMPLIFIER ASSY(TPO, SG-4) (a) A/C Amplifier Connector Wire Harness View: (b) (c) A11 TPO (+) SG-4 (-) I30331 Remove the A/C amplifier assy with connectors still connected. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A11-6 (TPO) A11-1 (SG-4) FACE 3.5 to 4.5 V A11-6 (TPO) A11-1 (SG-4) DEF 0.5 to 1.5 V HINT: As the air outlet servomotor is moved from FACE side to DEF side, the voltage decreases gradually without interruption. OK REPLACE AIRCONDITIONER AMPLIFIER ASSY NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1347 05-1 158 DIAGNOSTICS 3 - AIR CONDITIONING SYSTEM INSPECT MODE DAMPER SERVO SUB-ASSY (a) (b) Mode Damper Servo Sub-assy Connector Wire Harness View: A15 (c) I30157 Remove the mode damper servo sub-assy. Measure resistance between terminals 1 and 2 of mode damper servo sub-assy connector. Standard: Tester connection Condition Specified condition A15-1 - A15-2 Always 4.2 to 7.8 kΩ While operating mode damper servo sub-assy as in the procedure on page 05-1 164, measure resistance between terminals 1 and 3 of mode damper servo sub-assy. Standard: Tester connection Condition Specified condition A15-1 - A15-3 DEF 3.4 to 6.2 kΩ A15-1 - A15-3 FACE 0.8 to 1.6 kΩ HINT: As the mode damper servo sub-assy moves from DEF side to FACE side, the resistance decreases gradually without interruption. FACE DEF I30333 Resistance (kΩ) 3.4 -6.2 Arm Position 0.8 - 1.6 DEF FACE I30161 NG REPLACE MODE DAMPER SERVO SUB-ASSY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1348 05-1 159 DIAGNOSTICS 4 - AIR CONDITIONING SYSTEM CHECK HARNESS AND CONNECTOR(MODE DAMPER SERVO SUB-ASSY - A/C AMPIFIER ASSY) (a) Mode Damper Servo Sub- assy Wire Harness View: A15 A/C Amplifier Connector Wire Harness View: A11 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A11-1 (SG-4) - A15-1 Always Below 1 Ω A11-9 (S5-4) - A15-2 Always Below 1 Ω A11-6 (TPO) - A15-3 Always Below 1 Ω A11-1 (SG-4) Body ground Always 10 kΩ or higher A11-9 (S5-4) Body ground Always 10 kΩ or higher A11-6 (TPO) Body ground Always 10 kΩ or higher SG-4 TPO S5-4 NG I41014 REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE AIRCONDITIONER AMPLIFIER ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1349 05-1 160 DIAGNOSTICS DTC - AIR CONDITIONING SYSTEM 05IU0-01 B1441/41 AIR MIX DAMPER CONTROL SERVOMOTOR CIRCUIT (PASSENGER SIDE) CIRCUIT DESCRIPTION This air mix damper servo sub-assy is controlled by the A/C amplifier assy and moves the air mix damper servo sub-assy to the desired position. DTC No. B1441/41 Detection Item Trouble Area Air mix dam damper er position osition sensor value does not change even if A/C am amplifier lifier assy o operates erates air mix dam damper er servo sub sub-assy. assy.
Air mix damper servo sub-assy
Harness or connector between air mix damper dam er servo subassy and A/C am amplifier lifier assy
A/C amplifier assy WIRING DIAGRAM A14 Air Mix Damper Servo Sub-assy A/C Amplifier Assy 2 LG-R 3 IJ1 P 12 A11 SG-1 1 P-L 4 IJ1 O 11 A11 S5-1 3 O 5 IJ1 SB 10 A11 TP 5 Y-G 1 IJ1 B 14 A11 AMH 4 Y 2 IJ1 GR 13 A11 AMC I30342 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1350 05-1 161 DIAGNOSTICS - AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 (a) (b) (c) PERFORM ACTUATOR CHECK Set to actuator check mode (see page 05-1 117). Press the DEF switch and change to step operation. Check the air flow temperature by hand. Display Code Air Mix Damper Operation 0 COOL side (-5 % open) 1 COOL side (-5 % open) 2 COOL side (-5 % open) 3 COOL side (-5 % open) 4 COOL/WARM (50 % open) 5 COOL/WARM (50 % open) 6 WARM side (105 % open) 7 WARM side (105 % open) 8 WARM side (105 % open) 9 WARM side (105 % open) OK: Air flow temperature changes in accordance with each display code. Result: NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1 129) C REPLACE AIRCONDITIONER AMPLIFIER ASSY A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1351 05-1 162 DIAGNOSTICS 2 - AIR CONDITIONING SYSTEM INSPECT AIRMIX DAMPER SERVO SUB-ASSY (a) (b) Air Mix Damper Servo Sub-assy Connector Wire Harness View: (c) A14 Remove the air mix damper servo sub-assy. Connect the positive (+) lead from the battery to terminal 4 and negative (-) lead to terminal 5, then check that the lever turns to ”COOL” side smoothly. Connect the positive (+) lead from the battery to terminal 5 and negative (-) lead to terminal 4, then check that the lever turns to ”WARM” side smoothly. I30157 To ”WARM” To ”COOL” I30334 NG REPLACE AIRMIX DAMPER SERVO SUB-ASSY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1352 05-1 163 DIAGNOSTICS 3 - AIR CONDITIONING SYSTEM CHECK HARNESS AND CONNECTOR(AIR MIX DAMPER SERVO SUB-ASSY - A/C AMPLIFIER ASSY) (a) Air Mix Damper Servo Sub- assy Connector Wire Harness View: A14 A/C Amplifier Connector Wire Harness View: Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A11-13 (AMC) - A14-4 Always Below 1 Ω A11-14 (AMH) - A14-5 Always Below 1 Ω A11-13 (AMC) Body ground Always 10 kΩ or higher A11-14 (AMH) Body ground Always 10 kΩ or higher A11 AMH AMC NG I41014 REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE AIRCONDITIONER AMPLIFIER ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1353 05-1 164 DIAGNOSTICS DTC - AIR CONDITIONING SYSTEM 05IU1-01 B1443/43 AIR OUTLET DAMPER CONTROL SERVOMOTOR CIRCUIT CIRCUIT DESCRIPTION This circuit turns the servomotor and changes each mode damper position by the signals from the A/C amplifier assy. When the AUTO switch is on, the A/C amplifier assy changes the mode automatically between (FACE), (BI-LEVEL) and (FOOT) according to the temperature setting. DTC No. Detection Item Trouble Area B1443/43 Air outlet damper position sensor value does not change even if A/C amplifier lifi assy operates t air i mode d d damper servo subb assy assy.
Mode damper servo sub-assy.
Harness or connector between mode damper dam er servo subassy and A/C am amplifier lifier assy.
A/C amplifier assy. WIRING DIAGRAM A15 Mode Damper Servo Sub-assy A/C Amplifier Assy 1 A11 SG-4 1 W 13 IL2 B 2 B 3 IL2 BR 3 G 14 IL2 R 6 A11 TPO 5 LG 15 IL2 V 8 A11 AOF 4 L 4 IL2 G 7 A11 AOD 9 A11 S5-4 I30342 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1354 05-1 165 DIAGNOSTICS - AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 (a) (b) (c) (d) PERFORM ACTUATOR CHECK Warm up engine. Set to actuator check mode (see page 05-1 117). Press the DEF switch and change it to step operation Press the DEF switch and check that the air flow by hand. Display code Air flow condition 0 FACE 1 FACE 2 FACE 3 FACE 4 FACE 5 B/L 6 FOOT 7 FOOT 8 FOOT/DEF 9 DEF OK: Air flow position changes in accordance with each display code. Result: NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1 129) C REPLACE AIRCONDITIONER AMPLIFIER ASSY A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1355 05-1 166 DIAGNOSTICS 2 - AIR CONDITIONING SYSTEM INSPECT MODE DAMPER SERVO SUB-ASSY (a) (b) Mode Damper Servo Sub-assy Connector Wire Harness View: (c) A15 Remove the air mode damper servo sub-assy. Connect the positive (+) lead from the battery to terminal 4 and negative (-) lead to terminal 5 then check that the lever turns to ”DEF” position. Connect the positive (+) lead from the battery to terminal 5 and negative (-) lead to terminal 4 then check that the lever turns to ”FACE” position. I30157 To ”DEF” To ”FACE” I30335 NG REPLACE MODE DAMPER SERVO SUB-ASSY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1356 05-1 167 DIAGNOSTICS 3 - AIR CONDITIONING SYSTEM CHECK HARNESS AND CONNECTOR(MODE DAMPER SERVO SUB-ASSY - A/C AMPLIFIER ASSY) (a) Mode Damper Servo Sub- assy Wire Harness View: A15 A/C Amplifier Connector Wire Harness View: Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A11-8 (AOF) - A15-5 Always Below 1 Ω A11-7 (AOD) - A15-4 Always Below 1 Ω A11-8 (AOF) Body ground Always 10 kΩ or higher A11-7 (AOD) Body ground Always 10 kΩ or higher A11 AOD AOF NG I41014 REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE AIRCONDITIONER AMPLIFIER ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1357 05-1 168 DIAGNOSTICS DTC - AIR CONDITIONING SYSTEM 0522E-05 B1499/99 MULTIPLEX COMMUNICATION CIRCUIT CIRCUIT DESCRIPTION The ECM and A/C amplifier communicate via BEAN. This DTC is output when communication stops. DTC No. B1499/99 Detection Item Trouble Area
O Open en in i multiplex multi lti lex l communication i ti circuit i it M lti lex Multiplex Multi l communication i ti circuit i it WIRING DIAGRAM ECM A/C Amplifier Assy ECM Body ECU 6 18 MPX1 W E6 10 MPX1 B10 MPX2 B9 12 IL2 O 1 IB2 GR 8 MPX2 E6 GR 1 IL2 11 4 MPD1 MPD2 IF3 8 IB2 SB P5 Power Window Master SW With ECU 29 7 5 4F 4A BR 2 1 S31 S31 Passenger Side J/B 9 SB V (*1) 5 Y V MPX2 MPX1 7 G5 Gateway ECU G (*1) R 2 A11 MPX+ G (*2) 21 MPX+ C11 C12 MPXCombination Meter Y Short Connector 1 12 3E 3J G 9 A10 MPX- Center J/B *1: w/ Navigation System *2: w/o Navigation System I38778 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1358 05-1 169 DIAGNOSTICS - AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 CHECK MULTIPLEX COMMUNICATION SYSTEM NG GO TO MULTIPLEX COMMUNICATION SYSTEM OK REPLACE AIRCONDITIONER AMPLIFIER ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1359 05-1 170 DIAGNOSTICS - AIR CONDITIONING SYSTEM 05IU2-01 IG POWER SOURCE CIRCUIT CIRCUIT DESCRIPTION This is the power source for the A/C amplifier assy and servomotor, etc. WIRING DIAGRAM A/C Amplifier Assy Instrument Panel J/B I15 Ignition SW 2 Center J/B 4 G AM1 IG1 7 1C HEATER 6 1C AM1 W 1 W 2 2 ALT F7 Fusible Link Block FL MAIN Battery 13 1K B 4 3A 7 3J BR 13 6 3J W-B 2 A10 IG 1 1A 1 B W-B 3F 11 A10 GND IB I38766 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1360 05-1 171 DIAGNOSTICS - AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 (a) (b) CHECK FUSE(HEATER, AM1 FUSES) Remove the HEATER and AM1 fuses from the instrument panel J/B. Check that the continuity exists in HEATER and AM1 fuses. NG REPLACE FUSE OK 2 INSPECT AIRCONDITIONER AMPLIFIER ASSY(IG, GND) (a) A/C Amplifier Connector Wire Harness View: (b) A10 GND (-) IG (+) I30331 Remove the A/C amplifier assy with connectors still connected. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A10-2 (IG) A10-11 (GND) Ignition switch ON 10 to 14 V OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1 129) NG 3 CHECK HARNESS AND CONNECTOR(A/C AMPLIFIER ASSY - BODY GROUND) (a) A/C Amplifier Connector Wire Harness View: A10 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A10-11 (GND) Body ground Always Below 1 Ω GND I38763 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1361 05-1 172 DIAGNOSTICS 4 - AIR CONDITIONING SYSTEM CHECK HARNESS AND CONNECTOR(A/C AMPLIFIER ASSY - BATTERY) (a) A/C Amplifier Connector Wire Harness View: A10 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A10-2 (IG) Body ground Ignition switch OFF → ON Below 1.0 V → 10 to 14 V IG I38763 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE AIRCONDITIONER AMPLIFIER ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1362 05-1 173 DIAGNOSTICS - AIR CONDITIONING SYSTEM 05IU3-01 BACK-UP POWER SOURCE CIRCUIT CIRCUIT DESCRIPTION This is the back-up power source for the A/C amplifier assy. Power is supplied even when the ignition switch is off and is used for diagnostic trouble code memory, etc. WIRING DIAGRAM W 3 1 W 1 2I D.C.C ECU-B A/C Amplifier Assy Instrument Panel J/B Engine Room J/B 4 W-L 5 2A IC3 BR 10 1G 2 1K W 12 A10 +B F7 Fusible Link Block FL MAIN Battery I30515 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1363 05-1 174 DIAGNOSTICS - AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 (a) (b) CHECK FUSE(ECU-B FUSE) Remove the ECU-B fuse from the engine room J/B. Check that the continuity exits of ECU-B fuse. NG REPLACE FUSE OK 2 INSPECT AIRCONDITIONER AMPLIFIER ASSY(+B) (a) A/C Amplifier Connector Wire Harness View: (b) A10 +B (+) I30331 Remove the A/C amplifier assy with connectors still connected. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A10-12 (+B) Body ground Always 10 to 14 V OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1 129) NG 3 CHECK HARNESS AND CONNECTOR(A/C AMPLIFIER ASSY - BATTERY) (a) A/C Amplifier Connector Wire Harness View: (b) A10 GND +B I38763 Remove the A/C amplifier assy and disconnect the connector. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A10-12 (+B) A10-11 (GND) Always 10 to 14 V NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE AIRCONDITIONER AMPLIFIER ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1364 05-1 187 DIAGNOSTICS - AIR CONDITIONING SYSTEM 05IU7-03 HEATER RELAY CIRCUIT CIRCUIT DESCRIPTION The heater relay is switched on by signals from the A/C amplifier assy. It supplies power to the blower motor. WIRING DIAGRAM A/C Amplifier Assy Instrument Panel J/B I15 Ignition SW 2 AM1 IG1 4 G 7 1C HEATER 10A 6 1C W AM1 2 8 1G Y A Y 1 W B 2 W 1 ALT HEATER 50A 7 BR A 3 1 1A 1 H9 Heater Relay J5 J/C 1 IK4 2 IL2 O 7 A10 HR 5 From Blower B Motor 2 4 Passenger Side J/B 7 7 4L 4H W-B B-Y F7 Fusible Link Block W-B FL MAIN IC Battery I40780 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1377 05-1 188 DIAGNOSTICS - AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 (a) (b) (c) CHECK FUSE(15 A HEATER, 50 A HEATER, AM1 FUSES) Remove the 15 A HEATER and AM1 fuses from the instrument panel J/B. Remove the 50 A HEATER fuse from fusible link block. Check that the continuity exists in 15 A HEATER and 50 A HEATER, AM1 fuses. NG REPLACE FUSE OK 2 3 INSPECT HEATER BLOWER MOTOR RELAY ASSY 4 (a) 5 3 1 1 5 4 (b) 2 2 Z19533 Check that the continuity exists between each pair of terminals of heater blower motor relay assy, as shown in the chart. Tester connection Condition Specified condition 2-1 Always 10 kΩ or higher 2-4 Always Below 1.0 Ω Check continuity between each pair of terminals, as shown the chart. Tester connection Condition Specified condition 2-1 When battery voltage applied to terminals 3 and 5 Below 1.0 Ω 2-4 When battery voltage applied to terminals 3 and 5 10 kΩ or higher NG REPLACE HEATER BLOWER MOTOR RELAY ASSY OK 3 INSPECT AIRCONDITIONER AMPLIFIER ASSY(HR) (a) A/C Amplifier Connector Wire Harness View: (b) A10 HR I30331 Remove the A/C amplifier assy with connectors still connected. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A10-7 (HR) Body ground Ignition switch OFF 0V A10-7 (HR) Body ground Ignition switch ON Blower switch ON Below 1.0 V A10-7 (HR) Body ground Ignition switch ON Blower switch OFF 10 to 14 V OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1378 05-1 189 DIAGNOSTICS 4 - AIR CONDITIONING SYSTEM CHECK HARNESS AND CONNECTOR (a) A/C Amplifier Connector Wire Harness View: A10 Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A10-7 (HR) Body ground Ignition switch OFF → ON Below 1 V → 10 to 14 V HR I38763 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPAIR OR REPLACE AIRCONDITIONER AMPLIFIER ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1379 05-1 190 DIAGNOSTICS - AIR CONDITIONING SYSTEM 05IU8-01 COMPRESSOR CIRCUIT CIRCUIT DESCRIPTION The ECM and A/C amplifier communicate via BEAN. The A/C amplifier assy outputs the magnetic clutch ON signal to the ECM. Receiving this signal, the ECM sends a signal through terminal ACMG and switches the magnetic clutch relay ON, thus turning on the magnetic clutch. WIRING DIAGRAM ECM From Battery Y 7 B-R IK2 Engine Room J/B 8 Magnetic Clutch Relay 2 1 2 2A 2C 5 3 3 2E From Fan No. 3 Relay 18 Y-G O IK3 Y-G 2 E6 ACMG 9 EB2 B-Y 3 A2 A/C Magnetic Clutch and Lock Sensor I30520 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1380 05-1 191 DIAGNOSTICS - AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 READ VALUE OF HAND-HELD TESTER (a) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the hand-held tester main switch ON. (c) Select the items below in the DATA LIST, and read the displays on the hand-held tester. ENGINE AND ECT / ALL: Item Measurement Item/Display (Range) Normal Condition Diagnostic Note A/C SIG A/C signal/ ON or OFF A/C ON: ON - A/C MAG CLUTCH A/C magnet clutch/ ON or OFF A/C magnet clutch ON: ON - NG INSPECT CIRCUIT MULTIPLEX COMMUNICATION OK 2 PERFORM ACTIVE TEST USING HAND-HELD TESTER (a) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the hand-held tester main switch ON. (c) Select the item below in the ACTIVE TEST, and then check that the relay operates. ENGINE AND ECT / ALL: Item Test Details/Display (Range) Diagnostic Note A/C MAG CLUTCH Magnetic clutch relay / OFF, ON Operating sound can be heard NG Go to step 3 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1 129) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1381 05-1 192 DIAGNOSTICS 3 - AIR CONDITIONING SYSTEM INSPECT MAGNET-CLUTCH RELAY (a) Remove the relay (magnet clutch relay) from the engine room R/B. Measure the resistance according to the value(s) in the table below. Standard: 3 2 (b) 1 5 3 1 2 Tester connection Condition Specified condition 3-5 Always 10 kΩ or higher 3-5 When battery voltage applied to terminals 1 and 2 Below 1 Ω 5 Z18060 NG REPLACE MAGNET-CLUTCH RELAY OK 4 INSPECT MAGNET CLUTCH ASSY (a) (b) Magnet Clutch Assy Connector From View: Disconnect the connector from the magnet clutch assy. Connect the positive (+) lead from the battery to terminal 3 and negative (-) lead to body ground, then check that the magnet clutch assy is engaged. A2 E05280 le 3 2 NG REPLACE MAGNET CLUTCH ASSY OK 5 INSPECT ECM (a) (b) ECM Connector Wire Harness View: E6 Remove the ECM and disconnect the connector. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition E6-2 (ACMG) - Body ground Ignition switch ON 10 to 14 V NG I36159 REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1382 05-1 193 DIAGNOSTICS 6 - AIR CONDITIONING SYSTEM CHECK HARNESS AND CONNECTOR (a) (b) ECM Connector Wire Harness View: E6 Disconnect the connector. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A2-3 - Body ground Ignition switch ON When using service wire, terminal E6-2 (ACMG) and Body ground are not connect Below 1 V A2-3 - Body ground Ignition switch ON When using service wire, terminal E6-2 (ACMG) and Body ground are connect 10 to 14 V ACMG Magnet Clutch Assy Connector Wire Harness View: A2 I36159 E51630 I38853 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE ECM 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1383 05-1 181 DIAGNOSTICS - AIR CONDITIONING SYSTEM 05IU6-01 BLOWER MOTOR CIRCUIT CIRCUIT DESCRIPTION Blower Level The blower motor is operated by signals from the A/C amplifier assy. Blower motor speed signals are transmitted by changes in the Duty Ratio. Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity in one cycle, B is the period of non-continuity. HI M3 M2 M1 LO 0 29 41 53 67 89 Si duty (%) Duty Ratio = A A+B x 100 (%) A ON OFF B 1 cycle WIRING DIAGRAM B6 Blower Motor 1 2 A/C Amplifier Assy B7 Blower Motor Control R VM 4 SI P-L 2 1 IH1 W 5 IL2 LG 17 A10 BLW B B 2 IH1 B B 3 +B GND 1 W-B From H9 Heater Relay 3 IH1 W-B IA I30519 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1371 05-1 182 DIAGNOSTICS - AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 (a) (b) (c) PERFORM ACTUATOR CHECK Set the actuator check mode (see page 05-1 117). Press the blower switch to change to the step operation. Check the air flow level by hand. Display Code Blower level 0 0 1 1 2 14 3 14 4 14 5 14 6 14 7 14 8 14 9 31 OK: Blower level changes in accordance with each display code. NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1 129) 2 CHECK HARNESS AND CONNECTOR(BLOWER MOTOR CONTROLLER - A/C AMPLIFIER) (a) Blower Motor Controller Connector Front View: B7 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A10-17 (BLW) B7-2 (SI) Always Below 1 Ω A10-17 (BLW) Body ground Always 10 kΩ or higher SI A/C Amplifier Connector Wire Harness View: A10 NG REPAIR OR CONNECTOR REPLACE HARNESS OR I41004 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1372 05-1 183 DIAGNOSTICS 3 - AIR CONDITIONING SYSTEM CHECK HARNESS AND CONNECTOR(BLOWER MOTOR CONTROLLER - BODY GROUND) (a) Blower Motor Controller Connector Front View: B7 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition B7-1 (GND) Body ground Always Below 1 Ω NG GND E69146 REPAIR OR CONNECTOR REPLACE HARNESS OR OK 4 INSPECT COOLING UNIT MOTOR SUB-ASSY W/FAN Blower w/ Fan Motor Sub-assy Front View: + E68546 B6 - E69147 (a) (b) Remove the blower w/ fan motor sub-assy. Connect positive (+) lead to terminal 2 of the blower motor connector and negative (-) lead to terminal 1. Standard: Blower motor operates smoothly. NG REPLACE COOLING UNIT MOTOR SUB-ASSY W/FAN OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1373 05-1 184 DIAGNOSTICS 5 - AIR CONDITIONING SYSTEM CHECK A/C SUB NO.2 WIRE (a) A/C Sub No.2 Wire Connector Front View: Wire to wire Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition IH1-2 - B6-2 Always Below 1 Ω IH1-2 - B7-3 (+B) Always Below 1 Ω B6-2 - B7-3 (+B) Always Below 1 Ω IH1 A/C Sub No.2 Wire Connector Front View: B7 +B A/C Sub No.2 Wire Connector Front View: B6 I41008 NG REPAIR OR REPLACE A/C SUB NO.2 WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1374 05-1 185 DIAGNOSTICS 6 - AIR CONDITIONING SYSTEM CHECK HARNESS AND CONNECTOR(BLOWER MOTOR CONTROLLER BLOWER MOTOR) (a) Blower Motor Controller Connector Front View: B7 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition B7-4 (VM) - B6-1 Always Below 1 Ω B7-4 (VM) Body ground Always 10 kΩ or higher VM Blower Motor Connector Front View: B6 NG I36240 REPAIR OR CONNECTOR REPLACE HARNESS OR OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1375 05-1 186 DIAGNOSTICS 7 - AIR CONDITIONING SYSTEM INSPECT AIR CONDITIONING AMPLIFIER(BLW - BODY GROUND) (a) (b) (c) A10 A/C Amplifier Connector Wire Harness View: Remove the A/C amplifier with the connectors still connected. Turn the ignition switch to the ON position. Turn the blower switch on (Lo). BLW I38764 (d) 2V/ Division Measure the waveform between terminal BLW (A10-17) of the A/C amplifier and body ground. OK: Waveform operates as shown in the illustration. HINT: Waveform varies with the blower level. GND 500m sec./ Division I31456 NG REPLACE AIR CONDITIONING AMPLIFIER OK REPLACE BLOWER MOTOR CONTROL 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1376 05-1 177 DIAGNOSTICS - AIR CONDITIONING SYSTEM 05IU5-02 RECIRCULATION DAMPER SERVOMOTOR CIRCUIT CIRCUIT DESCRIPTION The A/C amplifier assy controls the recirculation damper servo sub-assy and moves it to the desired position. WIRING DIAGRAM A13 Recirculation Damper Servo Sub-assy (Air Inlet Control Servo Motor) A/C Amplifier Assy 5 Y 4 A10 MR/F 2 W 6 A10 AIF 1 B 5 A10 AIR I30344 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1367 05-1 178 DIAGNOSTICS - AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 (a) (b) (c) (d) PERFORM ACTUATOR CHECK Remove the glove box to see and check the recirculation damper servo sub-assy operation. Set to the actuator check mode (see page 05-1 117). Press the DEF switch and change it to step operation. Press the DEF switch in order and check the operation of recirculation damper servo sub-assy. Display code Recirculation damper position 0 FRESH 1 FRESH 2 FRESH 3 FRESH 4 RECIRCULATION 5 RECIRCULATION 6 RECIRCULATION 7 RECIRCULATION 8 RECIRCULATION 9 RECIRCULATION OK: Recirculation damper position changes in accordance with each display code. Result: NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1 129) C REPLACE AIRCONDITIONER AMPLIFIER ASSY A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1368 05-1 179 DIAGNOSTICS 2 - AIR CONDITIONING SYSTEM INSPECT RECIRCULATION DAMPER SERVO SUB-ASSY(AIR INLET CONTROL SERVO MOTOR) Recirculation Damper Servo Sub-assy Connector Wire Harness View: (a) (b) (c) A13 Remove the recirculation damper servo sub-assy. Connect the positive (+) lead to from the battery to terminal 5 and negative (-) lead to terminal 2, then check that the lever turns to ”FRESH” side smoothly. Connect the positive (+) lead to from the battery to terminal 1 and negative (-) lead to terminal 5, then check that the lever turns to ”RECIRCULATION” side smoothly. I30157 To ”FRESH” To ”RECIRCULATION” I30336 NG REPLACE RECIRCULATION DAMPER SERVO SUB-ASSY(AIR INLET CONTROL SERVO MOTOR) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1369 05-1 180 DIAGNOSTICS 3 - AIR CONDITIONING SYSTEM CHECK HARNESS AND CONNECTOR(RECIRCULATON DAMPER SERVO SUB-ASSY (AIR INLET CONTROL SERVO MOTOR) - A/C AMPLIFIER ASSY) (a) Recirculation Damper Servo Subassy Wire Harness View: A13 A/C Amplifier Connector Wire Harness View: A10 AIF Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A10-4 (MR/F) - A13-5 Always Below 1 Ω A10-6 (AIF) - A13-2 Always Below 1 Ω A10-5 (AIR) - A13-1 Always Below 1 Ω A10-4 (MR/F) Body ground Always 10 kΩ or higher A10-6 (AIF) Body ground Always 10 kΩ or higher A10-5 (AIR) Body ground Always 10 kΩ or higher MR/F NG AIR I41014 REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE AIRCONDITIONER AMPLIFIER ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1370 05-1 175 DIAGNOSTICS - AIR CONDITIONING SYSTEM 05IU4-01 ACC POWER SOURCE CIRCUIT CIRCUIT DESCRIPTION This circuit supplies power to the A/C amplifier assy. It supplies power to the illumination for the clock. WIRING DIAGRAM A/C Amplifier Assy I15 Ignition SW ACC 3 L 2 AM1 W 1 W Instrument Panel J/B 3 2 RADIO NO. 2 1K 1C 6 1C AM1 2 2 1 Center J/B V 13 3A 4 11 3I GR 13 A10 ACC 1 1A B ALT F7 Fusible Link Block FL MAIN Battery I40781 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1365 05-1 176 DIAGNOSTICS - AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 (a) (b) CHECK FUSE(RADIO NO. 2, AM1 FUSES) Remove the RADIO No. 2 and AM1 fuses from the instrument panel J/B. Check that the continuity exits in RADIO No. 2 and AM1 fuses. NG REPLACE FUSE OK 2 INSPECT AIRCONDITIONER AMPLIFIER ASSY(ACC) (a) A/C Amplifier Connector Wire Harness View: (b) A10 ACC I30331 Remove the A/C amplifier assy with connectors still connected. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A10-13 (ACC) Body ground Ignition switch ACC 10 to 14 V OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1 129) NG 3 CHECK HARNESS AND CONNECTOR(A/C AMPLIFIER ASSY - BATTERY) (a) A/C Amplifier Connector Wire Harness View: (b) A10 GND ACC I38763 Remove the A/C amplifier assy and disconnect the connector. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A10-13 (ACC) A10-11 (GND) Always 10 to 14 V NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE AIRCONDITIONER AMPLIFIER ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1366 05-1 116 DIAGNOSTICS - AIR CONDITIONING SYSTEM 0521Y-03 CUSTOMER PROBLEM ANALYSIS CHECK AIR CONDITIONING SYSTEM Check Sheet Inspector’s name: VIN Customer’s Name Production Data Licence Plate No. Date Vehicle Brought In / / Date of Problem Occurrence / How Often does Problem Occur?
Continuous Weather
Fine Outdoor Temperature
Hot Symptoms km miles Odometer Reading
Intermittent
Cloudy
Warm /
Snowy
Cool ( times a day)
Various / Other
Cold (Approx. °F °C ) Air Flow Control is Faulty
Blower motor does not operate
Blower motor speed does not change (Always Hi, Always Med, Always Lo) Temperature Control is Faulty
Cabin temperature does not go down
Cabin temperature does not rise
Response is slow Air Inlet Control is Faulty
Cannot change between FRS and REC (Always Fresh or always Recirculating) Vent Control is Faulty
Mode does not change
Unable to enter the desired mode 1st Time
Normal System Code
Malfunction Code (Code ) 2nd Time
Normal System Code
Malfunction Code (Code ) DTC Check I30150 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1306 05-1 125 DIAGNOSTICS - AIR CONDITIONING SYSTEM 05220-03 DIAGNOSTIC TROUBLE CODE CHART If malfunction code is displayed during the DTC check (sensor check), check the circuit listed for that code in the table below (Proceed to the page given for that circuit). DTC No. (See Page) 00 Detection Item Normal Room temperature sensor circuit B1411/11*1 (05-1130) Ambient temperature sensor circuit B1412/12*2 (05-1134) Evaporator temperature sensor circuit B1413/13 (05-1138) Solar sensor circuit (short) B1421/21*3 (05-1142) Memory*4 - -
Cooler (room temperature sensor) thermistor
Harness or connector between cooler (room temperature sensor) thermistor and A/C amplifier assy
A/C amplifier assy  (8.5 min. or more)
Cooler (ambient temperature sensor) thermistor
Harness or connector between cooler (ambient temperature sensor) thermistor and ECM
ECM
A/C amplifier assy  (8.5 min. or more)
Cooler thermistor No. 1 (Evaporator temperature sensor)
Harness or connector between cooler thermistor No. 1 sensor and A/C amplifier assy
A/C amplifier assy  (8.5 min. or more)
Cooler (solar sensor) thermistor
Harness or connector between cooler (solar sensor) thermistor and A/C amplifier assy
A/C amplifier assy  (8.5 min. or more)
Cooler (solar sensor) thermistor
Harness or connector between A/C solar sensor and A/C amplifier assy
A/C amplifier assy - All conditions below are detected for 3 sec. or more (a) Engine speed: 450 rpm or more (b) Ratio between engine and compressor rpm deviates 20% or more in comparison to normal operation.
Cooler compressor assy
Cooler compressor assy drive belt
Cooler compressor assy lock sensor
Harness and connector between ECM and cooler compressor assy, cooler compressor assy and body ground
Multiplex communication circuit
ECM
A/C amplifier assy - Pressure switch circuit
Pressure switch
Harness or connector between pressure switch and ECM
Multiplex communication circuit
ECM
A/C amplifier assy -
Air mix damper position sensor
Harness or connector between air mix damper servo subassy and A/C amplifier assy
A/C amplifier assy  (1 min. or more)
Mode damper position sensor
Harness or connector between mode damper servo subassy and A/C amplifier assy
A/C amplifier assy  (1 min. or more)
Air mix damper servo sub-assy
Air mix damper position sensor
Harness or connector between air mix damper servo subassy and A/C amplifier assy
A/C amplifier assy  (15 sec.) Solar sensor circuit (open) B1421/21*3 (05-1142) B1422/22*5 (05-1146) Trouble Area B1423/23 (05-1149) Air mix damper position sensor circuit B1431/31 (05-1152) Air outlet damper position sensor circuit B1433/33 (05-1156) Air mix control servo motor circuit B1441/41 (05-1160) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1315 05-1 126 DIAGNOSTICS Air outlet control servo motor circuit B1443/43 (05-1164) B1499/99 (05-1168) Multiplex communication circuit - AIR CONDITIONING SYSTEM
Mode damper servo sub-assy
Mode damper position sensor
Harness or connector between mode damper servo subassy and A/C amplifier assy
A/C amplifier assy
Open in multiplex communication circuit  (15 sec.) - HINT:




*1: If the room temperature is approx. -18.6°C (-1.48°F) or lower, DTC B1411/11 may be output even though the system is normal. *2: If the ambient temperature is approx. -52.9°C (-63.22°F) or lower, DTC B1412/12 may be output even though the system is normal. *3: If the check is being performed in a dark place, DTC B1421/21 (solar sensor circuit abnormal) could be displayed. *4: The A/C amplifier assy memorizes the DTC of the respective malfunction it has occurred for the period of the time indicated in the brackets. *5: Compressor lock (DTC B1422/22) is indicated only for a current malfunction. (see page 05-1 146) To confirm DTC B1422/22, perform the following steps. (1) With the engine ON, enter the DTC check mode. (2) Press the R/F switch to enter actuator check mode, and set the operation to Step No. 3. (3) Press the AUTO switch to return to DTC check mode. (4) The DTC is displayed after approximately 3 seconds. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1316 05-1 114 DIAGNOSTICS - AIR CONDITIONING SYSTEM AIR CONDITIONING SYSTEM 0521X-03 HOW TO PROCEED WITH TROUBLESHOOTING 1 VEHICLE BROUGHT TO WORK SHOP 2 CUSTOMER PROBLEM ANALYSIS (SEE PAGE 05-1 116) 3 CHECK AND CLEAR DTC (SEE PAGE 05-1 117) 4 PROBLEM SYMPTOM CONFIRMATION SYMPTOM DOES NOT OCCUR (GO TO STEP 5) SYMPTOM OCCURS (GO TO STEP 8) 5 SYMPTOM SIMULATION (SEE PAGE 01-26 ) 6 CHECK MULTIPLEX COMMUNICATION SYSTEM MULTIPLEX COMMUNICATION SYSTEM DTC OUTPUTS (PROCEED TO ’’MULTIPLEX COMMUNICATION SYSTEM) NO MULTIPLEX COMMUNICATION SYSTEM DTC (GO TO STEP 7) 7 CHECK BEAN COMMUNICATION SYSTEM BEAN DTC OUTPUTS (PROCEED TO ’’COMMUNICATION SYSTEM’’) NO BEAN DTC (GO TO STEP 8) 8 DTC CHECK (OTHER THAN MULTIPLEX COMMUNICATION SYSTEM DTC) MALFUNCTION CODE (GO TO STEP 9) NORMAL CODE (GO TO STEP 10) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1304 05-1 115 DIAGNOSTICS 9 - AIR CONDITIONING SYSTEM DTC CHART (SEE PAGE 05-1 125) GO TO STEP 10 10 PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1 129) 11 ACTUATOR CHECK (SEE PAGE 05-1 117) 12 CIRCUIT INSPECTION (SEE PAGE 05-1 130 - 05-1 190) 13 IDENTIFICATION OF PROBLEM 14 PARTS INSPECTION 15 REPAIR 16 CONFIRMATION TEST END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1305 05-1 127 DIAGNOSTICS - AIR CONDITIONING SYSTEM 05221-03 LOCATION Engine Room J/B
Magnetic Clutch Relay
ECU-B Fuse
50 A HEATER Fuse Condenser Pressure Switch Ambient Temperature Sensor Compressor and Magnetic Clutch I30305 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1317 05-1 128 DIAGNOSTICS - AIR CONDITIONING SYSTEM w/o Navigation System: Instrument Panel J/B
15 A HEATER Fuse
RADIO No. 2 Fuse
AM1 Fuse w/ Navigation System: Multi Display Assy Solar Sensor Heater Control Assembly
A/C Amplifier Assy Room Temperature Sensor Evaporator Air Outlet Damper Control Servomotor Evaporator Temperature Sensor Expansion Valve Recirculation Damper Servomotor Heater Radiator Blower Motor Blower Motor Linear Controller Air Mix Damper Control Servomotor I41028 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1318 05-1 117 DIAGNOSTICS - AIR CONDITIONING SYSTEM 05IU9-01 PRE-CHECK 1. LIST OF OPERATION METHODS By operating each of the A/C control switches as shown in the diagram below, it is possible to enter the diagnosis check mode. Turn igniton switch ON with AUTO and R/F switches held down. If both AUTO switch and R/F switches are not pressed at the same time. Indicator Check OFF DTC Check (Sensor Check) (continuous operation) R/F Actuator Check (continuous operaiton) AUTO DEF OFF DTC Check (Sensor Check) (stepped operation) R/F R/F AUTO OFF DEF Actuator Check (stepped operation) OFF AUTO DEF DEF Cancel check mode and start A/C control. : Indicates a switch operation R/F: Recirculation/Fresh 2. (a) w/o Navigation System INDICATOR CHECK Turn the ignition switch ON while pressing the A/C control AUTO switch and R/F switch simultaneously. I30328 w/ Navigation System I38758 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1307 05-1 118 DIAGNOSTICS (b) w/o Navigation System - AIR CONDITIONING SYSTEM Check that the indicators light up and go off at 1 second intervals 4 times in succession. HINT:

After the indicator check is completed, the system enters the DTC automatically. Press the OFF switch when desiring to cancel the check mode. I41003 w/ Navigation System I38757 1 Sec. 1 Sec. ON OFF I36113 w/o Navigation System 3. (a) DTC (b) DTC CHECK (SENSOR CHECK) Perform an indicator check. After the indicator check is completed, the system enters the DTC check mode automatically. Read the code displayed on the panel. Refer to the list of codes on page 05- 1125 when reading the codes. (Trouble codes are output at the temperature display.) I30327 w/ Navigation System DTC I38759 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1308 05-1 119 DIAGNOSTICS w/o Navigation System - AIR CONDITIONING SYSTEM (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. (a) CLEARING DTC 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. (a) (b) (c) DTC CHECK USING HAND-HELD TESTER Connect the hand-held tester to the DLC3. Power switch ON (ready). Read the DTC following the prompts on the tester screen. Please refer to the hand-held tester operator’s manual for further details. Clear the DTCs. I30328 w/ Navigation System I38758 Engine Room J/B ECU-B Fuse I30337 F46779 (d) 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 details. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1309 05-1 120 DIAGNOSTICS - AIR CONDITIONING SYSTEM 6. (a) w/o Navigation System I30329 w/ Navigation System ACTUATOR CHECK Turn the ignition switch to the ON position while pressing the A/C control AUTO switch and R/F (Recirculation / Fresh) switch simultaneously. (b) As each damper, motor and relay automatically operate the actuator check at 1 second intervals from step No.1 to No.10 continuously, check the temperature and air flow visually and by hand. If a slower display is desired, press the temperature up switch and change the display in the step operation. Each time the temperature up switch is pressed, the display changes by 1 step. HINT:
Codes are displayed from the smaller to the larger numbers in order.
To cancel the check mode, press the ”OFF” switch. I38758 4 Conditions Display code Blower level 1 0 0 FACE FRESH OFF ”COOL” side (Fully closed) 2 1 1 FACE FRESH OFF ”COOL” side (Fully closed) 3 2 17 FACE FRESH ON ”COOL” side (Fully closed) 4 3 17 FACE FRESH ON ”COOL” side (Fully closed) 5 4 17 FACE RECIRCULATION ON ”COOL”/ ”WARM ” (50% open) 6 5 17 B/L RECIRCULATION ON ”COOL”/ ”WARM ” (50% open) 7 6 17 FOOT RECIRCULATION ON ”WARM” side (Fully opened) 8 7 17 FOOT RECIRCULATION ON ”WARM” side (Fully opened) 9 8 17 FOOT/ DEF RECIRCULATION ON ”WARM” side (Fully opened) 10 9 31 DEF RECIRCULATION ON ”WARM” side (Fully opened) Step No. Air flow vent Air inlet damper Magnetic clutch Air mix damper 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1310 05-1 121 DIAGNOSTICS 7. (a) 1 2 3 4 5 6 7 8 - AIR CONDITIONING SYSTEM CHECK DLC3 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. 9 10111213141516 DLC3 A04550 Terminal No. Connection/Voltage or Resistance Condition 7 Bus + Line/Pulse generation During transmission 4 Chassis Ground - Body Ground/1 Ω or less Always 5 Signal Ground - Body Ground/1 Ω or less Always 16 Battery Positive - Body Ground/9 to 14 V Always 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 ”DATA LIST”. ALL: Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/C SIG A/C signal / ON or OFF A/C ON: ON - Item Measurement Item/Display (Range) Normal Condition Diagnostic 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-D Solar sensor (Driver side) /min.: 0 max.: 255 Changes 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.: 255 Actual 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) - A C: 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1311 05-1 122 DIAGNOSTICS - AIR CONDITIONING SYSTEM Item Measurement Item/Display (Range) Normal Condition Diagnostic Note A/O DAMP POS Air outlet damper position /min.: -14% max.: 113.5% Changes depending on air outlet power position - A/M DAMP TARG-D Air mix damper target position (Driver side) /min.: -14% max.: 113.5% Changes depending on the set temperature (Driver side) - A/O DAMP TARG Air outlet damper target position /min.: -14% max.: 113.5% Changes depending on air outlet power position - BLOWER LEVEL Blower motor speed level /min.: Level 0 max.: Level 31 Changes depending on blower level - #CODES Number of Trouble Codes /min.: 0 max.: 255 - - HAND FREE TEL Hands free telephone / OFF, ON - - SET TEMP SHIFT Shift set temperature/2C decr, 1C decr, NORMAL, 1C incr, 2C incr Changes depending on shift set temperature *1 - COMPRESSOR MODE Compressor mode /AUTO, MANUAL Changes depending on compressor mode *1 - COMPRS/DEF OPER Compressor/DEF operation mode /LINK, NORMAL Changes depending on compressor/DEF operation mode *1 - HINT: *1: It differs depending on the user setting. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1312 05-1 129 DIAGNOSTICS - AIR CONDITIONING SYSTEM 05223-03 PROBLEM SYMPTOMS TABLE Symptom Suspect Area See page Whole functions of the A/C system does not operate. 1. IG power source circuit 2. A/C amplifier assy 05-1170 01-36 Air Flow Control: No blower operation 1. Heater relay circuit 2. Blower motor circuit 3. A/C amplifier assy 05-1187 05-1181 01-36 Air Flow Control: No blower control 1. Blower motor circuit 05-1181 Air Flow Control: Insufficient air output 1. Blower motor circuit 2. A/C amplifier assy 05-1181 01-36 1. Volume of refrigerant 2. Drive belt tension 3. Refrigerant pressure 4. Compressor circuit 5. Compressor lock sensor circuit 6. Pressure switch circuit 7. Air mix control servomotor circuit 8. Air mix damper position sensor circuit 9. Room temperature sensor circuit 10.Ambient temperature sensor circuit 11.A/C amplifier assy 55-11 19-12 19-36 55-11 05-1190 05-1146 05-1149 05-1160 05-1152 05-1130 05-1134 01-36 Temperature Control: No warm air comes out 1. 2. 3. 4. 5. 6. 7. Air mix control servomotor circuit Air mix damper position sensor circuit Ambient temperature sensor circuit Room temperature sensor circuit Evaporator temperature sensor circuit A/C amplifier assy Heater radiator 05-1160 05-1152 05-1134 05-1130 05-1138 01-36 - Temperature Control: Output air is warmer or cooler than the set temperature or response is slow. 1. 2. 3. 4. 5. 6. Room temperature sensor circuit Ambient temperature sensor circuit Solar sensor circuit Air mix damper position sensor circuit Air mix control servomotor circuit A/C amplifier assy 05-1130 05-1134 05-1142 05-1152 05-1160 01-36 Temperature Control: No temperature control (only Max. cool or Max. warm) 1. Air mix control servomotor circuit 2. Air mix damper position sensor circuit 3. A/C amplifier assy 05-1160 05-1152 01-36 No air inlet control 1. Recirculation damper control servomotor circuit 2. A/C amplifier assy 05-1177 01-36 No air outlet control 1. Air outlet damper position sensor circuit 2. Air outlet control servomotor circuit 3. A/C amplifier assy 05-1156 05-1164 01-36 Engine idle up does not occur, or is continuous. 1. Compressor circuit 2. Compressor lock sensor circuit 3. A/C amplifier assy 05-1190 05-1146 01-36 Set temperature value displayed does not match up with operation of temperature control switch. 1. A/C amplifier assy 01-36 Brightness does not change when rheostat volume or light control switch is turned. 1. Illumination light system 2. A/C amplifier assy 01-36 Unable to access the diagnosis mode 1. A/C amplifier assy DTC not recorded. Set mode is cleared when IG switch is turned off. 1. Back-up power source circuit 2. A/C amplifier assy Temperature Control: No cool air comes out 2AZ-FE 3MZ-FE 01-36 05-1173 01-36 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1319 05-1 123 DIAGNOSTICS - AIR CONDITIONING SYSTEM 05IUA-02 TERMINALS OF ECU A/C AMPLIFIER A/C Amplifier Wire Harness View: A11 A10 8 76 5 4 3 2 1 11 10 9 8 7 6 5 4 3 2 1 2221 2019 1817161514 13 12 16151413121110 9 I30330 Terminal No. (Symbols) Wiring Color Terminal Description Condition Specification 0 → 10 to 14 V A10-2 (IG) - A10-11 (GND) BR - W-B Main power supply Ignition switch: LOCK or ACC → ON A10-4 (MR/F) - A10-6 (AIF) Y-W Recirculation damper servomotor operation signal Ignition switch: ON R/F switch: RECIRCULATION → FRESH Below 1.0 → 10 to 14 V A10-5 (AIR) - A10-4 (MR/F) B-Y Recirculation damper servomotor operation signal Ignition switch: ON R/F switch: FRESH → RECIRCULATION Below 1.0 → 10 to 14 V A10-7 (HR) - A10-11 (GND) O - W-B Blower speed operation signal Ignition switch: ON Blower switch: ON → OFF Below 1.0 → 10 to 14 V A10-9 (MPX-) A10-11 (GND) G - W-B Multiplex communication signal Ignition switch: ON Pulse generate A10-11 (GND) - Body ground W-B - Body ground Ground for main power supply Always Below 1.0 Ω A10-12 (+B) - A10-11 (GND) W - W-B Back up power supply Always 10 to 14 V A10-13 (ACC) - A10-11 (GND) GR -W-B Power supply for accessories Ignition switch: LOCK → ON 0 → 10 to 14 V A10-17 (BLW) - A10-11 (GND) LG - W-B Blower speed operation signal Ignition switch: ON Blower switch: OFF → LO, M1, M2, M3, HI Pulse generate A11-4 (TR) - A11-3 (SG-3) W- Y Room temperature sensor signal Ignition switch: ON Cabin temperature: 40
C (104
F) → 25
C (77
F) 1.2 to 1.6 → 1.8 to 2.2 V A11-5 (TE) - A11-12 (SG-1) LG -P Evaporator temperature sensor signal Ignition switch: ON Evaporator temperature: 15
C (59
F) → 0
C (32
F) 1.4 to 1.8 → 2.0 to 2.4 V A11-6 (TPO) - A11-12 (SG-1) R-P Mode damper servomotor operation signal Ignition switch: ON R/F switch: DEF → FACE 0.5 to 1.5 → 3.5 to 4.5 V A11-7 (AOD) - A10-11 (GND) G -W-B Mode damper servomotor operation signal Ignition switch: ON Mode switch: FACE → DEF Below 1.0 → 10 to 14 V A11-8 (AOF) - A10-11 (GND) V - W-B Mode damper servomotor operation signal Ignition switch: ON Mode switch: DEF → FACE Below 1.0 → 10 to 14 V A11-9 (S5-4) - A10-11 (GND) BR - W-B Ignition switch signal Ignition switch: ON 4.5 to 5.5 V A11-10 (TP) - A10-11 (GND) SB - W-B Air mix damper servomotor operation signal Ignition switch: ON Set temperature: MAX. WARM → MAX. COOL 0.5 to 1.5 → 3.5 to 4.5 V A11-1 1 (S5-1) A11-12 (SG-1) O-P Power supply for air mix control servomotor Ignition switch: ON 4.5 to 5.5 V A11-13 (AMC) A10-11 (GND) GR - W-B Air mix damper servomotor operation signal Ignition switch: ON Set temperature: MAX. WARM → MAX. COOL Below 1.0 → 10 to 14 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1313 05-1 124 DIAGNOSTICS - AIR CONDITIONING SYSTEM Terminal No. (Symbols) Wiring Color Terminal Description Condition Specification A11-14 (AMH) A10-11 (GND) B - W-B Air mix damper servomotor operation signal Ignition switch: ON Set temperature: MAX. COOL → MAX. WARM Below 1.0 → 10 to 14 V Solar sensor signal Ignition switch: ON Solar sensor subject to electric light → Solar sensor is covered by a cloth 4.5 to 5.5 → Below 4.0 V A11-16 (TS) - A11-15 (S5-3) L-W ECM ECM Connector Wire Harness View: E7 E8 E9 E6 E5 I30693 Terminal No. (Symbols) E6-32 (TAM) - E7-28 (E2) Wiring Color B - BR Terminal Description Condition Specification Ambient temperature signal Ignition switch: ON Ambient temperature: 40
C (104
F) → 25
C (77
F) 0.8 to 1.2 → 1.4 to 1.8 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1314 05-1879 DIAGNOSTICS - COMBINATION METER 05IPW-01 DATA LIST/ACTIVE TEST DATA LIST According to the DATA LIST displayed by the hand-held tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten work time. (a) Warm up the engine. (b) Turn the ignition switch to OFF. (c) Connect the hand-held tester to DLC3. (d) Turn the ignition switch to ON. (e) Operate the hand-held tester according to the steps on the display and select ”DATA LIST”. METER: Item Measurement Item/ Range (Display) Normal Condition SPEED METER Vehicle speed / Min.: 0 km/h (0 mph), Max.: 255 km/h (158 mph) TACHO METER Engine speed / Min.: 50 rpm, Max.: Almost same as actual engine 12,750 rpm speed (When engine is running) Diagnostic Note Almost same as actual vehicle speed (When driving) - Fuel input signal Min.: 0, Max.: 255 Fuel gauge indicates (F): 48 Fuel gauge indicates (3/4): 93 Fuel gauge indicates (1/2): 148 Fuel gauge indicates (1/4): 188 Fuel gauge indicates (E): 206 - LIGHT RHEOSTAT Light control rheostat / Min.: 0, Max.: 255 Light control rheostat switch is Dark (0) → Bright (255) - ODO/TRIP SW ODO/TRIP switch is ON / OFF ON: Switch is pushed OFF: Switch is released - TAIL CANCEL SW TAIL CANCEL switch is ON / OFF ON: Tail cancel position OFF: Except tail cancel position - Item Measurement Item/ Range (Display) FUEL GAUGE ECM: Normal Condition Diagnostic Note VEHICLE SPEED Vehicle speed / Min.: 0 km/h (0 mph), Max.: 255 km/h (158 mph) Almost same as actual vehicle speed (When driving) - ENGINE SPD Engine speed / Min.: 0 rpm, Max.: 16,383 rpm Almost same as actual engine speed (When engine is running) - COOLANT TEMP Coolant Temperature / Min.: -40
C After warming up: 80 to 95°C (176 (-40 °F), Max.: 140
C (284°F) to 203°F) If the value is ”-40
C (-40°F)” or ”140
C (284°F)”, sensor circuit is open or shorted. ABS: Item (FR/FL/RR/RL) SPD Measurement Item/ Range (Display) Vehicle speed / Min.: 0 km/h (0 mph), Max.: 326 km/h (202 mph) Normal Condition Diagnostic Note Almost same as actual speed (When driving) - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2069 05-1880 DIAGNOSTICS - COMBINATION METER ACTIVE TEST Performing the ACTIVE TEST using the hand-held tester allows the meters, indicators and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one way to shorten labor time. It is possible to display the DATA LIST on hand-held tester during the ACTIVE TEST. (a) Connect the hand-held tester to DLC3. (b) Turn the ignition switch to the ON position. (c) From the display on tester, perform the ”ACTIVE TEST”. METER: Item Test Details Diagnostic Note SPEED METER 0 / 40(25) / 80(50) / 120(75) / 160(99) / 200(124) km/h(mph) - TACHOMETER 0rpm / 1000rpm / 2000rpm / 3000rpm / 4000rpm / 5000rpm / 6000rpm / 7000rpm - FUEL GAUGE OFF, METER F, 3/4, 1/2, 1/4, METER E, EMPTY - COOLANT TEMP LOW, 60
C, 70
C, 80
C, NORMAL, 110
C, 120
C, HIGH - SHIFT INDIC A/T indicator operation (P, R, N, D, S, 3, 2, L) Comfirm that the vehicle is stopped and engine idling LOW FUEL WARN Indicat. Lamp FUEL (OFF/ON) Comfirm that the vehicle is stopped and engine idling D-BEL T REMIND Indicat. Lamp D-SEAT BELT (OFF/ON) Comfirm that the vehicle is stopped and engine idling Indicat. Lamp OIL (OFF/ON) Comfirm that the vehicle is stopped and engine idling Indicat. Lamp CHARGE (OFF/ON) Comfirm that the vehicle is stopped and engine idling Indicat. Lamp TAIL (OFF/ON) Comfirm that the vehicle is stopped and engine idling CRUISE INDIC Indicat. Lamp CRUISE (OFF/ON) Comfirm that the vehicle is stopped and engine idling Rr FOG INDIC Indicat. Lamp Rr FOG (OFF/ON) Comfirm that the vehicle is stopped and engine idling SRS WARN Indicat. Lamp AIRBAG (OFF/ON) Comfirm that the vehicle is stopped and engine idling Indicat. Lamp TRAC (TRC) OFF (OFF/ON) Comfirm that the vehicle is stopped and engine idling Indicat. Lamp SLIP (OFF/ON) Comfirm that the vehicle is stopped and engine idling O/D OFF INDIC Indicat. Lamp O/D OFF (OFF/ON) Comfirm that the vehicle is stopped and engine idling ODO/TRIP DISP Indicat. ODO/TRIP DISPLAY (OFF/ON) Comfirm that the vehicle is stopped and engine idling A/T OIL TEMP A/T OIL temperatue operation (OFF/ON) Comfirm that the vehicle is stopped and engine idling Fr FOG INDIC Indicat. Lamp Fr FOG (OFF/ON) Comfirm that the vehicle is stopped and engine idling Indicat. Lamp TIRE PRESS (OFF/ON) Comfirm that the vehicle is stopped and engine idling Indicat. Lamp DOOR (OFF/ON) Comfirm that the vehicle is stopped and engine idling Indicat. Lamp ECT SNOW (OFF/ON) Comfirm that the vehicle is stopped and engine idling Key remained buzzer (OFF/ON) Comfirm that the vehicle is stopped and engine idling OIL PRESS WARN DISCHARGE WARN TAILLIGHT INDIC TRC OFF INDIC SLIP INDIC TIRE PRESS WARN DOOR WARN ECT SNOW WARN KEY REMND BUZZR 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2070 05-1881 DIAGNOSTICS Item - COMBINATION METER Test Details Diagnostic Note SEAT BELT BUZZR Seat Belt buzzer (OFF/ON) Comfirm that the vehicle is stopped and engine idling REVERSE BUZZER Reverse buzzer (OFF/ON) Comfirm that the vehicle is stopped and engine idling S SHFT RJCT BUZ Sports Shift reject buzzer (OFF/ON) Comfirm that the vehicle is stopped and engine idling Speed buzzer (OFF/ON) Comfirm that the vehicle is stopped and engine idling Warning buzzer (OFF/ON) Comfirm that the vehicle is stopped and engine idling SPEED BUZZER WARNING BUZZER 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2071 05-1898 DIAGNOSTICS - COMBINATION METER 05IQ1-02 SEAT BELT WARNING LAMP FOR DRIVER’S SEAT DOES NOT OPERATE WIRING DIAGRAM C12 Combination Meter Assy Airbag Sensor Assembly 9 MPX+ BEAN B19 Front Seat Inner Belt Assy (Driver’s Side) 6 2 LBE- A16 A16 (*2) (*1) 19 11 LBE+ A16 A16 (*2) (*1) R 3 G 1 *1: w/o Curtain Shield Airbag *2: w/ Curtain Shield Airbag I40146 INSPECTION PROCEDURE HINT: If there is an open in the ground circuit (Airbag sensor assy center), the airbag sensor assy center outputs DTCs. Perform troubleshooting with the ”Supplemental Restraint System 05-1200 ”. 1 PERFORM ACTIVE TEST BY HAND-HELD TESTER (a) Operate the hand-held tester according to the steps on the display and select the ”ACTIVE TEST”. METER: Item D-BEL T REMIND Test Details Diagnostic Note Confirm that the vehicle is stopped and engine idling Indicat. Lamp D-SEAT BELT (OFF/ON) NG REPLACE COMBINATION METER ASSY (SEE PAGE 71-18 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2088 05-1899 DIAGNOSTICS 2 - COMBINATION METER READ VALUE OF HAND-HELD TESTER(DRIVER SEAT BELT) (a) Operate the hand-held tester according to the steps on the display and select the ”DATA LIST”. SRS AIRBAG: Item D SEAT BUCKL Measurement Item/ Range (Display) Normal Condition Driver seat belt buckle switch is ON / OFF NG Diagnostic Note ON: Seat belt is fastened OFF: Seat belt is unfastened - Go to step 3 OK REPLACE COMBINATION METER ASSY(SEE PAGE 71-18 ) 3 INSPECT FRONT SEAT INNER BELT ASSY (DRIVER SIDE) Front Seat Inner Belt Assy (Driver Side) Connector Front View: B4 I40135 (a) Disconnect the connector from the front seat inner belt assy (Driver Side). (b) Measure the resistance according to the value(s) in the table below. Standard: Terminal No Condition Specified condition B4-2 - B4-5 Seat belt is fastened Approx. 330 Ω B4-2 - B4-5 Seat belt is unfastened Approx. 1,330 Ω NG REPLACE FRONT SEAT INNER BELT ASSY (DRIVER SIDE) OK 4 CHECK HARNESS AND CONNECTOR(FRONT SEAT INNER BELT ASSY - BODY GROUND)(SEE PAGE 01-26 ) Front Seat Inner Belt Assy (Driver Side) Wire Harness View: B4 (a) Disconnect the connector from the front seat inner belt assy (Driver Side). (b) Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Condition Specified Condition B4-5 - Body ground Always Below 1 Ω NG Go to step 5 E58133 OK END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2089 05-1900 DIAGNOSTICS 5 - COMBINATION METER CHECK HARNESS AND CONNECTOR(FRONT SEAT INNER BELT ASSY - AIRBAG SENSOR ASSY CENTER)(SEE PAGE 01-26 ) Front Seat Inner Belt Assy (Driver Side) Wire Harness View: B4 (a) (b) Disconnect the B4, A23 connectors. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Condition Specified Condition B4-2 - A23-10 Always Below 1 Ω A23-10 - Body ground Always 10 kΩ or higher Airbag Sensor Assy Center Wire Harness View: A23 NG I39225 REPAIR OR CONNECTOR REPLACE HARNESS OR OK END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2090 05-1883 DIAGNOSTICS - COMBINATION METER 05IPX-02 ENTIRE COMBINATION METER DOES NOT OPERATE WIRING DIAGRAM 4 4M W Combination Meter Assy J6 J/C Passenger Side J/B 1 4E P 9 IL1 P E E SB 13 C11 P 1 C11 Center J/B I15 Ignition SW Instrument Panel J/B 13 1K BR HEATER IGN 6 1G 10 1G 7 3C 4 3A B 7 1C W G 1 1C 1 1K 4 IG1 AM1 2 6 IG2 AM2 7 Y GR 5 IC3 F7 FL Block AM2 1 2I D.C.C ALT B 2 ECU-B 4 2A 1 IC1 L-Y 10 1 W-L Engine Room J/B W 3 W 2 C11 LG Instrument Panel J/B 6 1 AM1 1C 1A 1 2 Center J/B BR 2 3K 12 3B R 11 C11 FL MAIN Battery IB I40141 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2073 05-1884 DIAGNOSTICS - COMBINATION METER INSPECTION PROCEDURE 1 INSPECT COMBINATION METER ASSY (a) Measure the resistance according to the value(s) in the table below. Standard: Wire Harness View: C11-2 C11-1 Terminal No Condition Specified condition C11-1 1 - Body ground Always Below 1 Ω (b) Measure the voltage according to the value(s) in the table below. Standard: C11-1 1 C11-13 I40698 Terminal No Condition Specified condition C11-2 - Body ground Always 10 to 14 V C11-1 - Body ground Ignition switch ON 10 to 14 V C11-13 - Body ground Ignition switch ON 10 to 14 V NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE COMBINATION METER ASSY(SEE PAGE 71-18 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2074 05-1885 DIAGNOSTICS - COMBINATION METER 05IPY-02 MALFUNCTION IN SPEEDOMETER WIRING DIAGRAM Skid Control ECU With Actuator SP1 12 S27 Combination Meter Assy 15 IC4 BR-R 18 IF3 BR GR 6 C12 I40142 INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY HAND-HELD TESTER (a) Operate the hand-held tester according to the steps on the display and select the ”ACTIVE TEST”. METER: Item SPEED METER Test Details Diagnostic Note 0 / 40(24) / 80(48) / 120(72) / 160(96) / 200(120) km/h(mph) - OK: Needle indication is normal. NG REPLACE COMBINATION METER ASSY (SEE PAGE 71-18 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2075 05-1886 DIAGNOSTICS 2 - COMBINATION METER READ VALUE OF HAND-HELD TESTER(VEHICLE SPEED SIGNAL) (a) Operate the hand-held tester according to the steps on the display and select the ”DATA LIST”. METER: Item SPEED METER Measurement Item/ Range (Display) Vehicle speed / Min.: 1 km/h (1 mph), Max.: 255 km/h (158 mph) Normal Condition Diagnostic Note Almost same as actual vehicle speed (When driving) - OK: Vehicle speed displayed on the tester is almost the same as the actual vehicle speed. NG Go to step 3 OK REPLACE COMBINATION METER ASSY(SEE PAGE 71-18 ) 3 READ VALUE OF HAND-HELD TESTER(VEHICLE SPEED SIGNAL) (a) Operate the hand-held tester according to the steps on the display and select the ”DATA LIST”. ABS: Item (FR/FL/RR/RL) SPD Measurement Item/ Range (Display) Vehicle speed / Min.: 0 km/h (0 mph), Max.: 326 km/h (202 mph) Normal Condition Diagnostic Note Almost same as actual speed (When driving) - OK: Vehicle speed displayed on the tester is almost the same as the actual vehicle speed. NG GO TO BRAKE CONTROL SYSTEM (SEE PAGE 05-761 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2076 05-1887 DIAGNOSTICS 4 - COMBINATION METER INSPECT COMBINATION METER ASSY INSPECTION USING OSCILLOSCOPE (a) Check the input signal waveform. (1) Remove the combination meter assy. (2) Connect the oscilloscope to the terminals C12-6 and body ground. (3) Start the engine. Wire Harness View: C12-6 I30440 (4) Check the signal waveform according to the condition (s) in the table below. Item Condition Tool setting 5 V/DIV, 20 ms/DIV Vehicle condition Driving at approx. 20 Km/h (12 mph) OK: As shown in the illustration A05135 HINT: As vehicle speed increases, the cycle of the signal waveform narrows. NG Go to step 5 OK REPLACE COMBINATION METER ASSY(SEE PAGE 71-18 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2077 05-1888 DIAGNOSTICS 5 - COMBINATION METER CHECK HARNESS AND CONNECTOR(ABS&TRACTION ACTUATOR ASSY(VSC) COMBINATION METER ASSY)(SEE PAGE 01-26 ) (a) (b) Disconnect the C12 and S27 connectors. Measure the resistance according to the value(s) in the table below. Standard: ABS&Traction Actuator Assy (VSC) Wire Harness View: S27-12 Tester Connection Condition Specified Condition C12-6 - S27-12 Always Below 1 Ω C12-6 - Body ground Always 10 kΩ or higher NG REPLACE Combination Meter Assy Wire Harness View: C12-6 I40607 REPAIR OR CONNECTOR HARNESS AND OK 6 INSPECT COMBINATION METER ASSY (a) (b) Disconnect the S27 connector. Measure the voltage according to the value(s) in the table below. Standard: ABS&Traction Actuator Assy (VSC) Wire Harness View: S27-12 I40133 Tester Connection Condition Specified Condition S27-12 - Body ground Ignition switch ON 10 to 14 V NG REPLACE COMBINATION METER ASSY (SEE PAGE 71-18 ) OK GO TO BRAKE CONTROL SYSTEM(SEE PAGE 05-761 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2078 05-1893 DIAGNOSTICS - COMBINATION METER 0524B-04 MALFUNCTION IN FUEL RECEIVER GAUGE WIRING DIAGRAM Combination Meter Assy J13 J/C P A F12 FUEL SENDER (FUEL PUMP AND SENDER) P 5 BH1 O 2 IR2 O O 14 BH1 Y 11 IR2 V A 9 C11 2 3 O D D Center J/B 6 3B 2 3K BR IB I40596 INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY HAND-HELD TESTER (a) Operate the hand-held tester according to the steps on the display and select the ”ACTIVE TEST”. METER: Item FUEL GAUGE Test Details Diagnostic Note OFF, EMPTY, 1/2, FULL - OK: Needle indication is normal. NG REPLACE COMBINATION METER ASSY (SEE PAGE 71-18 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2083 05-1894 DIAGNOSTICS 2 - COMBINATION METER READ VALUE OF HAND-HELD TESTER(FUEL GAUGE) (a) Operate the hand-held tester according to the steps on the display and select the ”DATA LIST”. METER: Item FUEL GAUGE Measurement Item/ Range (Display) Normal Condition Diagnostic Note Fuel gauge indicates (F): 48 Fuel gauge indicates (3/4): 93 Fuel gauge indicates (1/2): 148 Fuel gauge indicates (1/4): 188 Fuel gauge indicates (E): 206 Fuel input signal Min.: 0, Max.: 255 - OK: Fuel input signal displayed on the tester is almost the same as Needle indication. NG Go to step 3 OK REPLACE COMBINATION METER ASSY(SEE PAGE 71-18 ) 3 INSPECT FUEL SENDER GAUGE ASSY (a) Measure the voltage according to the value(s) in the table below. Standard: Fuel Sender Gauge Connector Front View: I30899 Tester Connection Condition Specified Condition F20-1 - F20-3 Ignition switch ACC or ON Below 1 to 5 V (b) (c) (d) (e) Remove the fuel sender gauge assy. Connect the fuel sender gauge connector. Check that the float position is between E and F. Measure the voltage between the terminals 2 and 1 of connector according to the value(s) in the table below. Standard: F Warning Float level Float position mm (in.) Voltage (V) F -34.8 (-1.37)
3 (0.12) 4.5 to 4.75 1/2 92.8 (3.65)
3 (0.12) 1.41
1.61 Warning 137.0 (5.39)
3 (0.12) 0.20 to 0.45 E I39224 NG REPLACE FUEL SENDER GAUGE ASSY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2084 05-1895 DIAGNOSTICS 4 - COMBINATION METER CHECK HARNESS AND CONNECTOR(FUEL SENDER GAUGE ASSY COMBINATION METER ASSY)(SEE PAGE 01-26 ) (a) (b) Disconnect the F12 and C11 connectors. Measure the resistance according to the value(s) in the table below. Standard: Combination Meter Assy Wire Harness View: Tester Connection Condition Specified Condition Below 1 Ω C11-9 - F12-2 Always F12-3 - Body ground Always Below 1 Ω F11-9 - Body ground Always 10 kΩ or higher C11-9 Fuel Sender Gauge Connector Front View: F12 NG I40609 REPAIR OR CONNECTOR REPLACE HARNESS OR OK END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2085 05-1869 DIAGNOSTICS - COMBINATION METER 05246-04 CUSTOMER PROBLEM ANALYSIS CHECK COMBINATION METER SYSTEM Check Sheet Inspector’s name: VIN Customer’s Name Production Date Licence Plate No. Date of Vehicle Brought In / / Odometer Reading / Date Problem First Occurred Frequency Problem Occurs Weather Conditions When Problem Occurred Weather km mile /  Constantly  Sometimes ( Times per day, month)  Once only  Fine  Cloudy  Rainy  Snowy  Various/Others  Warm Outside Temperature  Hot  Cold (Approx.  Cool °F ( °C)) Gauge
Malfunction in speedometer
Malfunction in tachometer
Malfunction in water temperature receiver gauge
Malfunction in fuel receiver gauge
Entire combination meter does not operate

Others Problem Symptom
Seat belt warning lamp for driver’s seat does not operate







2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2059 05-1868 DIAGNOSTICS - COMBINATION METER COMBINATION METER 05245-04 HOW TO PROCEED WITH TROUBLESHOOTING 1 VEHICLE BROUGHT TO WORKSHOP 2 CUSTOMER PROBLEM ANALYSIS (SEE PAGE 05-1869 ) 3 PROBLEM SYMPTOM CONFIRMATION (SEE PAGE 05-1882 ) 4 CHECK MULTIPLEX COMMUNICATION SYSTEM (SEE PAGE 05-2095 ) (a) Check for DTC outputs. MULTIPLEX DTC OUTPUTS (PROCEED TO ”BODY MULTIPLEX COMMUNICATION SYSTEM”) NO MULTIPLEX DTC (GO TO STEP 5) 5 (a) CHECK CAN COMMUNICATION SYSTEM (SEE PAGE 05-2095 ) Check for DTC outputs. CAN DTC OUTPUTS (PROCEED TO ”CAN COMMUNICATION SYSTEM”) NO CAN DTC (GO TO STEP 6) 6 CIRCUIT INSPECTION (SEE PAGE 05-1883 - 05-1898 ) 7 REPAIR OR REPLACE 8 CONFIRMATION TEST END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2058 05-1889 DIAGNOSTICS - COMBINATION METER 05IPZ-02 MALFUNCTION IN TACHOMETER WIRING DIAGRAM Combination Meter Assy ECM Passenger Side J/B TACH 5 E5 B 5 4F 11 4L GR 21 IL2 O 1 C12 I40143 INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY HAND-HELD TESTER (a) Operate the hand-held tester according to the steps on the display and select the ”ACTIVE TEST”. METER: Item Test Details Diagnostic Note TACHOMETER 0rpm / 1000rpm / 2000rpm / 3000rpm / 4000rpm / 5000rpm / 6000rpm / 7000rpm - OK: Needle indication is normal. NG REPLACE COMBINATION METER ASSY (SEE PAGE 71-18 ) OK Author
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: 2079 05-1890 DIAGNOSTICS 2 - COMBINATION METER READ VALUE OF HAND-HELD TESTER(ENGINE SPEED SIGNAL) (a) Operate the hand-held tester according to the steps on the display and select the ”DATA LIST”. METER: Item TACHO METER Measurement Item/ Range (Display) Normal Condition Diagnostic Note Engine speed / Min.: 50 rpm, Max.: Almost same as actual engine 12,750 rpm speed (When engine is running) - OK: Engine speed displayed on the tester is almost the same as the actual engine speed. NG Go to step 3 OK REPLACE COMBINATION METER ASSY(SEE PAGE 71-18 ) 3 READ VALUE OF HAND-HELD TESTER(ENGINE SPEED SIGNAL) (a) Operate the hand-held tester according to the steps on the display and select the ”DATA LIST”. ALL (ECM): Item ENGINE SPD Measurement Item/ Range (Display) Normal Condition Diagnostic Note Engine speed / Min.: 50 rpm, Max.: Almost same as actual engine 12,750 rpm speed (When engine is running) - OK: Engine speed displayed on the tester is almost the same as the actual engine speed. NG GO TO ENGINE CONTROL SYSTEM (SEE PAGE 05-5 , 05-362 ) OK Author
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: 2080 05-1891 DIAGNOSTICS 4 - COMBINATION METER INSPECT COMBINATION METER ASSY INSPECTION USING OSCILLOSCOPE (a) Check the input signal waveform. (1) Remove the combination meter assy. (2) Connect the oscilloscope to the terminals C12-1 and body ground. (3) Start the engine. Wire Harness View: C12-1 I30440 (4) Check the signal waveform according to the condition (s) in the table below. Item Condition Tool setting 5 V/DIV, 10 ms/DIV Vehicle condition Engine idle speed OK: As shown in the illustration A05138 NG Go to step 5 OK REPLACE COMBINATION METER ASSY(SEE PAGE 71-18 ) Author
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: 2081 05-1892 DIAGNOSTICS 5 - COMBINATION METER CHECK HARNESS AND CONNECTOR(ECM - COMBINATION METER ASSY) (SEE PAGE 01-26 ) (a) (b) Disconnect the C12 and E5 connectors. Measure the resistance according to the value(s) in the table below. Standard: ECM Wire Harness View: E5-5 Tester Connection Condition Specified Condition C12-1 - E5-5 Always Below 1 Ω C12-1 - Body ground Always 10 kΩ or higher NG REPLACE Combination Meter Assy Wire Harness View: C12-1 I40608 REPAIR OR CONNECTOR HARNESS AND OK 6 INSPECT COMBINATION METER ASSY (a) (b) Disconnect the E5 connector. Measure the voltage according to the value(s) in the table below. Standard: ECM Wire Harness View: E5-5 I40144 Tester Connection Condition Specified Condition E5-5 - Body ground Ignition switch ON 10 to 14 V NG REPLACE COMBINATION METER ASSY (SEE PAGE 71-18 ) OK GO TO ENGINE CONTROL SYSTEM(SEE PAGE 05-5 , 05-366 ) Author
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: 2082 05-1896 DIAGNOSTICS - COMBINATION METER 05IQ0-05 MALFUNCTION IN WATER TEMPERATURE RECEIVER GAUGE WIRING DIAGRAM C11 Combination Meter Assy ECM 21 BEAN E2 28 E7 Short Connector 5 5 BR S29 S28 BR BR*1 1 W-B*2 THW 19 E7 MPX- G-B E2 Engine Coolant 2 Temp Sensor *1: 2AZ-FE *2: 3MZ-FE I44266 INSPECTION PROCEDURE HINT: If there is an open or short in the engine coolant temperature sensor circuit, the ECM outputs DTCs. Perform troubleshooting with the ”SFI System 05-5 ,.05-366 ”. 1 PERFORM ACTIVE TEST BY HAND-HELD TESTER (a) Operate the hand-held tester according to the steps on the display and select the ”ACTIVE TEST”. METER: Item COOLANT TEMP Test Details Diagnostic Note LOW / NORMAL / HI - OK: Needle indication is normal. NG REPLACE COMBINATION METER ASSY (SEE PAGE 71-18 ) OK Author
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: 2086 05-1897 DIAGNOSTICS 2 - COMBINATION METER READ VALUE OF HAND-HELD TESTER(ENGINE COOLANT) (a) Operate the hand-held tester according to the steps on the display and select the ”DATA LIST”. ECM: Item COOLANT TEMP Measurement Item/ Range (Display) Normal Condition Coolant Temperature / Min.: -40
C After warming up: 80 to 95°C (176 (-40 °F), Max.: 140
C (284°F) to 203°F) Diagnostic Note If the value is ”-40
C (-40°F)” or ”140
C (284°F)”, sensor circuit is open or shorted. OK: Coolant temperature displayed on the tester is between 80
C (176
F) and 95
C (203
F) after warning up. NG GO TO ENGINE CONTROL SYSTEM (SEE PAGE 05-5 , 05-366 ) OK 3 REPLACE COMBINATION METER ASSY OK: Normal operation NG GO TO ENGINE CONTROL SYSTEM (SEE PAGE 05-5 , 05-366 ) OK END Author
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: 2087 05-1870 DIAGNOSTICS - COMBINATION METER 05IPU-01 LOCATION Fuel Sender Gauge Brake Fluid Warning Switch Skid Control ECU with Actuator Rear Door Courtesy Switch Front Door Courtesy Switch Engine Room J/B
DOME Fuse
ECU-B Fuse Washer Level Warning Switch I40697 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2060 05-1871 DIAGNOSTICS - COMBINATION METER Passenger Seat Belt Warning ECM Body ECU Center J/B Combination Meter Passenger Side J/B Occupant Detection ECU Instrument Panel J/B
IGN Fuse Buckle Switch Airbag Sensor Assy Center I40158 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2061 05-1872 DIAGNOSTICS - COMBINATION METER 2AZ-FE Engine: Engine Coolant Temperature Sensor Oil Pressure Switch 3MZ-FE Engine: Engine Coolant Temperature Sensor Oil Pressure Switch I30455 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2062 05-1873 DIAGNOSTICS - COMBINATION METER C12 C11 I30438 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2063 05-1874 DIAGNOSTICS - COMBINATION METER C12-1 (TACHO) C11-1 1 (SIGNAL GND) C11-7 (ILL) Light Control Rheostat SW ODO/TRIP SW LCD C12-6 (SI) SPEED TACHO FUEL C12-13 (4P OUT) CPU TEMP C11-9 (FUEL) C11-13 (IG2) C11-1 (IG+) C11-2 (ECU+B) C11-12 (DOME) C11-22 (POWER GND) BUZZER CPU DOOR I40058 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2064 05-1875 DIAGNOSTICS - COMBINATION METER P R N D 3 2 L CPU S FUEL O/D OFF ECT SNOW CHARGE OIL PRESSER CRUISE SEAT BELT AIRBAG SLIP TRC/TRAC OFF A/T OIL TEMP OIL MAINT TIRE AIR PRESS OIL LEVEL TURN L C11-14 (TURN L) TURN R C11-15 (TURN R) BEAM C11-19 (BEAM-) WASHER LEVEL C12-12 (WASHER LEVEL) C12-16 (BEAM+) CHECK ENGINE C12-4 (CHECK ENGINE) C12-10 (BRAKE LEVEL) C12-11 (BRAKE) C11-17 (ABS) ACTIVE CIRCUIT C12-7 (VSC) BRAKE ABS VSC C12-9 (MPX+) CPU C11-21 (MPX-) I40059 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2065 05-1876 DIAGNOSTICS Terminal No. C11 1 C12 - COMBINATION METER Wire Harness Side HEATER Fuse 2 ECU-B Fuse 7 PANEL Fuse 9 Fuel sender gauge 11 Ground (Signal Ground) 12 DOME Fuse 13 IGN Fuse 14 Turn Signal Flasher 15 Turn Signal Flasher 17 Skid Control ECU 19 Headlight Dimmer Switch 21 Multiplex Communication Line (MPX-) 22 Ground (Power Ground) 1 ECM 4 ECM 6 Skid Control ECU (SI) 7 Skid Control ECU (VSC) 9 Multiplex Communication Line (MPX+) 10 Brake Warning Switch 11 Skid Control ECU 12 Washer Level Warning Switch 13 Speed Control Unit (4P-OUT) 16 Headlight Relay 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2066 05-1882 DIAGNOSTICS - COMBINATION METER 05248-04 PROBLEM SYMPTOMS TABLE Chart No. Symptom See page 1 Entire combination meter does not operate 05-1883 2 Malfunction in speedometer 05-1885 3 Malfunction in tachometer 05-1889 4 Malfunction in fuel receiver gauge 05-1893 5 Malfunction in water temperature receiver gauge 05-1896 7 Seat belt warning lamp for driver’s seat does not operate 05-1898 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2072 05-1877 DIAGNOSTICS - COMBINATION METER 05IPV-03 TERMINALS OF ECU COMBINATION METER ASSY C12 C11 I30439 Symbols (Terminals No.) IG+ (C11-1) - Body ground ECU+B (C11-2) - Body ground Wiring Color P - Body ground LG - Body ground Terminal Description Condition Ignition switch signal Ignition switch OFF → ON Battery Always Specified Condition Below 1 V → 10 to 14 V 10 to 14 V ILL (C11-7) - Body ground B - Body ground Illumination signal Tail light OFF → ON FUEL (C11-9) - Body ground O - Body ground Fuel signal Ignition switch ON, fuel level is FULL → EMPTY SIGNAL GND (C11-1 1) Body ground R - Body ground Ground Always Below 1 Ω DOME (C11-12) - Body ground V - Body ground Battery Always 10 to 14 V Ignition switch signal Ignition switch OFF → ON Below 1 V → 10 to 14 V IG2 (C11-13) - Body ground SB - Body ground Pulse generation Below 1 V → 4 to 7 V TURN L (C11-14) Body ground L - Body ground Turn signal L Ignition switch ON, turn signal LH indicator OFF → ON Below 1 V → 10 to 14 V TURN R (C11-15) Body ground GR - Body ground Turn signal R Ignition switch ON, turn signal RH indicator OFF → ON Below 1 V → 10 to 14 V ABS signal Ignition switch ON, ABS warning light ON → OFF 6.7 to 12 V → Below 1 V Hi-Beam signal Headlight dimmer switch Lo → Hi 10 to 14 V → Below 1 V Communication signal Communication circuit Ground Always ABS (C11-17) - Body ground BEAM- (C11-19) Body ground MPX- (C11-21) POWER GND (C11-22) Body ground W - Body ground BR - Body ground W-B - Body ground Below 1 Ω Pulse generation (See waveform 2) TACH (C12-1) - Body ground O - Body ground Tacho meter signal (Input) Engine running CHECK ENGINE (C12-4) Body ground L - Body ground CHECK ENGINE signal Ignition switch ON, CHECK ENGINE warning light ON → OFF Below 1 V → 10 to 14 V SP1 (C12-6) - Body ground GR - Body ground Speed signal (Input) Ignition switch ON and turn the wheel slowly Pulse generation (See waveform 1) VSC (C12-7) - Body ground P - Body ground VSC signal Ignition switch ON, VSC warning light ON → OFF Below 1 V → 10 to 14 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2067 05-1878 DIAGNOSTICS MPX+ (C12-9) - COMBINATION METER - Communication signal Communication circuit BRAKE (C12-10) - Body ground V - Body ground Brake fluid level signal Ignition switch ON, brake fluid level (LO) → NORMAL Below 1 V → 10 to 14 V BRAKE (C12-11) Body ground B - Body ground Brake signal Ignition switch ON, BRAKE warning light ON → OFF 6.7 to 12 V → Below 1 V Washer level signal Washer indicator OFF → ON 10 to 14 V → Below 1 V WASHER LEVEL (C12-12) Body ground BR - Body ground - 4P OUT (C12-13) Body ground W - Body ground Speed signal (Output) Ignition switch ON and turn the wheel slowly BEAM+ (C12-16) Body ground G - Body ground Hi-Beam signal Hi-Beam OFF → ON Pulse generation (See waveform 1) Below 1 V → 10 to 14 V Waveform 1 (Reference): Item Contents Tool setting 5 V/DIV, 20 ms/DIV Vehicle condition Driving at approx. 20 Km/h HINT: As the vehicle speed increases, the cycle of the signal waveform narrows. A05135 Waveform 2 (Reference): Item Contents Tool setting 5 V/DIV, 10 ms/DIV Vehicle condition Engine idle speed A05138 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2068 05-1981 DIAGNOSTICS - SLIDING ROOF SYSTEM 05JFT-02 SLIDING ROOF DOES NOT MOVE BY SLIDING ROOF CONTROL SWITCH CIRCUIT DESCRIPTION The sliding roof drive gear sub-assy (sliding roof ECU) monitors a sliding roof motor switch signal in line, and the motor built in the sliding roof drive gear sub-assy (sliding roof ECU) is driven. WIRING DIAGRAM S20 Sliding Roof Control ECU J17 J/C P 3 IE1 2 IE1 P E E W AM1 IG1 2 Instrument Panel J/B 9 1D 8 1H L 1 G UP 2 S/ROOF 5 I15 O5 Ignition SW Over Head J/B 4 G 7 1C W 6 1C B 6 W DWN AM1 8 4 IG1 9 1 R IG3 1 1A 10 1G 11 2 1D BR W-B 7 GR Engine W-L Room J/B 4 2A 9 W-B IG B W-B IG 10 E MPX1 6 IE1 E6 ECM 5 4D 6 4M 7 4L 2 ALT 1 W FL Main Y Passenger Side J/B D.C.C F7 FL Block DWN 8 IE1 ECU-B 1 2I 3 W UP 1 4 IE1 5 IC3 B W-B GND V 6 ECUB Instrument Panel J/B W-B 4 1E 1 4N GR MPX2 29 GR 1 IL2 W-B W-B 14 1D SB C12 Combination Meter W-B Battery IA IC 9 MPX+ B80388 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2171 05-1982 DIAGNOSTICS 1 - SLIDING ROOF SYSTEM READ VALUE OF HAND-HELD TESTER (a) Connect the hand-held tester to the DLC3. (b) Enter into the DATA LIST of the hand-held tester. Sliding Roof ECU Item Switch condition Standard value OPEN SW Pressed → Unpressed ON/OFF CLOSE SW Pressed → Unpressed ON/OFF NG Go to step 4 OK 2 PERFORM ACTIVE TEST BY HAND-HELD TESTER (a) Connect the hand-held tester to the DLC3. (b) Enter into the ACTIVE TEST of the hand-held tester. Sliding Roof ECU Item Condition Sliding Roof CLOSE/UP Sliding Roof OPEN/DOWN NG Go to step 6 OK 3 READ VALUE OF HAND-HELD TESTER (a) Connect the hand-held tester to the DLC3. (b) Enter into the DATA LIST of the hand-held tester. Sliding Roof ECU Item Switch condition Standard value Hall IC condition Do sliding and tiling operation ON/OFF OK REPLACE SLIDING SUB-ASSY ROOF DRIVE GEAR NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2172 05-1983 DIAGNOSTICS 4 - SLIDING ROOF SYSTEM CHECK WIRE HARNESS (a) (b) Wire Harness Side S20 Sliding Roof Control ECU B ECUB Symbol (Terminal No.) Condition E (S20-7) ⇔ Body ground Constant Continuity B (S20-1) ⇔ E (S20-7) Constant 10 to 14 V ECUB (S20-5) ⇔ E (S20-7) Constant 10 to 14 V E B80389 (c) (d) Wire Harness Side O5 Overhead J/B Disconnect the S20 roof drive gear connector. Check the voltage or continuity between the terminals of the S20 roof drive gear wire harness side connector. Standard: Disconnect the O5 overhead J/B connector. Check the voltage or continuity between the terminals of the O5 overhead J/B wire harness side connector. Standard: Symbol (Terminal No.) GND IG (O5-9) ⇔ GND (O5-1) condition Specified condition Ignition switch position OFF → ON 0V → 10V - 14V Constant Continuity GND (O5-1) ⇔ Body ground IG Specified condition B80390 (e) (f) Wire Harness Side S20 Sliding Roof Control ECU UP Disconnect the O5 overhead J/B connector. Check the continuity between the S20 drive gear and O5 overhead J/B wire harness side connectors. Standard: Symbol (Terminal No.) (Drive gear ⇔ Motor switch) Specified condition UP (S20-8) ⇔ UP (O5-6) Continuity DWN (S20-9) ⇔ DOWN (O5-4) Continuity IG (S20-6) ⇔ IG3 (O5-11) Continuity DWN O5 OVERHEAD J/B DOWN UP NG REPAIR OR REPLACE WIRE HARNESS B70473 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2173 05-1984 DIAGNOSTICS 5 - SLIDING ROOF SYSTEM INSPECT SLIDE ROOF MOTOR SWITCH (a) O5 OVERHEAD J/B Inspect the overhead J/B continuity. Standard: Terminal No. Condition Specified condition 1⇔8 Slide open Continuity 1⇔9 Tilt up Continuity B78737 6 (a) NG REPLACE SLIDE ROOF MOTOR SWITCH OK REPLACE SLIDING SUB-ASSY ROOF DRIVE GEAR CHECK MOVEMENT OF SLIDING ROOF Remove the sliding roof drive gear, then check that the sliding roof can be moved by hand. NG REPAIR OR REPLACE SLIDING ROOF OK REPLACE SLIDING ROOF DRIVE GEAR SUB-ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2174 05-1975 DIAGNOSTICS - SLIDING ROOF SYSTEM 051RB-03 CUSTOMER PROBLEM ANALYSIS CHECK SLIDING ROOF CONTROL SYSTEM Check Sheet Inspector’s name: Registration No. Registration Year Customer’s Name Frame No. Date Vehicle Brought in / / / Date Problem First Occurred Frequency Problem Occurs Weather Conditions When Problem Occurred km miles Odometer Reading
Constant
Once only
Sometimes ( / Times per day, month)
Fine
Cloudy
Rainy
Various/Others
Hot
Warm
Cool Outdoor temperature
Cold (Approx. °C ( °F)) Weather
Snowy Problem Symptom
Sliding roof control system does not operate.
Sliding roof operates abnormally or stops halfway. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2165 05-1974 DIAGNOSTICS - SLIDING ROOF SYSTEM SLIDING ROOF SYSTEM 051RA-04 HOW TO PROCEED WITH TROUBLESHOOTING HINT: Troubleshoot in accordance with the procedure on the following pages. 1 VEHICLE BROUGHT TO WORKSHOP 2 CUSTOMER PROBLEM ANALYSIS (See page 05-1975 ) 3 PROBLEM SYMPTOM CONFIRMATION (a) (b) If the symptom does not occur, proceed to A. If the symptom occurs, proceed to B. A SYMPTOM SIMULATION B 4 PROBLEM SYMPTOMS TABLE (See page 05-1980 ) 5 CIRCUIT INSPECTION (See page 05-1981 ) 6 IDENTIFICATION OF PROBLEM 7 REPAIR OR REPLACE 8 CONFIRMATION TEST END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2164 05-1977 DIAGNOSTICS - SLIDING ROOF SYSTEM 051RC-04 LOCATION Sliding Roof Housing Sliding Roof Drive Gear Sub-assy (Sliding Roof ECU) Slide Roof Motor Switch B51423 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2167 05-1976 DIAGNOSTICS - SLIDING ROOF SYSTEM 0523P-03 PRE-CHECK 1. CHECK USING HAND-HELD TESTER (a) Connect the hand-held tester to the DLC3. (b) Select the DATA LIST mode on the hand-held tester. Sliding Roof ECU Item Switch condition Standard value OPEN SW Pressed→Unpressed ON/OFF CLOSE SW Pressed→Unpressed ON/OFF Position detection SW 1 Do sliding and tilting operation ON/OFF Position detection SW 2 Do sliding and tilting operation ON/OFF Hall IC condition Do sliding and tiling operation Normal/Abnormal Hall IC out put Do sliding and tiling operation Lo/Hi IG Ignition Switch ON→OFF ON/OFF IG line signal Ignition Switch ON→OFF ON/OFF Operation possible after key-OFF Ignition Switch ON→OFF ON/OFF (c) The active test will indicate if the part is normal or malfunctioning. Sliding Roof ECU Item Condition Sliding Roof CLOSE/UP Sliding Roof OPEN/DOWN 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2166 05-1980 DIAGNOSTICS - SLIDING ROOF SYSTEM 051RE-04 PROBLEM SYMPTOMS TABLE Symptom Suspected Area See page Sliding roof system operates abnormally. 1. Slide roof control switch 2. Sliding roof control motor and relay 3. Wire harness 05-1981 05-1981 - Sliding roof system stops operation halfway. (No foreign materials are trapped in motor assembly) 1. Slide roof control switch 2. Sliding roof control motor and relay 3. Wire harness 05-1981 05-1981 - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2170 05-1978 DIAGNOSTICS - SLIDING ROOF SYSTEM 05JFS-03 TERMINALS OF ECU 1. S20 INSPECT SLIDING ROOF DRIVE GEAR SUB-ASSY (SLIDING ROOF ECU) B31361 (a) Disconnect the sliding roof ECU connector, and check the voltage or continuity of each terminal of the wire harness side connector. Standard: Symbols (Terminals No.) Wiring color ECUB (S20-5) ⇔ Body ground Condition Specified condition B⇔ - Constant 10 to 14 V B (S20-1) ⇔ Body ground L⇔ - Constant 10 to 14 V E (S20-7) ⇔ Body ground W-B ⇔ - Constant Continuity If the result is not as specified, there may be a malfunction on the wire harness. 2. CHECK OVERHEAD J/B O5 B78737 (a) Disconnect the overhead J/B connector, and check the voltage or continuity of each terminal of the connector. Standard: Symbols (Terminals No.) Wiring color UP (O5-6) ⇔ Body ground Condition Specified condition G⇔- Each switch OFF Continuity DOWN (O5-4) ⇔ Body ground W⇔- Each switch OFF Continuity 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2168 05-1979 DIAGNOSTICS Symbols (Terminals No.) Wiring color - SLIDING ROOF SYSTEM Condition Specified condition G⇔-
Ignition switch ON
Sliding roof fully closed
Slide open switch OFF → ON (Slide open side) 0 V → 10 to 14 V DOWN (O5-4) ⇔ Body ground W⇔-
Ignition switch ON
Sliding roof fully opened
Tilt up switch OFF → ON (Slide close side) 0 V → 10 to 14 V IG (O5-9) ⇔ Body ground GR ⇔ - Ignition switch ON 0 V → 10 to 14 V GND (O5-1) ⇔ Body ground W-B ⇔ - Constant Continuity UP (O5-6) ⇔ Body ground If the result is not as specified, there may be a malfunction on the wire harness. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2169 05-2036 DIAGNOSTICS - THEFT DETERRENT SYSTEM 05ITO-02 BACK DOOR KEY LOCK AND UNLOCK SWITCH CIRCUIT CIRCUIT DESCRIPTION The back door key lock and unlock switch comes on when the back door key cylinder is turned to the unlock side with the key. WIRING DIAGRAM Theft Warning ECU Assy B14 Back Door Key Lock and Unlock Switch LOCK BR 9 BG3 V 14 IA2 Y 17 IL2 SB 15 T4 L Y 4 BG2 B 4 IA2 LG 8 IL2 BR 33 T4 UL 2 1 W-B UNLOCK 3 A J14 J/C BE B51271 INSPECTION PROCEDURE 1 CHECK BACK DOOR KEY LOCK AND UNLOCK SWITCH (a) (b) Remove the switch. Measure the resistance. Standard: Tester Connection Condition 1-2 Turned to lock side Below 1 Ω 1-2, 1-3 Not turned 10 kΩ or higher 1-3 Turned to unlock side Below 1 Ω LOCK UNLOCK Specified Condition I07296 NG REPLACE BACK DOOR KEY LOCK AND UNLOCK SWITCH OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2226 05-2037 DIAGNOSTICS 2 - THEFT DETERRENT SYSTEM CHECK WIRE HARNESS (THEFT WARNING ECU ASSY - BACK DOOR KEY LOCK AND UNLOCK SWITCH) (a) (b) (c) Wire Harness Side B14 Back Door Key Lock and Unlock Switch Disconnect the T4 ECU connector. Disconnect the B14 switch connector. Measure the resistance between the wire harness side connectors. Standard: Tester Connection Specified Condition B14-2 (LOCK) - T4-15 (L) Below 1 Ω B14-8 (UNLOCK) - T4-33 (UL) Below 1 Ω T4 Theft Warning ECU Assy B77251 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 3 CHECK BACK DOOR KEY LOCK AND UNLOCK SWITCH (BODY GROUND) Wire Harness Side B14 Back Door Key Lock and Unlock Switch (a) (b) B31046 Disconnect the B14 switch connector. Measure the resistance between the wire harness side connector and body ground. Standard: NG Tester Connection Specified Condition B14-1 - Body ground Below 1 Ω REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE THEFT WARNING ECU ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2227 05-2026 DIAGNOSTICS - THEFT DETERRENT SYSTEM 0522S-06 ECU POWER SOURCE CIRCUIT CIRCUIT DESCRIPTION This circuit provides power to operate the theft deterrent (warning) ECU. WIRING DIAGRAM 5 IC3 BR 1G 10 T4 Theft Warning ECU Assy J17 J/C Instrument Panel J/B Assy P P 1D 9 L W-L E E 4 IC3 W 11 O 2 IL1 2 IF1 L 3 +B1 +B2 Engine Room J/B Assy 4 2A 2A 5 ECU-B SECURITY D.C.C W-B 1 2I 29 E 3 W F7 FUSIBLE LINK BLOCK 1 Center J/B 3D 5 W FL Main Battery 3F 13 W-B IB B80399 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2216 05-2027 DIAGNOSTICS - THEFT DETERRENT SYSTEM INSPECTION PROCEDURE 1 (a) (b) CHECK THEFT WARNING ECU ASSY (ECU-B) Remove the ECU-B fuse from the engine room J/B. Measure the resistance. Standard: Below 1 Ω OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 2 CHECK WIRE HARNESS (POWER SOURCE) (a) (b) Wire Harness Side T4 Theft Warning ECU Assy B63408 Disconnect the T4 ECU connector. Measure the voltage of the wire harness side connector. Standard: NG Tester Connection Specified Condition T4-2 (+B1) - T4-29 (E) 10 to 14 V REPAIR OR CONNECTOR REPLACE HARNESS AND OK 3 CHECK THEFT WARNING ECU ASSY (GROUND) (a) (b) Wire Harness Side T4 Theft Warning ECU Assy Disconnect the T5 ECU connector. Measure the resistance between the wire harness side connector and body ground. Standard: Tester Connection Specified Condition T4-2 (+B1) - Body ground Below 1 Ω T4-29 (E) - Body ground Below 1 Ω B63408 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK PROCEED TO NEXT CIRCUIT INSPECTION 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2217 05-2038 DIAGNOSTICS - THEFT DETERRENT SYSTEM 05ITP-01 ENGINE HOOD COURTESY SWITCH CIRCUIT CIRCUIT DESCRIPTION The hood door courtesy switch is built in the engine hood lock assembly. The switch comes on when the engine hood is opened and goes off when the engine hood is closed. WIRING DIAGRAM Theft Warning ECU Assy E3 Security Courtesy Switch (Engine Hood Courtesy Switch) W-B 2 A 15 IK3 G-B 1 6 IL2 G 34 T4 DSWH W J1 J/C EG B51273 INSPECTION PROCEDURE 1 INSPECT SECURITY COURTESY SWITCH Not Pushed (ON) Security Courtesy Switch (a) (b) Remove the courtesy switch. Measure the resistance of the switch. Tester Connection Condition Specified Condition 1-2 Pushed (OFF (Lock)) 10 kΩ or higher 1-2 Not pushed (ON (Unlock)) Below 1 Ω Pushed (OFF) I04148 NG REPLACE SECURITY COURTESY SWITCH OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2228 05-2039 DIAGNOSTICS 2 - THEFT DETERRENT SYSTEM CHECK WIRE HARNESS (THEFT WARNING ECU ASSY - SECURITY COURTESY SWITCH (a) (b) (c) Wire Harness Side E3 Security Courtesy Switch Disconnect the T4 ECU connector. Disconnect the E3 switch connector. Measure the resistance between the wire harness side connectors. Standard: Tester Connection Specified Condition T4-34 (DSWH) - E3-1 Below 1 Ω T4 Theft Warning ECU Assy NG B77252 REPAIR OR CONNECTOR REPLACE HARNESS AND OK 3 CHECK WIRE HARNESS (SECURITY COURTESY SWITCH - BODY GROUND) (a) (b) Wire Harness Side E3 Security Courtesy Switch Disconnect the E3 switch connector. Measure the resistance between the wire harness side connector and body ground. Standard: NG B31016 Tester Connection Specified Condition E3-2 - Body ground Below 1 Ω REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE THEFT WARNING ECU ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2229 05-2031 DIAGNOSTICS - THEFT DETERRENT SYSTEM 0522U-05 IGNITION SWITCH CIRCUIT CIRCUIT DESCRIPTION When the ignition switch is turned to the ON position, battery positive voltage is applied to terminal IG of the ECU. When battery positive voltage is applied to terminal IG of the ECU while the theft deterrent system is operating, the warning stops. Furthermore, the power supplied from terminal IG of the ECU is used as the power for the door courtesy switch and position switch, etc. WIRING DIAGRAM Center J/B G 2 AM1 IG1 W 4 Theft Warning ECU Assy Instrument Panel J/B I15 Ignition Switch 7 1C ECU-IG 6 AM1 1C 9 1K R 10 G T4 IG 1 B 1A 2 5 3E 1 3A 1 F7 FL Block FL Main W 1 2 Battery B51270 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2221 05-2032 DIAGNOSTICS - THEFT DETERRENT SYSTEM INSPECTION PROCEDURE 1 CHECK ECU-IG FUSE (ECU-IG) (a) (b) ECU-IG Fuse B51577 Remove the ECU-IG fuse from the engine room J/B. Measure the resistance. Standard: Below 1 Ω NG REPLACE FUSE OK 2 CHECK THEFT WARNING ECU ASSY (IG VOLTAGE) (a) (b) (c) Wire Harness Side T4 Theft warning ECU Assy B63408 Disconnect the T4 ECU connector. Turn the ignition switch ON. Measure the voltage between the wire harness side connector and body ground. Standard: NG Tester Connection Specified Condition T4-10 (IG) - Body ground 10 to 14 V REPAIR OR CONNECTOR REPLACE HARNESS AND OK CHECK AND REPLACE THEFT WARNING ECU ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2222 05-2024 DIAGNOSTICS - THEFT DETERRENT SYSTEM 05ITK-02 INDICATOR LIGHT CIRCUIT CIRCUIT DESCRIPTION While the theft deterrent system is preparing to be set, this circuit lights up the indicator lamp. When the system is set, it continuously turns the indicator lamp on for 0.75 seconds and then turns it off for 1.25 seconds, thus the indicator lamp blinks. WIRING DIAGRAM Theft Warning ECU Assy Center J/B W-B B 1 2 11 3F 13 3F 2 3B 8 3C R 25 T4 IND T5 Security Indicator Lamp Assy W-B IB B65516 INSPECTION PROCEDURE 1 CHECK SECURITY INDICATOR LAMP ASSY (OPERATION) (a) (b) Disconnect the T5 indicator lamp connector. Check if the security indicator lamp comes on when battery voltage is applied to each terminal of the connector. 1 Standard: 2 Measuring Condition Specified Operation Battery positive (+) - Terminal 2 Battery negative (-) - Terminal 1 Indicator lamp comes on. B51710 NG REPLACE SECURITY INDICATOR LAMP ASSY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2214 05-2025 DIAGNOSTICS 2 - THEFT DETERRENT SYSTEM CHECK WIRE HARNESS (THEFT WARNING ECU ASSY - SECURITY INDICATOR LAMP ASSY) (a) (b) Wire Harness Side Disconnect the T5 indicator lamp and T4 ECU connectors Measure the resistance between the wire harness side connecters. Standard: T5 Security Indicator Lamp Assy Tester Connection Specified Condition T4-25 (IND) - T5-2 Below 1 Ω T4 Theft Warning ECU Assy NG B77249 REPAIR OR CONNECTOR REPLACE HARNESS AND OK 3 CHECK WIRE HARNESS (SECURITY INDICATOR LAMP ASSY - BODY GROUND) (a) (b) Wire Harness Side T5 Theft Deterrent Indicator Lamp Assy B78292 Disconnect the T5 indicator lamp connector Measure the resistance between the wire harness side connector and body ground. Standard: NG Tester Connection Specified Condition T5-1 - Body ground Below 1 Ω REPAIR OR CONNECTOR REPLACE HARNESS AND OK CHECK AND REPLACE THEFT WARNING ECU ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2215 05-2033 DIAGNOSTICS - THEFT DETERRENT SYSTEM 05ITN-03 UNLOCK WARNING SWITCH CIRCUIT CIRCUIT DESCRIPTION The key unlock warning switch comes on when the ignition key is inserted in the ignition key cylinder and goes off when the ignition key is removed. The ECU operates the key confinement prevention function while the key unlock warning switch is on. WIRING DIAGRAM Theft Warning ECU Assy W-B K4 Unlock Warning J6 Switch J/C 1 DG 2 G D 18 IL2 P 12 T4 KSW D Passenger Side J/B 9 4G Body ECU 4N 1 4L 7 W-B W-B IC B80391 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2223 05-2034 DIAGNOSTICS - THEFT DETERRENT SYSTEM INSPECTION PROCEDURE 1 INSPECT UN-LOCK WARNING SWITCH ASSY (a) (b) Not Pushed (ON) Remove the warning switch. Measure the resistance of the switch. Standard: Pushed (OFF) 2 1 4 3 Tester Connection Condition Specified Condition 1-2 Not pushed (ON (Key inserted)) Below 1 Ω 1-2 Pushed (OFF (Key removed)) 10 kΩ or higher B51581 NG REPLACE UN-LOCK WARNING SWITCH ASSY OK 2 CHECK WIRE HARNESS (THEFT WARNING ECU ASSY - UNLOCK WARNING SWITCH ASSY) (a) (b) (c) Wire Harness Side K4 Unlock Warning Switch Disconnect the T4 ECU connector. Disconnect the K4 switch connector. Measure the resistance between the wire harness side connectors. Standard: Tester Connection Specified Condition T4-12 (KSW) - K4-2 Below 1 Ω T4 Theft Warning ECU Assy NG B77247 REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2224 05-2035 DIAGNOSTICS 3 - THEFT DETERRENT SYSTEM CHECK WIRE HARNESS (UNLOCK WARNING SWITCH ASSY - BODY GROUND) Wire Harness Side K4 Unlock Warning Switch B31124 (a) (b) Disconnect the K4 switch connector. Measure the resistance between the wire harness side connector and body ground. Standard: NG Tester Connection Specified Condition (K4-1) - Body ground Below 1 Ω REPAIR OR CONNECTOR REPLACE HARNESS AND OK CHECK THEFT WARNING ECU ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2225 05-2028 DIAGNOSTICS - THEFT DETERRENT SYSTEM 05ITM-04 THEFT DETERRENT HORN CIRCUIT CIRCUIT DESCRIPTION When the theft deterrent system is operating, the relay in the ECU turns on and off in a cycle of approximately 0.2 seconds, causing the theft warning horn to blow (see the wiring diagram below). WIRING DIAGRAM INSTRUMENT PANEL J/B ASSY 5 IC3 W - L BR 1G 10 1D 9 E 4 IC3 2A 5 Theft Warning ECU Assy 11 O 2 IL1 P P L 4 2A T4 J17 J/C E 2 IF1 W 3 L +B1 +B2 Engine Room J/B ECU-B SECURITY D.C.C 2I 17 1 IF3 LG B 1 SH- 3 W F7 FUSIBLE LINK BLOCK 1 IC3 2 W B - O FL MAIN 1 BATTERY T1 Theft Deterrent Horn B80404 INSPECTION PROCEDURE 1 (a) (b) CHECK THEFT WARNING ECU ASSY (SECURITY) Remove the SECURITY fuse from the engine room J/B. Measure the resistance. Standard: Below 1 Ω NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2218 05-2029 DIAGNOSTICS 2 - THEFT DETERRENT SYSTEM CHECK THEFT WARNING ECU ASSY (THEFT WARNING ECU - BODY GROUND) (a) (b) Wire Harness Side T4 Theft Warning ECU Assy Disconnect the T4 ECU connector. Measure the voltage between the T4 ECU connector and body ground. Standard: Tester Connection Specified Condition T4-3 (+B2) - Body ground 10 to 14 V NG B63408 REPAIR OR CONNECTOR REPLACE HARNESS AND OK 3 CHECK SECURITY HORN ASSY (a) (b) 1 B51580 B64984 Disconnect the T1 security horn connector. Check operation of the security horn. Standard: Measurement Condition Specified Condition Battery positive (+) → Terminal 1 Battery negative (-) → Body ground Security horn blows NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2219 05-2030 DIAGNOSTICS 4 - THEFT DETERRENT SYSTEM CHECK SECURITY HORN ASSY (THEFT WARNING ECU ASSY - SECURITY HORN ASSY) (a) (b) (c) Wire Harness Side T4 Theft Warning ECU Assy Disconnect the T4 ECU connector. Disconnect the T1 security horn connector. Measure the resistance between the wire harness side connectors. Standard: Tester Connection Specified Condition T4-1 (SH-) - T1-1 Below 1 Ω T1 Security Horn Assy 1 NG B63408 B58961 REPLACE SECURITY HORN ASSY B64978 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2220 05-2013 DIAGNOSTICS - THEFT DETERRENT SYSTEM 0522N-03 CUSTOMER PROBLEM ANALYSIS CHECK THEFT DETERRENT SYSTEM Check Sheet Inspector’s name: VIN Production Date Customer’s Name Licence Plate No. Date Vehicle Brought in / / / Date Problem First Occurred
Constant
Once only Frequency Problem Occurs Weather Conditions When Problem Occurred km miles Odometer Reading
Sometimes ( / Times per day, month)
Fine
Cloudy
Rainy
Various/Others
Hot
Warm
Cool Outdoor temperature
Cold (Approx. °C ( °F)) Weather
Snowy Problem Symptom
Theft deterrent system cannot be set.
Indicator lamp does not flash when theft deterrent system is set. (It stays on or does not illuminate at all.)
Theft deterrent system does not operate.
When unlocked using door lock knob.
When engine hood is opened.
Theft deterrent system cannot be canceled once set.
When door is unlocked using key or wireless door lock control system.
When key is inserted into ignition key cylinder and turned to ACC or ON (however, only when the system has never operated).
When back door is opened with key.
Theft deterrent system cannot be canceled during warning operation.
When door is unlocked using key or wireless door lock control system.
When key is inserted into ignition key cylinder and turned to ACC or ON. Malfunction
Horns only
Warning only
Headlights only
Taillights only
Starter cut only
Door lock operation only
Warning operation does not start when system is set and door or back door is opened with key.
Other 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2203 05-2012 DIAGNOSTICS - THEFT DETERRENT SYSTEM THEFT DETERRENT SYSTEM 0522M-03 HOW TO PROCEED WITH TROUBLESHOOTING HINT: Use this procedure to troubleshoot the theft deterrent system. 1 VEHICLE BROUGHT TO WORKSHOP 2 CUSTOMER PROBLEM ANALYSIS AND SYMPTOM CHECK (See page 05-2013 ) 3 PROBLEM SYMPTOMS TABLE (See page 05-2023 ) (a) (b) If the fault is not listed on the problem symptoms table, proceed to A. If the fault is listed on the problem symptoms table, proceed to B. B Go to step 5 A 4 (a) (b) OVERALL ANALYSIS AND TROUBLESHOOTING Pre-check (see page 05-2014 ). Terminals of ECU (see page 05-2022 ). 5 ADJUST, REPAIR OR REPLACE 6 CONFIRMATION TEST END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2202 05-2021 DIAGNOSTICS - THEFT DETERRENT SYSTEM 0522O-03 LOCATION Theft Warning Horn Assy Security Courtesy Switch Security Indicator Lamp Assy Center J/B Assy Theft Warning ECU Engine Room J/B  SECURITY Fuse  ECU-B Fuse ECM Passenger Side J/B Assy Rear Door Lock Assy RH Front Door Lock Assy RH Key Unlock Warning Switch Assy Instrument Panel J/B Assy  ECU-IG Fuse Front Door Courtesy Lamp Switch Assy Back Door Key Lock and Unlock Switch Front Door Lock Assy LH Front Door Courtesy Lamp Switch Assy Rear Door Lock Assy LH Rear Door Courtesy Lamp Switch Assy Rear Door Courtesy Lamp Switch Assy Back Door Lock Assy B77253 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2211 05-2014 DIAGNOSTICS - THEFT DETERRENT SYSTEM 0522Y-04 PRE-CHECK 1. OUTLINE OF THEFT DETERRENT SYSTEM When the theft deterrent system is set and any of the following conditions is met, the system sounds the horns and flashes the headlights and the taillights for approximately 1 minute. At the same time, the system locks all the doors (If all the doors are not locked at once, the system repeats the door locking operation every 6.38 seconds during the 1-minute-alarming time). There are 2 modes in this system; one is the active arming mode and another is the passive arming mode. The system is set initially in the active arming mode. It can be switched to the passive arming mode by a specified operation (See step 4).  Any of the doors (including the engine hood and back door) is unlocked or opened without the key. *1  The battery terminal is disconnected and reconnected.  The system receives a panic signal from the transmitter. *2 *1: Only in the active arming mode. *2: When the ignition key is not inserted into the key cylinder. HINT: There are 4 states in each mode: disarmed state, arming preparation state, armed state and alarm sounding state. (1) Disarmed state:  When the theft deterrent function does not operate. (2) Arming preparation state:  Time from a user locks a door to leave the vehicle.  Time until transferring to the armed state.  When the theft deterrent function does not operate. (3) Armed state:  When a user leaves the vehicle completely.  When the theft deterrent function operates. (4) Alarm sounding state:  In this condition, once a theft is detected, the lights will flash and the horns will sound to alert people around the vehicle to the theft. Refer to the table for alarming method and time. Horn Theft deterrent horn Alarming method Headlight Taillight Alarming time 60 seconds Alarming output Continuous 0.40 sec. (ON) 0.40 sec. (OFF) HINT: In the alarm sounding state, when either of the doors is unlocked and no key is in the key cylinder, a force lock signal is output. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2204 05-2015 DIAGNOSTICS 2. - THEFT DETERRENT SYSTEM ACTIVE ARMING MODE Disarmed state (No key inserted in ignition cylinder.) Perform any of the following and the system will go to ”Arming preparation state”:
When all doors and engine hood are closed, lock all doors using the key.
When all doors and engine hood are closed, lock all doors using transmitter.
When all doors are locked, open and close any door or the engine hood, then close and lock all doors and engine hood. Arming preparation state Perform any of the following and the system will return to ”Disarmed state”:
Open any door or engine hood.
Unlock any door.
Insert key into the ignition key cylinder.
Reconnect battery. Perform the following and the system will go to ”Armed state”:
Allow 30 seconds to elapse when engine hood is closed and all doors are locked. Armed state Perform any of the following and the system will return to ”Disarmed state”:
Unlock doors using transmitter.
Unlock doors using key.
Insert key into ignition key cylinder and turn ignition switch ON. Perform any of the following and the system will go to ”Alarm sounding state”:
Open any door.
Unlock doors without using key or transmitter.
Open engine hood.
Reconnect battery.
Turn ignition switch ON. Alarm Sounding State Once a theft is detected, the lights will flash and the horns will sound to alert people around the vehicle to the theft (60 seconds). Perform any of the following and the system will return to ”Disarmed state”:
Unlock doors using transmitter.
Unlock doors using key.
Insert key into ignition key cylinder and turn ignition switch ON. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2205 05-2016 DIAGNOSTICS - THEFT DETERRENT SYSTEM Indicator light output: Condition Indicator lamp Disarmed state OFF Arming preparation state ON Armed state BLINK Alarm sounding state ON HINT: Even in the disarmed state, the indicator lamp flashes, due to a signal output from the immobiliser system. Also, the indicator light flashes whenever receiving a signal from the immobiliser system at any time in the armed state. Flashing frequency: 0.2 seconds (ON) 1.8 seconds (OFF) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2206 05-2017 DIAGNOSTICS 3.   - THEFT DETERRENT SYSTEM PASSIVE ARMING MODE This mode can be turned on according to the specified method (see step 4). The initially set mode (when shipped from factory) is the active arming mode (No passive arming mode). Disarmed state (A) Perform the following and the system will go to ”Disarmed state (B)”:
Insert and remove key from ignition key cylinder, and then open and close driver’s door. Disarmed state (B) Perform any of the followings and the system Perform the following and the system will return to ”Disarmed state (A)”: will go to ”Arming preparation state”:
Push unlock switch on transmitter.
Close all doors and engine hood.
Insert key into driver’s or passenger’s door lock cylinder and turn key to unlock position.
Insert key into ignition key cylinder.
Reconnect battery. Arming preparation state Perform the following and the system will return to ”Disarmed state (B)”:
Open any door or the engine hood. Perform any of the following and the system will return to ”Disarmed state (A)”:
Push unlock switch on transmitter.
Insert key into driver’s or passenger’s door lock cylinder or back door lock cylinder and turn key to unlock position. Insert the key into ignition key
cylinder.
Reconnect battery. Continued from next page Perform the following and the system will go to ”Armed state”:
Allow 30 seconds to elapse with all doors and engine hood closed. Continued on next page 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2207 05-2018 DIAGNOSTICS Continued on previous page - THEFT DETERRENT SYSTEM Continued from previous page Armed state Perform any of the following and the system will return to ”Disarmed state (A)”:
Push unlock switch on transmitter.
Insert key into driver’s or passenger’s door lock cylinder or back door lock cylinder, and turn key to unlock position.
Insert key into ignition key cylinder and turn it ON.
Run engine at 550 rpm or faster for more than 10 seconds. Perform any of the following and the system will go on to ”Alarm sounding state”:
Open any door and allow entry delay time*1 to pass.
Open engine hood.
Open back door without using key or transmitter.
Reconnect the battery. *1: See the ”Entry delay function” on the next page. Alarm sounding state Perform the following and the system will return to ”Armed state”:
Allow the alarm sounding period (60 sec.) to pass. Perform any of the following and the system will return to ”Disarmed state (A)”:
Push unlock switch on transmitter.
Insert key into driver’s or passenger’s door lock cylinder or back door lock cylinder and turn key to unlock position.
Insert key into ignition key cylinder and turn it ON.
Run engine at 550 rpm or faster for more than 10 seconds. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2208 05-2019 DIAGNOSTICS - THEFT DETERRENT SYSTEM Entry delay function: HINT: In the armed state, if any closed door is opened, entry delay time will start. If the transferring condition (Armed state → Disarmed state) is satisfied during the entry delay time, the system will switch to the disarmed state. However if the condition is not satisfied, the system will judge it to be a theft, and then the system will switch to the alarm sounding state. . Door Close Open Indicator ON OFF Alarming output ON OFF System condition Entry delay time (0, 14, 30 sec.) Armed state Alarm sounding state HINT: The entry delay time can be selected among 0, 14, 30 seconds by the customizing function. Indicator lamp output: Condition Indicator Disarmed state OFF Arming preparation state ON Armed state (Entry delay time) BLINK (ON) Alarm sounding state ON HINT: Even in the disarmed state, the indicator lamp flashes, due to a signal output from the immobilizer system. Also, the indicator flashes whenever receiving a signal from the immobilizer system at any time in the armed state. Flashing frequency: 0.2 seconds (ON) 1.8 seconds (OFF) Switching to the active arming mode: HINT: In each state of the passive arming mode, when the switching condition to the active arming mode (disarmed state of active arming mode → arming preparation state of active arming mode) is satisfied, the system will switch to each state of the active arming mode. In this case, the active arming mode will continue until the system switches to the disarmed state. State of passive arming mode before switch State of active arming mode after switch Disarmed state Arming preparation state Arming preparation state Arming preparation state (continuing for 30 sec.) Armed state (During entry delay time) Armed state (After alarming time has elapsed, armed state) Alarm sounding state After alarming time has elapsed, armed state 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2209 05-2020 DIAGNOSTICS 4. - THEFT DETERRENT SYSTEM CHANGING METHOD OF PASSIVE ARMING MODE (ON or OFF) Remove ignition key from key cylinder. All doors are closed and unlocked. Engine hood is opened. Any door is locked and unlocked 3 times by key or transmitter. Input to vehicle Output from vehicle Within 30 sec. Driver’s door is opened. Driver’s door lock knob is locked and unlocked 3 times. Within 2 sec. System starts force lock once after 2 sec. Driver’s door lock knob is unlocked. Within 20 sec. Driver’s door is closed and opened 2 times Driver’s door is closed and opened 3 to 5 times 3 times Driver’s door lock knob is locked and unlocked. 5 times Driver’s door lock knob is locked and unlocked. * 0 sec. Within 2 sec. 4 times * 14 sec. * 30 sec. System starts force lock once after 2 sec. System starts force lock once after 2 sec. PASSIVE MODE OFF PASSIVE MODE ON HINT:
Initial mode is PASSIVE MODE OFF.
If there is a different signal in the middle of changing. It is invalid. *: Entry delay time 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2210 05-2023 DIAGNOSTICS - THEFT DETERRENT SYSTEM 0522Q-03 PROBLEM SYMPTOMS TABLE Proceed to the reference page shown in the matrix chart below for each malfunction symptom and perform a troubleshooting for each circuit. HINT: Troubleshooting of the theft deterrent system is based on the premise that the door lock control system is operating normally. Accordingly, before troubleshooting the theft deterrent system, first make certain that the door lock control system is operating normally. Symptom Suspected Area See Page Theft deterrent system cannot be set. 1. 2. 3. 4. 5. 6. Indicator lamp circuit ECU power source circuit Key un-lock warning switch circuit Back door key lock and unlock switch circuit Engine hood courtesy switch circuit Theft warning ECU 05-2024 05-2026 05-2033 05-2036 05-2038 - Indicator lamp does not blink when theft deterrent system is set. 1. Indicator lamp circuit 05-2024 When theft deterrent system is set (System does not operate when the engine hood is opened). 1. Engine hood courtesy switch circuit 2. Theft warning ECU 05-2038 - When theft deterrent system is set (It is not canceled when the ignition key is turned to ACC or ON position). 1. Ignition switch circuit 05-2031 When theft deterrent system is set (It is still operating when back door is opened with key). 1. Back door key lock and un-lock switch circuit 05-2036 While theft deterrent system is in warning operation (Horns do not sound). 1. Horn circuit 05-2028 Even when theft deterrent system is not set (Horns sound). 1. Horn circuit 05-2028 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2213 05-2022 DIAGNOSTICS - THEFT DETERRENT SYSTEM 0522P-04 TERMINALS OF ECU 1. CHECK THEFT WARNING ECU ASSY (THEFT DETERRENT ECU) T4 B50657 (a) Disconnect the T4 ECU connector, and check the voltage or continuity of each terminal of the wire harness side connector. Standard: Symbols (Terminal No.) E (T4-29) - Body ground +B1 (T4-2) - Body ground +B2 (T4-3) - Body ground L (T4-15) - Body ground UL (T4-33) (T4 33) - Body B d ground d Wiring color Condition Specified Condition W-B Constant - Body ground Below 1 Ω O- Body ground Constant 10 to 14 V L- Body ground Constant 10 to 14 V SB Using key, back door lock cylinder - Body ground LOCK → UNLOCK BR Using key, back door lock cylinder - Body ground UNLOCK → Other position IG (T4-10) - E (T4-29) G - W-B Below 1 Ω → 10 kΩ or higher Ignition switch OFF → ON 0V → 10 to 14 V If the result is not as specified, there may be a malfunction on the wire harness side. (b) Reconnect the T4 ECU connector, and check the voltage of each terminal of the connector. Standard: Symbols (Terminal No.) Wiring Color Condition Specified Condition DSWH (T4-34) - E (T4-29) W - W-B Engine hood courtesy switch OFF (Closed) → ON (Opened) 10 to 14 V → 0 V KSW (T4-12) - E (T4-29) P - W-B Key unlock warning switch ON (Key inserted) → OFF (Key removed) 10 to 14 V → 0 V IND (T4-25) - E (T4-29) R - W-B During set preparation 3 to 5 V (Waveform) Alarm sounding state 10 to 14 V → 0 V (Waveform) SH- (T4-1) - Body ground LG - Body ground If the result is not as specified, the theft warning ECU assy may malfunction. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2212 05-1954 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM 0526M-02 ALL DOORS ARE NOT OPERATED BY THE DRIVER’S DOOR KEY CYLINDER FOR INTERLOCKED WITH KEY CIRCUIT DESCRIPTION A lock or unlock signal via the manual switch (built in the master switch) and driver door key is transmitted to the multiplex network body ECU multiply from the master switch (door ECU), and the multiplex network body ECU drives the door lock motor of each door. WIRING DIAGRAM HINT: Refer to See page 05-1944 . INSPECTION PROCEDURE 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2144 05-1955 DIAGNOSTICS 1 - POWER DOOR LOCK CONTROL SYSTEM INSPECT FRONT DOOR LOCK ASSY LH (a) Inspect the door lock assy continuity. Standard: Switch position Tester connection Lock 2⇔4 OFF - Unlock 2⇔3 Unlock Specified condition Continuity No continuity Continuity OFF Lock B51545 (b) Unlock Lock (c) Inspect the door lock motor operation. Standard: Measuring condition Operation Battery positive - Terminal 5 Battery negative - Terminal 6 Lock Battery positive - Terminal 6 Battery negative - Terminal 5 Unlock Inspect the position switch continuity. Standard: Measuring condition Tester connection Battery positive Terminal 6 Battery negative Terminal 5 1⇔2 Specified condition Continuity B51546 NG REPLACE FRONT DOOR LOCK ASSY LH OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2145 05-1956 DIAGNOSTICS 2 - POWER DOOR LOCK CONTROL SYSTEM CHECK WIRE HARNESS (a) (b) Power Window Regulator Master Switch Assy (Door ECU) Disconnect the master switch and door lock connector. Check the continuity between the master switch and door lock. Standard: Terminals (Switch ⇔ Door Lock) Specified condition 16 ⇔ 1 Continuity 4⇔4 Continuity 14 ⇔ 3 Continuity Front Door Lock Assy LH B51572 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE POWER WINDOW REGULATOR MASTER SWITCH ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2146 05-1944 DIAGNOSTICS DTC - POWER DOOR LOCK CONTROL SYSTEM 0526J-03 B1222/22 DOOR LOCK SWITCH CIRCUIT ON DRIVER DOOR CIRCUIT DESCRIPTION This DTC will be output when the driver door unlock switch (for key operation) of the power window regulator master switch assy is on. DTC No DTC Detecting Condition B1222/22 Trouble Area
Power window regulator master switch assy (door ECU)
Front door lock assy LH (driver side)
Multiplex network body ECU Stick of key lock and unlock switch WIRING DIAGRAM Multiplex Network Body ECU (Body ECU) P5 Power Window Regulator Master Switch Assy (Door ECU) 9 W-L Instrument Panel J/B Assy L-W 10 R-L 20 CPUB MPX2 1 8 GR IB2 5 IF3 Y O BDR MPX1 SIG GND KL KUL LSWE 4 2 14 7 10 B9 MPX2 6 B10 MPX1 MPX Line LSW 3 16 W-B 2 IB1 Passenger Side Junction Block Assy 6 4M 8 4L G Y LG BR 4 3 2 1 L UL E LSSR L 5 IB1 5 W W-B UL 6 R J5 J/B B B L 4 IB1 L BR 1 B12 ACT+ 2 B12 ACTD W-B D12 Front Door Lock Assy LH (Driver Side) Instrument Panel J/B Assy 4 1E 14 1D W-B IA B78721 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2134 05-1945 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM INSPECTION PROCEDURE 1 (a) CHECK DIAGNOSTIC CODE OUTPUT Check if code B1222/22 will disappear but only B1211/11 (communication stop) will be output when the master switch connector is disconnected. (1) B1222/22 code output, proceed to A. (2) B1211/11 code output, proceed to B. B REPLACE MULTIPLEX NETWORK BODY ECU A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2135 05-1946 DIAGNOSTICS 2 - POWER DOOR LOCK CONTROL SYSTEM INSPECT FRONT DOOR LOCK ASSY LH (a) Inspect the door lock assy continuity. Standard: Switch Position Tester Connection Lock 3⇔5 OFF - Unlock 4⇔5 Unlock Specified Condition Continuity No continuity Continuity OFF Lock B51545 (b) Unlock Lock (c) Inspect the door lock motor operation. Standard: Measuring Condition Operation Battery positive - Terminal 1 Battery negative - Terminal 2 Lock Battery positive - Terminal 2 Battery negative - Terminal 1 Unlock Inspect the position switch continuity. Standard: Measuring Condition Tester Connection Battery positive Terminal 2 Battery negative Terminal 1 1⇔2 Specified Condition Continuity B61505 NG REPLACE FRONT DOOR LOCK ASSY RH OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2136 05-1947 DIAGNOSTICS 3 - POWER DOOR LOCK CONTROL SYSTEM CHECK WIRE HARNESS (a) Power Window Regulator Master Switch Assy (Door ECU) (b) Disconnect the connector from the master switch and front door lock motor LH. Check the connector on the harness side. Continuity: Tester Connection (Switch ⇔ Motor) Specified Condition 4⇔4 Continuity 14 ⇔ 3 Continuity (c) Check the master switch connector on the wire harness side. Continuity: Front Door Lock Motor Assy (Driver Side) Tester Connection Specified Condition 4 ⇔ Body ground No continuity 14 ⇔ Body ground No continuity Voltage: Tester Connection Specified Condition 4 ⇔ Body ground 0V 14 ⇔ Body ground 0V B52424 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE POWER WINDOW REGULATOR MASTER SWITCH ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2137 05-1948 DIAGNOSTICS DTC - POWER DOOR LOCK CONTROL SYSTEM 0526K-02 B1223/23 POWER WINDOW SWITCH CIRCUIT ON PASSENGER DOOR CIRCUIT DESCRIPTION This DTC is output when any switch of the door control switch is on. DTC No B1223/23 DTC Detecting Condition Trouble Area
Power window regulator switch assy (passenger side)
Multiplex network body ECU Stick of power window switch WIRING DIAGRAM P10 Power Window Regulator Switch Assy (Passenger Side) SU SD Multiplex Network Body ECU 4 Y 11 IN2 B 21 B10 PU 5 LG 4 IN2 GR 20 B10 PD B78722 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2138 05-1949 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM INSPECTION PROCEDURE 1 INSPECT POWER WINDOW REGULATOR SWITCH ASSY (PASSENGER’S SIDE) (a) Inspect the power window switch continuity. Switch Position Tester Connection Up 3-5 OFF - Down 4-5 Specified Condition Continuity No continuity Continuity B31305 NG REPLACE POWER SWITCH ASSY WINDOW REGULATOR OK 2 CHECK WIRE HARNESS (a) (b) Disconnect the connector from the door control switch. Check the connector on the wire harness side. Continuity: Tester Connection 8 7 6 5 4 Specified Condition 1 ⇔ Body ground Continuity 4 ⇔ Body ground No continuity 5 ⇔ Body ground No continuity Voltage: B51844 NG Tester Connection Specified Condition 1 ⇔ Body ground 0V 4 ⇔ Body ground 0V 5 ⇔ Body ground 0V REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE MULTIPLEX NETWORK BODY ECU 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2139 05-1950 DIAGNOSTICS DTC - POWER DOOR LOCK CONTROL SYSTEM 0526L-04 B1224/24 Door lock switch circuit on passenger door CIRCUIT DESCRIPTION This DTC is output when the passenger door unlock switch (for key operation) of the door control switch is on. DTC No. DTC Detecting Condition B1224/24 Trouble Area
Door control switch assy (passenger side)
Front door lock assy RH
Multiplex network body ECU Stick of key lock and unlock switch WIRING DIAGRAM Multiplex Network Body ECU D13 Front Door Lock Assy RH W-B 2 IN1 L W-B 5 GR 1 IN2 V 8 B10 PKL V 8 IN2 SB 13 B10 PKUL BR 2 IN2 BR 11 B10 LSWP 3 E UL 10 4L 4 Passenger Side J/B LSSR 6 4M 6 W-B L W 1 5 IN1 J5 J/C L L B 4 1E Instrument Panel J/B Assy UL R 2 4 IN1 B J5 J/C W C C 1 B12 ACT+ B-W 6 W B12 ACT- 14 1D W-B IA B78720 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2140 05-1951 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM INSPECTION PROCEDURE 1 INSPECT DOOR CONTROL SWITCH ASSY (a) Inspect the door control switch continuity. Switch Position Tester Connection Lock 3-6 OFF - Unlock 3-5 2 1 6 5 4 3 Specified Condition Continuity No continuity Continuity B51554 NG REPLACE DOOR CONTROL SWITCH ASSY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2141 05-1952 DIAGNOSTICS 2 - POWER DOOR LOCK CONTROL SYSTEM INSPECT FRONT DOOR LOCK ASSY RH (a) Inspect the door lock assy continuity. Standard: Switch Position Tester Connection Lock 3⇔5 OFF - Unlock 4⇔5 Unlock Specified Condition Continuity No continuity Continuity OFF Lock B51543 (b) Unlock (c) Lock Inspect the door lock motor operation. Standard: Measuring Condition Operation Battery positive - Terminal 1 Battery negative - Terminal 2 Lock Battery positive - Terminal 2 Battery negative - Terminal 1 Unlock Inspect the position switch continuity. Standard: Measuring Condition Tester Connection Battery positive Terminal 2 Battery negative Terminal 1 5⇔6 Specified Condition Continuity B51544 NG REPLACE FRONT DOOR LOCK ASSY RH OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2142 05-1953 DIAGNOSTICS 3 - POWER DOOR LOCK CONTROL SYSTEM CHECK WIRE HARNESS (a) Multiplex Network Body ECU (b) Disconnect the connector from the body ECU B10 connector and front door lock assy RH connector. Check the connector on the wire harness side. Continuity: B10 (c) Front Door Lock Assy RH Tester Connection (Body ECU ⇔ Door Lock) Specified Condition B10-8 ⇔ 3 Continuity B10-13 ⇔ 4 Continuity Check the master switch connector on the wire harness side. Continuity: Tester Connection (Body ECU or Door Lock ⇔ Body ground) Specified Condition B10-8 or 3 ⇔ Body ground No continuity B10-13 or 4 ⇔ Body ground No continuity Voltage: Tester Connection (Body ECU or Door Lock ⇔ Body ground) Specified Condition B10-8 or 3 ⇔ Body ground 0V B10-13 or 4 ⇔ Body ground 0V B61507 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE MULTIPLEX NETWORK BODY ECU 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2143 05-1957 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM 0526N-02 KEY CONFINEMENT PREVENTION FUNCTION DOES NOT WORK PROPERLY (MANUAL OPERATION AND INTERLOCKED WITH KEY ARE ACTIVE) CIRCUIT DESCRIPTION The multiplex network body ECU senses, by the un-lock warning switch, that the ignition key is in the key cylinder. Because of this, the multiplex network body ECU will unlock all the doors immediately after locking them if a door has been locked while the key is in the ignition key cylinder. WIRING DIAGRAM Multiplex Network Body ECU K4 Un-lock Warning Switch Assy Passenger Side J/B W-B W-B 7 4L 9 4G G W-B 1 1 4N J6 J/C 2 G D D D7 Front Door Courtesy Lamp Switch Assy (Driver Side) 9 B IA1 1 IC B 2 B10 KSW 11 B11 DCTY Combination Meter Assy 9 MPX+ C12 SB 21 C11 Y MPX Line W 6 B10 MPX1 O 10 B9 Door Open Indicator MPX- MPX Line MPX2 B78723 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2147 05-1958 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM INSPECTION PROCEDURE 1 CHECK MANUAL DOOR LOCK OPERATION NG GO TO POWER WINDOW CONTROL SYSTEM (See page 05-1912 ) OK 2 INSPECT UN-LOCK WARNING SWITCH ASSY (a) OFF ON Inspect the un-lock warning switch continuity. Standard: Condition Tester Connection Specified Condition Switch OFF (Key removed) - No continuity Switch ON (Key set) 1⇔2 Continuity B52271 NG REPLACE UN-LOCK WARNING SWITCH ASSY OK 3 CHECK MULTIPLEX NETWORK BODY ECU (a) B10 Disconnect the multiplex network body ECU B10 connector and inspect the body ECU B10-2 terminal. Standard: Tester Connection Condition Specified Condition B10-2 ⇔ Body ground Constant 12 - 14 V B61511 NG REPLACE MULTIPLEX NETWORK BODY ECU OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2148 05-1959 DIAGNOSTICS 4 - POWER DOOR LOCK CONTROL SYSTEM CHECK WIRE HARNESS (a) Wire Harness Side Disconnect the un-lock warning switch connector and inspect the connector on the wire harness side. Standard: Tester Connection Condition Specified Condition 2 ⇔ Body ground Constant 10 - 14 V 1 ⇔ Body ground Constant Continuity B51904 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 5 (a) CHECK DOOR OPEN WARNING LIGHT Check that the door open warning light will be on when the driver door is opened. OK REPLACE MULTIPLEX NETWORK BODY ECU NG 6 (a) INSPECT FRONT DOOR COURTESY LAMP SWITCH ASSY Inspect the door courtesy lamp switch continuity. Standard: Switch Position Specified Condition ON (switch pin released: opened door) Continuity OFF (switch pin pushed in: closed door) No continuity NG REPLACE FRONT DOOR COURTESY LAMP SWITCH ASSY OK REPAIR OR REPLACE WIRE HARNESS (COURTESY LIGHT SWITCH - BODY ECU) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2149 05-1937 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM 0526D-02 CUSTOMER PROBLEM ANALYSIS CHECK POWER DOOR LOCK CONTROL SYSTEM Check Sheet Inspector’s name: Registration No. Registration Year Customer’s Name Frame No. Date Vehicle Brought in / / / Date Problem First Occurred Frequency Problem Occurs Problem Symptom Weather Conditions When Problem Occurred km miles Odometer Reading  Constant  Once only /  Sometimes ( Times per day, month)  Fine  Cloudy  Rainy  Various/Others  Hot  Warm  Cool Outdoor temperature  Cold (Approx.
C (
F)) Weather  Snowy  Malfunction in Door Lock/Unlock Operation Using Door Lock Control Switch.  Driver side door lock control switch.  Driver side door  Passenger side door  Passenger side door key lock and unlock control switch.  Driver side door  Passenger side door  Malfunction in Door Lock/Unlock Operation Using Key.  Driver side door key lock and unlock control switch.  Driver side door  Passenger side door  Passenger side door key lock and unlock control switch.  Driver side door  Passenger side door  2-operation unlock function of driver side door key lock and unlock switch.  Malfunction in Key Lock-In Prevention Function.  Malfunction in Luggage Compartment Door Opener Function.  Others. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2127 05-1939 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM 0526F-02 DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the DTC check, check the circuit listed for that code in the table below (Proceed to the page given for that circuit.). DTC No. (See Page) Detection Item B1224/24 (05-1950 ) Open Door Warning Light
Power window regulator master switch assy (door ECU)
Front door lock assy RH (driver side)
Multiplex Network Body ECU Blinks Power window switch circuit on passenger door
Door control switch assy (passenger side)
Multiplex Network Body Body ECU Blinks Door lock switch circuit on passenger door
Door control switch assy (passenger side)
Front door lock assy RH (passenger side)
Multiplex Network Body Body ECU Blinks Door lock switch circuit on driver door B1222/22 (05-1944 ) B1223/23 (05-1948 ) Trouble Area 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2129 05-1935 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM 0526C-02 HOW TO PROCEED WITH TROUBLESHOOTING HINT: Troubleshoot in accordance with the procedure on the following pages. 1 VEHICLE BROUGHT TO WORKSHOP 2 SYMPTOM CHECK 3 INSPECT COMMUNICATION FUNCTION OF LARGE-SCALE MULTIPLEX COMMUNICATION SYSTEM (BEAN) (a) Check that there is no abnormality in the communication system by inspecting the communication function of the multiplex communication system with the hand-held tester. (1) (ECU unconnected, communication line abnormal) Without code output, proceed to A. (2) (ECU unconnected, communication line abnormal) With code output, proceed to B. B GO TO MULTIPLEX COMMUNICATION SECTION A 4 (a) DIAGNOSIS CODE CHECK (See page 05-1939 ) Check diagnosis code. (1) Without code output, proceed to A. (2) With code output, proceed to B. B GO TO DTC CHART (See page 05-1939 ) A 5 (a) (b) PROBLEM SYMPTOMS TABLE (See page 05-1943 ) Without applicable symptoms, proceed to A. With applicable symptoms, proceed to B. B GO TO SYMPTOMS TABLE A 6 (a) (b) PERFORM TROUBLESHOOTING IN THE FOLLOWING METHOD, DEPENDING ON MALFUNCTION SYMPTOM Pre-inspection (See page 05-1938 ) (1) Inspection with the hand-held tester (ECU DATA MONITOR) ECU terminal position 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2125 05-1936 DIAGNOSTICS 7 - POWER DOOR LOCK CONTROL SYSTEM ADJUSTMENT, REPAIR OR REPLACEMENT END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2126 05-1940 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM 0526G-01 LOCATION Multiplex Network Body ECU Door Control Switch Assy Power Window Regulator Master Switch Assy (Door ECU) Front Door Lock Assy RH Front Door Lock Assy LH Rear Door Lock Assy RH Front Door Courtesy Lamp Switch Assy Front Door Courtesy Lamp Switch Assy Back Door Lock Assy Rear Door Lock Assy LH B51123 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2130 05-1934 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM POWER DOOR LOCK CONTROL SYSTEM 0526B-01 PRECAUTION 1. (a) NOTICES OF REMOVAL AND INSTALLATION OPERATIONS Before performing operations related to the door lock and door lock cylinder, be sure to disconnect the battery terminal or the connector of the window regulator motor. CAUTION: If the operation is performed with the connectors being connected, the door control switch inside the door lock might be unexpectedly actuated, which results in injury. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2124 05-1938 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM 0526E-01 PRE-CHECK 1. USING HAND-HELD TESTER (a) Hook up the hand-held tester to the DLC3. (b) Monitor the ECU data by following the prompts on the tester screen. HINT: Hand-held tester has a ”Snapshot” function which records the monitored data. Refer to the hand-held tester operator’s manual for further details. 2. DTC CLEAR (a) The DTCs and freeze frame data will be erased by the hand-held tester to erase the codes. 3. DATA LIST HINT: According to the DATA LIST displayed by the OBD II scan tool or hand-held tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as a first step of troubleshooting is one of the method to shorten the labor time. (a) Connect the OBD II scan tool or hand-held tester to the DLC3. (b) Turn the ignition switch ON. (c) According to the display on tester, read the ”DATA LIST”. Standard (Body ECU): Item Measurement Item/ Display (Range) KEY SW Key unlock warning SW signal/ON or OFF Normal Condition Diagnostic Note ON: Key is IG key cylinder OFF: Key is not in IG key cylinder - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2128 05-1943 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM 0526I-03 PROBLEM SYMPTOMS TABLE Symptom Suspected Area See Page All doors are not operated by driver’s door key cylinder for interlocked with key 1. 2. 3. 4. Body ECU monitor code Front door lock assy RH (driver side) Wire harness Power window regulator master switch assy (Door ECU) 05-1954 Key confinement prevention function does not work properly (Manual operation and operation interlocked with key are active) 1. 2. 3. 4. Un-lock warning switch assy Wire harness Door open warning Light (built in combination meter) Front door courtesy lamp switch assy (driver side) 05-1957 Door lock system does not operate at all 1. Door 20 A fuse 2. Multiplex Network Body ECU 3. Wire harness 05-2046 Door lock system does not operate by manual switch 1. Power window regulator master switch assy (door ECU) (Door control switch for manual operation) 2. Multiplex Network Body ECU 3. Wire harness 05-2046 Fault in key confinement prevention operate 1. 2. 3. 4. 05-1957 Only one door lock does not operate 1. Door lock assy 2. Wire harness 73-3 Fault in 2-operation unlock function of driver side door key lock and unlock switch 1. 2. 3. 4. 73-3 Multiplex Network Body ECU Un-lock warning switch assy Front door courtesy lamp switch assy (driver side) Wire harness Door key lock and unlock switch circuit Power window regulator master switch assy (Door ECU) Multiplex Network Body ECU Wire harness 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2133 05-1941 DIAGNOSTICS - POWER DOOR LOCK CONTROL SYSTEM 0526H-04 TERMINALS OF ECU 1. (a) (b) POWER WINDOW REGULATOR MASTER SWITCH ASSY (DOOR ECU) Disconnect the master switch connector. Check the voltage or continuity of each terminal of the wire harness side connector. P5 B51555 Standard: Symbols (Terminal No.) Wiring Color SIG (P5-20) ⇔ GND (P5-2) R-L ⇔ W-B Ignition switch OFF → ON Condition 0 V → 10 - 14 V Specified Condition BDR (P5-10) ⇔ GND (P5-2) L-W ⇔ W-B Constant 10 - 14 V CPUB (P5-9) ⇔ GND (P5-2) W-L ⇔ W-B Constant 10 - 14 V KL (P5-4) ⇔ GND (P5-2) G ⇔ W-B Driver side door lock key cylinder OFF → LOCK 10 - 14 V → Below 0 V KUL (P5-14) ⇔ GND (P5-2) Y ⇔ W-B Driver side door lock key cylinder OFF → UNLOCK 10 - 14 V → Below 0 V LSW (P5-16) ⇔ GND (P5-2) BR ⇔ W-B Driver side door LOCK → UNLOCK 10 - 14 V → Below 0 V LSWE (P5-3) ⇔ GND (P5-2) LG ⇔ W-B Constant Continuity GND (P5-2) ⇔ Body ground W-B ⇔ - Constant Continuity If the result is not as specified, there may be a malfunction on the wire harness side. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2131 05-1942 DIAGNOSTICS 2. - POWER DOOR LOCK CONTROL SYSTEM BODY ECU B11 B12 B10 B9 B51569 (a) (b) Disconnect the body ECU connectors B12, B10 and B9. Check the voltage or continuity of each terminal of the wire harness side connector. Symbols (Terminal No.) BDR1 (B12-4) ⇔ Body ground IG (B9-5) ⇔ Body ground Wiring Color B⇔ BR ⇔ - Condition Specified Condition Constant 10 - 14 V Ignition switch OFF → ON 0 V → 10 - 14 V Constant Continuity GND1 (B12-7) ⇔ Body ground W-B ⇔ - KSW (B10-2) ⇔ Body ground G⇔- No key in the ignition key cylinder → With key No continuity → Continuity ACC (B9-17) ⇔ Body ground B⇔ - Ignition switch OFF → ON 0 V → 10 - 14 V BECU (B12-9) ⇔ Body ground G⇔- Constant 10 - 14 V (c) Reconnect the body ECU connectors, and check the voltage of each terminal of the connectors. Symbols (Terminal No.) Wiring Color Condition Specified Condition DCTY (B11-1 1) ⇔ Body ground B⇔- Driver door CLOSED → OPEN 10 - 14 V → Below 0 V KSW (B10-2) ⇔ Body ground G⇔ - No key in the ignition key cylinder → With key 10 - 14 V → Below 0 V ACT+ (B12-1) ⇔ Body ground L⇔- Master switch and driver’s door key cylinder OFF → LOCK 0 V → 10 - 14 V → 0 V PCTY (B12-16) ⇔ Body ground SB ⇔ - Passenger door CLOSED → OPEN 10 - 14 V → Below 0 V RCTY (B12-15) ⇔ Body ground LG ⇔ - Rear door (RH, LH) CLOSED → OPEN 10 - 14 V → Below 0 V ACT- (B12-6) ⇔ Body ground W⇔- Master switch and driver’s door key cylinder OFF → UNLOCK 0 V → 10 - 14 V → 0 V If the result is not as specified, there may be a malfunction on the wire harness side. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2132 05-1970 DIAGNOSTICS - WIRELESS DOOR LOCK CONTROL SYSTEM 0526W-03 ONLY WIRELESS CONTROL FUNCTION IS INOPERATIVE CIRCUIT DESCRIPTION The door control receiver receives a signal from transmitter and sends it to body ECU by line. And the body ECU transmits the signal to the door lock assembly to control the door lock/unlock operation. NOTICE: The wireless door lock control system has a function with a large-scale multiplex communication system. First of all, inspect the communication function depending on the ”HOW TO PROCEED WITH TROUBLESHOOTING”, and check that the communication system has no malfunction. Then finally proceed with the troubleshooting. Also, in case that the wire harness between the body ECU and door control receiver has been short-circuited, diagnostic code 42 will be output and the wireless control will not function. INSPECTION PROCEDURE HINT: The initial condition that the customizing function by the hand-held tester is not chosen is shown. 1. VEHICLE’S INITIAL CONDITION (CONDITION OF WIRELESS CONTROL POSSIBLE) (a) No key in the ignition key cylinder. (b) All doors closed (door open indicator off). (c) All doors locked. HINT: The switch described in this text is a LOCK/ UNLOCK switch for transmitting, and it is built in the door control transmitter. 1 CHECK TRANSMITTER BATTERY SIMPLY (a) Check that the LED of the transmitter lights up 3 times when the switch has been pressed 3 times. HINT: If the LED does not light up when the switch has been pressed 3 times or more, it may be caused by the dead battery. Replace the battery with a new or normal one, and then check that doors will be locked or unlocked by the standard operation. NOTICE: Standard operation means to press and hold the transmitter switch for 1 second, facing the transmitter to the vehicle, in 1 m (3.28 ft) away from the driver’s door outside handle in the right direction. NG REPLACE TRANSMITTER (LITHIUM) BATTERY OK 2 CONFIRM ROOM LAMP ON (a) Check that the room lamp comes on. HINT: When the lamp does not come on, proceed with the self-diagnostic mode after repairing the room lamp. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2160 05-1971 DIAGNOSTICS 3 - WIRELESS DOOR LOCK CONTROL SYSTEM ENTER INTO SELF-DIAGNOSTIC MODE (a) Enter into the self-diagnostic mode by operating the ignition switch lock cylinder. (1) Insert the key into the ignition switch lock cylinder under the vehicle’s initial condition, and then operate the ignition switch assembly OFF → ON → OFF once within 5 seconds after the key is pulled out. (2) Within 30 seconds after the ignition switch assembly is turned OFF, operate the ignition switch assembly OFF → ON → OFF 9 times. NOTICE: The mode returns to the normal mode if even one of the above conditions has not been met. HINT:
The operation of the ignition switch assembly OFF → ON will finish the self-diagnostic mode.
Do not carry out the lock/unlock operations during the self-diagnostic mode. (b) Check that the system has entered into the self-diagnostic mode by blinks of the room lamp. NG Go to step 8 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2161 05-1972 DIAGNOSTICS 4 (a) - WIRELESS DOOR LOCK CONTROL SYSTEM CHECK BY SELF-DIAGNOSTIC MODE Check the output of the DTC when the door control transmitter switch has been kept pressed (The DTC output can be checked by the output of the room lamp). HINT:
In case of a reception of the normal wave of the LOCK/UNLOCK switch (room lamp blinking) and no DTC outputs (room lamp off), go to step A. In case of discord of recognition code (room lamp on), go to step B.
Normal wave of lock and unlock switch is received Room Lamp Output ON OFF 0.25 sec. 0.5 sec. Discord of recognition code Room Lamp Output ON OFF Wave Receiving No DTC is output Room Lamp Output OFF B51906 B Go to step 7 A 5 (a) CHECK THE WAVE REACHING RANGE Check that the diagnosis will be output when a new or normal door control transmitter switch for a same type vehicle, has been pressed. OK REPLACE TRANSMITTER SUB-ASSY MODULE SET DOOR CONTROL NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2162 05-1973 DIAGNOSTICS 6 - WIRELESS DOOR LOCK CONTROL SYSTEM CHECK DOOR CONTROL RECEIVER (a) (b) (c) Wire Harness Side Door Control Receiver W6 Check the DOME fuse. Disconnect the W6 receiver connector. Check the voltage or continuity between the W6 receiver wire harness side connector and body ground. Standard: Terminal No. Specified condition 5 - Body ground 10 - 14 V 1 - Body ground Continuity B51930 NG REPAIR OR REPLACE FUSE HARNESS AND CONNECTOR OR WIRE OK REPLACE DOOR CONTROL RECEIVER 7 (a) RE-REGISTER RECOGNITION CODE OF TRANSMITTER Check if it is possible to enter into the rewrite mode or the add mode for the recognition code registration, and if a recognition code can be registered, as well. NG REPLACE MULTIPLEX NETWORK BODY ECU OK NORMAL (FUNCTION) 8 CONFIRM INPUT METHOD OF SELF-DIAGNOSTIC MODE NG Go to step 3 OK 9 INSPECT UN-LOCK WARNING SWITCH ASSY (See page 05-1957 ) NG REPLACE UN-LOCK WARNING SWITCH ASSY OK REPLACE MULTIPLEX NETWORK BODY ECU 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2163 05-1968 DIAGNOSTICS DTC 42 - WIRELESS DOOR LOCK CONTROL SYSTEM 0526V-05 WIRELESS DOOR LOCK RECEIVER CIRCUIT MALFUNCTIONS CIRCUIT DESCRIPTION The door control receiver locks the doors via the wireless control by receiving and sending input/output signals from the body ECU. DTC No. 42 DTC Detection Condition Trouble Area In diagnostic mode, reception of applicable RDA signal is impossible within 1 second after PRG signal has been output from body ECU.
Wireless door control receiver
Wire harness
Body ECU HINT: In this circuit, the diagnostic mode means that the door open indicator inside the meter will blink by turning the ignition switch ON after short-circuited between terminals 13 (TC) and 4 (CG) of the DLC3 by SST. WIRING DIAGRAM Body ECU W6 Door Control Receiver PRG W-B 1 E A +B J19 J/C A RDA BR Y IO2 15 3 SB GR IO2 14 J18 J/C 2 B 5 B11 PRG 17 B11 RDA 16 B D D A 10 IO2 R W-B W-B To Battery BB BF B74777 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2158 05-1969 DIAGNOSTICS - WIRELESS DOOR LOCK CONTROL SYSTEM INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (MULTIPLEX NETWORK BODY ECU ⇔ DOOR CONTROL RECEIVER) Wire Harness Side MULTIPLEX NETWORK BODY ECU (a) (b) (c) B11 (d) RDA PRG Door Control Receiver W6 5 4 3 2 1 PRG Disconnect the B11 ECU connector. Disconnect the W6 receiver connector. Check the continuity between the B11 ECU and W6 receiver wire harness side connectors. Standard (OPEN): Symbol (Terminal No.) Specified condition RDA (B11-16) ⇔ RDA (W6-2) Continuity PRG (B11-17) ⇔ PRG (W6-3) Continuity Check the continuity between the B11 ECU or W6 receiver wire harness side connectors and body ground. Standard (SHORT): Symbol (Terminal No.) Specified condition RDA (B11-16) or RDA (W6-2) ⇔ Body ground No continuity PRG (B11-17) or PRG (W6-3) ⇔ Body ground No continuity RDA B51905 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2 (a) (b) CHECK DOOR CONTROL RECEIVER Check that the wireless system operates when connected to a new or normal door control receiver. Check if no diagnosis has been output. Standard: No diagnosis has been output OK REPLACE DOOR CONTROL RECEIVER NG REPLACE MULTIPLEX NETWORK BODY ECU 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2159 05-1962 DIAGNOSTICS - WIRELESS DOOR LOCK CONTROL SYSTEM 0526P-03 CUSTOMER PROBLEM ANALYSIS CHECK WIRELESS DOOR LOCK CONTROL System Check Sheet Inspector’s Name Registration No. Customer’s Name Registration Year / / Frame No. / Date Vehicle Brought In / / Date Problem First Occurred Frequency Problem Occurs Weather Weather Conditions When Problem Occurred Outdoor Temperature Place km miles Odometer Reading / Constant Sometimes ( times/per day, month) Once only Fine Cloudy Rainy Snowy Various/Others Warm Hot Cold (Approx. °C ( Cool °F)) Specific Locality( Everywhere / Date Transmitter Battery Last Replaced ) / Whole wireless door lock control system does not operate. Problem Symptom Only door unlock operation is impossible. Only door lock operation is impossible. Only key confinement prevention function is impossible. Wireless door lock function operates even when each door is opened. Wireless door lock functions incorrectly. ( Although one door is unlocked, when the transmitter switch is pressed, all doors become unlocked.) When RH door is unlocked. When LH door is unlocked. Others 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2152 05-1964 DIAGNOSTICS - WIRELESS DOOR LOCK CONTROL SYSTEM 0526R-02 DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the DTC check, check the circuit listed for that code in the table below (Proceed to the page given for that circuit). DTC No. (See Page) 42 (05-1968 ) Detection Item Wireless door lock receiver circuit malfunctions Open Door Warning Light Trouble Area
Wire harness
Wireless door lock receiver
Body ECU Blinks 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2154 05-1960 DIAGNOSTICS - WIRELESS DOOR LOCK CONTROL SYSTEM WIRELESS DOOR LOCK CONTROL SYSTEM 0526O-02 HOW TO PROCEED WITH TROUBLESHOOTING HINT: Troubleshoot in accordance with the procedure on the following pages. 1 VEHICLE BROUGHT TO WORKSHOP 2 CUSTOMER PROBLEM ANALYSIS AND SYMPTOM CHECK (See page 05-1962 ) 3 INSPECT COMMUNICATION FUNCTION OF LARGE-SCALE MULTIPLEX COMMUNICATION SYSTEM (BEAN) (a) Check that there is no abnormality in the communication system by inspecting the communication function of the body multiplex communication system with the hand-held tester. (1) (ECU unconnected, communication line abnormal) Without code output, proceed to A. (2) (ECU unconnected, communication line abnormal) With code output, proceed to B. B GO TO BODY MULTIPLEX COMMUNICATION SECTION (See page 05-2040 ) A 4 (a) (b) (c) CHECK DIAGNOSTIC TROUBLE CODE (See page 05-1964 ) Check a DTC and note it down if a code is output. Delete the DTC. Check if the DTC will be output once again, when the problem symptom is simulated based on the noted code. (1) Without an output of the code, proceed to A. (2) With an output of the code, proceed to B. B Go to step 7 A 5 (a) (b) PROBLEM SYMPTOMS TABLE (See page 05-1967 ) Without applicable symptoms, proceed to A. With applicable symptoms, proceed to B. B Go to step 7 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2150 05-1961 DIAGNOSTICS 6 (a) - WIRELESS DOOR LOCK CONTROL SYSTEM PERFORM TROUBLESHOOTING IN THE FOLLOWING METHOD, DEPENDING ON MALFUNCTION SYMPTOM Pre-check (See page 05-1963 ). (1) Inspection with the hand-held tester (ECU DATA MONITOR). (2) Inspection with the hand-held tester (ACTIVE TEST). Terminals of ECU (See page 05-1966 ). (b) 7 ADJUSTMENT, REPAIR OR REPLACEMENT END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2151 05-1965 DIAGNOSTICS - WIRELESS DOOR LOCK CONTROL SYSTEM 0526S-02 LOCATION Multiplex Network Body ECU (Body ECU) Door Control Switch Assembly Power Window Regulator Master Switch Assembly Front Door Lock Assembly RH Front Door Lock Assembly LH Rear Door Lock Assembly RH Door Control Receiver Front Door Courtesy Lamp Switch Assembly Rear Door Courtesy Lamp Switch Assembly Front Door Courtesy Lamp Switch Assembly Back Door Lock Assembly Rear Door Courtesy Lamp Switch Assembly Rear Door Lock Assembly LH B51134 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2155 05-1963 DIAGNOSTICS - WIRELESS DOOR LOCK CONTROL SYSTEM 0526Q-03 PRE-CHECK 1. (a) (b) INSPECT WITH HAND-HELD TESTER ECU Data Monitor (MPX Body ECU) (1) The ECU data monitor will indicate if the part is normal or malfunction. Item Inspecting condition Standard value KEY SW Ignition ON → No key ON → OFF Customizing Function (reference) (1) The use of the hand-held tester makes it possible to select the following controls on the door lock. Item Setting Wireless door lock operation With/ Without function Automatic locking time 30 sec. / 60 sec. Room lamp on when door unlocked via wireless control With/ Without function Open door warning ON / OFF Alarm function ON / OFF 2 times operation wireless unlock ON / OFF Unlock with 2 times driver’s door key operation ON / OFF 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2153 05-1967 DIAGNOSTICS - WIRELESS DOOR LOCK CONTROL SYSTEM 0526U-02 PROBLEM SYMPTOMS TABLE Symptom All functions of wireless door lock control system are inoperative (only wireless control function is inoperative). Suspected Area 1. 2. 3. 4. 5. 6. 7. See page Transmitter battery Door control transmitter Door control receiver DOME fuse Body ECU Un-lock warning SW Wire harness 05-1970 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2157 05-1966 DIAGNOSTICS - WIRELESS DOOR LOCK CONTROL SYSTEM 0526T-04 TERMINALS OF ECU 1. CHECK MULTIPLEX NETWORK BODY ECU (BODY ECU) B12 B11 B10 B9 B61267 (a) Disconnect the B9, B10 and B12 ECU connectors, and check the voltage or continuity of each terminal of the wire harness side connector. Standard: Symbols (Terminals No.) Wiring color BDR1 (B12-4) ⇔ Body ground B⇔ - IG (B9-5) ⇔ Body ground BR⇔ - GND1 (B12-7) ⇔ Body ground W-B ⇔ - KSW (B10-2) ⇔ Body ground Condition Specified condition Constant 10 - 14 V Ignition switch OFF → ON 0 V → 10 - 14 V Constant Continuity G⇔ - No key in ignition key cylinder → With key No continuity → Continuity ACC (B9-17) ⇔ Body ground B⇔ - Ignition switch OFF → ON 0 V → 10 - 14 V BECU (B12-9) ⇔ Body ground G⇔ - Constant 10 - 14 V If the result is not as specified, there may be a malfunction the wire harness side. (b) Reconnect the B9, B10 and B12 ECU connectors, and check the voltage of each terminal of the connector. Standard: Symbols (Terminals No.) Wiring color DCTY (B11-1 1) ⇔ Body ground Condition Specified condition B⇔ - Driver’s door CLOSED → OPEN 10 - 14 V → Below 1 V KSW (B10-2) ⇔ Body ground G⇔ - No key in ignition key cylinder → With key 10 - 14 V → Below 1 V ACT+ (B12-1) ⇔ Body ground L⇔ - Master switch and driver’s door key cylinder OFF → LOCK 0 V → 10 - 14 V → 0 V PCTY (B12-16) ⇔ Body ground SB⇔ - Passenger’s door CLOSED → OPEN 10 - 14 V → Below 1 V RCTY (B12-15) ⇔ Body ground LG⇔ - Rear door (RH, LH) CLOSED → OPEN 10 - 14 V → Below 1 V ACT- (B12-6) ⇔ Body ground W⇔ - Master switch and driver’s door key cylinder OFF → UNLOCK 0 V → 10 - 14 V → 0 V If the result is not as specified, the theft warning ECU assy may malfunction. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2156 05-2051 DIAGNOSTICS DTC - MULTIPLEX COMMUNICATION SYSTEM 0523X-05 B1211/11 DRIVER DOOR ECU COMMUNICATION STOP CIRCUIT DESCRIPTION B1211/11 will be output when the communication between the power window regulator master switch assy (door ECU) and multiplex network body ECU stops for more than 10 seconds. DTC No. B1211/11 DTC Detection Condition Door ECU communication stop Trouble Area
Power window regulator master switch assy (door ECU)
Wire harness 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2241 05-2052 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM WIRING DIAGRAM B9 Multiplex Network Body ECU Engine Room J/B ECU-B 2I 1 2A 4 D.C.C W-L IC3 5 W Y Y V 1D Instrument Panel J/B 6 1K G 10 P5 Power Window BDR Regulator Master Switch Assy (Door ECU) B 3 BR IB1 3 1 1A IF3 5 BR 1G 10 8 IL1 FR Door MPX2 10 O IB2 1 IB2 2 L 9 GR 8 MPX2 2 GND CPUB MPX1 7 V W-B IB2 8 IB1 2 3 2 SB F7 FL Block Assy ALT W-B 4F 8 4L 7 Passenger Side J/B 1 4L 7 4A 5 W Passenger Side J/B BR S31 2 FL Main Short Connector W-B S30 2 BR 22 Battery A17 Airbag Sensor Assembly MPX2 IC H45686 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2242 05-2053 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 (a) CHECK CONTINUITY OF COMMUNICATION LINE Check the wire harness between the multiplex network body ECU, power window regulator master switch assy (door ECU) and airbag sensor assembly. Airbag Sensor Assembly A17 Power Window Regulator Master Switch Assy (Door ECU) Multiplex Network Body ECU P5 B9 H45693 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2243 05-2054 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM (1) (2) Disconnect the connectors of the master switch, body ECU and air conditioner amplifier. Check the continuity between terminal P5-8 (MPX2) of the master switch vehicle’s side connector and terminal B9-10 (MPX2) of the body ECU vehicle’s side connector. Standard: Continuity (3) Check the continuity between terminal P5-7 (MPX1) of the master switch vehicle’s side connector and terminal A17-22 (MPX2) of the airbag sensor assembly vehicle’s side connector. Standard: Continuity NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2 CHECK POWER WINDOW REGULATOR MASTER SWITCH ASSY (a) P5 Inspect the power window regulator master switch assy (door ECU) (power source input). (1) Disconnect the master switch connector. (2) Check the voltage of each terminal of the master switch vehicle’s side connector. B51827 Standard: Symbols (Terminal No.) Condition Specified Condition CPUB (P5-9) ⇔ Body ground Constant 10 - 14 V BDR (P5-10) ⇔ Body ground Constant 10 - 14 V NG REPAIR OR REPLACE FUSE HARNESS AND CONNECTOR OR WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2244 05-2055 DIAGNOSTICS 3 - MULTIPLEX COMMUNICATION SYSTEM CHECK POWER WINDOW REGULATOR MASTER SWITCH ASSY (a) P5 B51828 Inspect the power window regulator master switch assy (door ECU) P5-2 (GND). (1) Disconnect the master switch connector. (2) Check the continuity between terminal P5-2 (GND) of the master switch and the body ground. Standard: Continuity NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE POWER WINDOW REGULATOR MASTER SWITCH ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2245 05-2056 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM DTC B1214 DOOR SYSTEM COMMUNICATION BUS MALFUNCTION (+B SHORT) DTC B1215 DOOR SYSTEM COMMUNICATION BUS MALFUNCTION (GND SHORT) 0523Y-04 CIRCUIT DESCRIPTION B1214 and B1215 will be output when +B and body ground is short-circuited on the communication bus. Detecting this condition will make all the BEAN communication unable and output some DTCs. DTC No. B1214 B1215 DTC Detecting Condition Trouble Area Communication circuit and +B battery system short
Power window regulator master switch assy (door ECU)
ECM
Air conditioner amplifier assy (A/C ECU)
Combination meter assy (meter ECU)
Theft warning ECU assy (theft deterrent ECU)
Sliding roof drive gear sub-assy (sliding roof ECU)
Wire harness
Multiplex network body ECU Communication circuit and body ground short
Power window regulator master switch assy (door ECU)
ECM
Air conditioner amplifier assy (A/C ECU)
Combination meter assy (meter ECU)
Theft warning ECU assy (theft deterrent)
Sliding roof drive gear sub-assy (sliding roof ECU)
Wire harness
Multiplex network body ECU 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2246 05-2057 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM WIRING DIAGRAM Multiplex Network Body ECU MPX2 B9 10 MPX1 B10 6 O IF3 W 5 18 Y MPX1 E6 ECM IB2 1 GR MPX2 8 MPX2 MPX1 V 7 P5 Power Window Regulator Master Switch Assy (Door ECU) 29 GR GR GR IB2 8 IE1 6 IL2 1 SB Y SB 10 MPX1 7 4F Passenger Side J/B C12 9 MPX+ Combination Meter Assy 5 4A MPXC11 21 BR 2 S31 Short 1 Connector S20 Sub Assy (Sliding Roof ECU) Y 1 3E R Center J/B IL2 12 12 3J 5 3H G 2 A11 9 MPXA10 MPX+ Air Conditioner Amplifier Assy G V 31 MPX1 T4 Theft Warning ECU Assy (Theft deterrent ECU) B78727 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2247 05-2058 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 (a) CHECK DIAGNOSTIC TROUBLE CODE (A ECU) Check whether the output of the DTC will stop when the A ECU connector is disconnected. Multiplex Network Body ECU Communication Circuit Communication Circuit A ECU Communication Circuit Communication Circuit B ECU C ECU B61052 NOTICE: Disconnect the connectors in the operational sequence, and start the next operation after the connector is connected. HINT: In this case, the A ECU represents the power window regulator master switch assy (door ECU). Standard: The disconnected A ECU is abnormal when the output of the DTC stops. OK REPLACE A ECU NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2248 05-2059 DIAGNOSTICS 2 (a) - MULTIPLEX COMMUNICATION SYSTEM CHECK DIAGNOSTIC TROUBLE CODE (B ECU) Check whether the output of the DTC will stop when the B ECU connector is disconnected. Multiplex Network Body ECU Communication Circuit Communication Circuit A ECU Communication Circuit Communication Circuit B ECU C ECU B61053 NOTICE: Disconnect the connectors in the operational sequence, and start the next operation after the connector is connected. HINT: In this case, the B ECU represents the sliding roof drive gear sub-assy (sliding roof ECU), combination meter assy (meter ECU), air conditioner amplifier assy (A/C ECU) or theft warning ECU assy (theft deterrent). Standard: The disconnected B ECU or the wire harness between the A ECU and B ECU is abnormal when the output of the DTC stops. NG Go to step 4 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2249 05-2060 DIAGNOSTICS 3 (a) - MULTIPLEX COMMUNICATION SYSTEM CHECK WIRE HARNESS BETWEEN A ECU AND B ECU Inspect short-circuit in +B or body ground. Multiplex Network Body ECU Communication Circuit Communication Circuit A ECU Communication Circuit Communication Circuit B ECU C ECU B61054 (1) Check whether the DTC will be output when the A ECU connector is connected. NOTICE: Disconnect the connectors in the operational sequence, and start the next operation after the connector is connected. OK REPLACE B ECU NG REPAIR OR REPLACE WIRE BETWEEN A ECU AND B ECU HARNESS 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2250 05-2061 DIAGNOSTICS 4 (a) - MULTIPLEX COMMUNICATION SYSTEM CHECK DIAGNOSTIC TROUBLE CODE (C ECU) Check whether the output of the DTC will stop when the A ECU connector is connected and the C ECU connector is disconnected. Multiplex Network Body ECU Communication Circuit Communication Circuit Communication Circuit Communication Circuit B ECU C ECU A ECU B60307 NOTICE: Disconnect the connectors in the operational sequence, and start the next operation when the connector is connected. HINT: In this case, the C ECU represents the ECM. Standard: The disconnected C ECU or the wire harness between the B ECU and C ECU is abnormal when the output of the DTC stops. NG Go to step 6 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2251 05-2062 DIAGNOSTICS 5 (a) - MULTIPLEX COMMUNICATION SYSTEM CHECK WIRE HARNESS BETWEEN B ECU AND C ECU Inspect short-circuit in +B or body ground. Multiplex Network Body ECU Communication Circuit Communication Circuit Communication Circuit A ECU B ECU Communication Circuit C ECU B60306 (1) Check whether the DTC will be output when the B ECU connector is connected. NOTICE: Disconnect the connectors in the operational sequence, and start the next operation after the connector is connected. OK REPLACE C ECU NG REPAIR OR REPLACE WIRE BETWEEN B ECU AND C ECU HARNESS 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2252 05-2063 DIAGNOSTICS 6 (a) - MULTIPLEX COMMUNICATION SYSTEM CHECK WIRE HARNESS MPX BODY ECU AND A ECU OR C ECU Inspect short-circuit in +B or body ground. Multiplex Network Body ECU Communication Circuit Communication Circuit Communication Circuit A ECU B ECU Communication Circuit C ECU B60308 (1) (2) Disconnect the connectors of the A ECU and multiplex network body ECU. Inspect short-circuit in +B of the wire harness between the A ECU and multiplex network body ECU, and also in the body ground. Standard: 0 V when short-circuited in +B. No continuity between each ECU terminal and the body ground when short-circuited in the body ground. HINT: In this case, the A ECU represents the power window regulator master switch assy (door ECU). (3) Inspect short-circuit in +B of the wire harness between the C ECU and multiplex network body ECU, and also in the body ground. Standard: 0 V when short-circuited in +B. No continuity between each ECU terminal and the body ground when short-circuited in the body ground. HINT: In this case, the C ECU represents the ECM. NG REPAIR OR REPLACE WIRE HARNESS BETWEEN MPX BODY ECU AND A ECU OR C ECU OK REPLACE MULTIPLEX NETWORK BODY ECU 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2253 05-2064 DIAGNOSTICS DTC B1241 - MULTIPLEX COMMUNICATION SYSTEM 05DW8-02 BODY ECU SWITCH CIRCUIT DIAGNOSIS CIRCUIT DESCRIPTION These DTC notify how the switch works as follows: If the DTC is not output when operating the switch, switch contact has failed. If the DTC is output when not operating the switch, it means the switch is ON or stuck. When something wrong is found by this diagnosis, inspect each switch. Replace the switch if there is a problem or check the body ECU and wire harness. DTC No. B1241/41 DTC Detecting Condition
Driver seat belt buckle switch is OFF (fastened) or stuck
Light control switch is ON (TAIL) or stuck
Light control switch is ON (HEAD) or stuck Trouble Area
Driver seat belt buckle switch
Light control switch
Multiplex network body ECU
Wire harness HINT: Please refer to the pages listed below for switch inspection.
For the driver seat belt buckle switch, see page 05-1898 .
For the light control switch, see page 05-1586 . 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2254 05-2065 DIAGNOSTICS DTC B1261 - MULTIPLEX COMMUNICATION SYSTEM 0523Z-04 ECM (ENGINE ECU) COMMUNICATION STOP CIRCUIT DESCRIPTION B1261 will be output when the communication between the ECM and multiplex network body ECU stops for more than 10 seconds. DTC No. B1261 DTC Detecting Condition No communication from ECM for more than 10 seconds Trouble Area
ECM
Wire harness 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2255 05-2066 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM WIRING DIAGRAM B10 Multiplex Network Body ECU Engine Room J/B 1 EFI No.1 5 MPX1 EFI Relay 6 2 1 2I 5 2B 3 BR W P-L W 4 2B 7 2B W B-W IK2 10 IK2 11 4 2F W W-B W W ECM 3 E5 1 E5 2 E5 MPX1 BATT +B E1 1 13 IK3 F7 FL Block Assy *1 E9 1 *2 E7 1 +B2 MREL E5 8 3 18 E6 MPX2 E6 29 BR GR B GR GR W A A IE1 6 J2 J/C FL MAIN Y S20 Sliding Roof Contorl ECU Battery J7 J/C IL2 1 10 A MPX1 BR SB EE *1 2 ED * EH 9 MPX+ *1: 2AZ-FE *2: 3MZ-FE C12 Combination Meter Assy (Meter ECU) B78728 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2256 05-2067 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 (a) CHECK CONTINUITY OF COMMUNICATION LINE Check the wire harness between the combination meter assy (meter ECU), ECM and multiplex network body ECU ECM E6 E5 Combination Meter Assy (Meter ECU) Multiplex Network Body ECU B10 C12 H45688 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2257 05-2068 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM (1) (2) Disconnect the connectors of the meter assy, ECM and body ECU. Inspect the continuity between terminals E6-18 (MPX1) of the ECM vehicle’s side connector and B10-6 (MPX1) of the body ECU vehicle’s side connector. Standard: Symbols (Terminal No.) Specified Condition MPX1 (E6-18) ⇔ MPX1 (B10-6) (equipped with 1MZ-FE) Continuity MPX1 (E6-18) ⇔ MPX1 (B10-6) (equipped with 2AZ-FE) Continuity (3) Inspect the continuity between terminals E6-29 (MPX2) of the ECM vehicle’s side connector and C12-9 (MPX+) of the meter assy vehicle’s side connector. Standard: Symbols (Terminal No.) Specified Condition MPX2 (E6-29) ⇔ MPX+ (C12-9) (equipped with 1MZ-FE) Continuity MPX2 (E6-29) ⇔ MPX+ (C12-9) (equipped with 2AZ-FE) Continuity NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2 CHECK ECM (a) Inspect the ECM (power source input). NOTICE: Do not disconnect the ECM connector. The inspection should be started from the backside of the connector. E7 E9 E8 E5 E6 A53766 Standard: Symbols (Terminal No.) In/Output BATT (E5-3) ⇔ Body ground Input Constant Condition 9 - 14 V +B (E5-1) ⇔ Body ground Input Engine stopped, ignition switch ON 9 - 14 V +B2 (E5-2) ⇔ Body ground Input Engine stopped, ignition switch ON 9 - 14 V NG Specified Condition REPAIR OR REPLACE FUSE HARNESS AND CONNECTOR OR WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2258 05-2069 DIAGNOSTICS 3 - MULTIPLEX COMMUNICATION SYSTEM CHECK ECM (a) Inspect the ECM (body ground). NOTICE: Do not disconnect the ECM connector. The inspection should be started from the backside of the connector. (1) Inspect the continuity between each terminal of the ECM connector and the body ground. E7 E6 E9 E8 E5 A53766 Standard: Symbols (Terminal No.) In/Output E1 (E9-1 (*1), E7-1 (*2)) ⇔ Body ground Input Condition Constant Specified Condition Continuity (*1) : 2AZ-FE (*2) : 3MZ-FE NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE ECM 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2259 05-2070 DIAGNOSTICS DTC - MULTIPLEX COMMUNICATION SYSTEM 05240-05 B1262/62 A/C ECU COMMUNICATION STOP CIRCUIT DESCRIPTION B1262/62 will be output when the communication between the air conditioner amplifier assy (A/C ECU) and multiplex network body ECU stops for more than 10 seconds. DTC No. B1262/62 DTC Detecting Condition No communication from A/C ECU for more than 10 seconds Trouble Area
Air conditioner amplifier assy (A/C ECU)
Wire harness 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2260 05-2071 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM WIRING DIAGRAM P5 Power Window Regulator Master Switch Assy (Door ECU) MPX1 7 V IB2 8 SB W-L 7 4F Passenger Side J/B Engine Room J/B BR 2 S31 Short 1 Connector BR R 1 2I 10 1G W 3 F7 FL Block Assy 5 4A 5 IC3 D.C.C. ECU-B 4 2A Instrument Panel J/B Assy 2 1K IL2 12 Air conditioner Amplifier Assy (A/C ECU) G 2 A11 1 W W FL MAIN 12 A10 +B MPX+ 11 GND A10 W-B MPX9 A10 G Center J/B 12 3J Center J/B 3J 6 3F 13 1 3E Battery W-B Y IB 21 MPX- C11 Combination Meter Assy (Meter ECU) B78729 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2261 05-2072 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 (a) CHECK CONTINUITY OF COMMUNICATION LINE Inspect the wire harness between the combination meter assy (meter ECU), air conditioner amplifier assy (A/C ECU) and power window regulator master switch assy (door ECU). Air Conditioner Amplifier Assy (A/C ECU) A11 A10 Combination Meter Assy (Meter ECU) C11 Power Window Regulator Master Switch Assy (Door ECU) P5 B51594 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2262 05-2073 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM (1) (2) Disconnect the connectors of the air conditioner amplifier, master switch and meter assy. Inspect the continuity between terminal A10-9 (MPX-) of the air conditioner amplifier vehicle’s side connector and terminal C11-21 (MPX-) of the meter assy vehicle’s side connector. Standard: Continuity (3) Inspect the continuity between terminal A11-2 (MPX+) of the air conditioner amplifier vehicle’s side connector and terminal P5-7 (MPX1) of the master switch. Standard: Continuity NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2 (a) CHECK AIRCONDITIONER AMPLIFIER ASSY Inspect the air conditioner amplifier assy (A/C ECU) (power source input). A10 B51596 (1) (2) Disconnect the air conditioner amplifier connector A10. Inspect the voltage between terminal A10-12 (+B) of the vehicle’s side connector and the body ground. Standard: 10 - 14 V NG REPAIR OR REPLACE FUSE HARNESS AND CONNECTOR OR WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2263 05-2074 DIAGNOSTICS 3 (a) - MULTIPLEX COMMUNICATION SYSTEM CHECK AIRCONDITIONER AMPLIFIER ASSY Inspect the air conditioner amplifier assy (A/C ECU) (body ground). A10 B51837 (1) (2) Disconnect the air conditioner amplifier connector A10. Inspect the continuity between terminal A10-11 (GND) of the vehicle’s side connector and the body ground. Standard: Continuity NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE AIRCONDITIONER AMPLIFIER ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2264 05-2075 DIAGNOSTICS DTC - MULTIPLEX COMMUNICATION SYSTEM 05241-06 B1269/69 THEFT DETERRENT ECU COMMUNICATION STOP CIRCUIT DESCRIPTION B1269/69 will be output when the communication between the theft warning ECU assy (theft deterrent ECU) and multiplex network body ECU stops for more than 10 seconds. DTC No. B1269/69 DTC Detecting Condition Trouble Area No communication from theft deterrent ECU for more than 10 seconds
Theft warning ECU assy (theft deterrent ECU)
Wire harness 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2265 05-2076 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM WIRING DIAGRAM T4 Theft Warning ECU Assy (Theft Deterrent ECU) 4 IC3 L Instrument Panel J/B 10 9 1G 1D BR 2 IF1 W J17 J/C 3 +B2 E P E L P E 11 IL1 O 2 29 +B1 MPX1 31 IC3 5 W-L 2A 4 2A 5 V W-B 5 3H 5 3D 13 3F Center J/B ECU-B Engine Room J/B SECURITY D.C.C. 1 2I W 3 F7 FL Block Assy 3E 3J 1 12 Y C11 21 MPXCombination Meter W-B G 1 W FL Main A10 Air Conditioner Amplifier Assy (A/C ECU) Battery 9 MPX- IB H45692 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2266 05-2077 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 (a) CHECK CONTINUITY OF COMMUNICATION LINE Check the wire harness between the combination meter, theft warning ECU assy (theft deterrent ECU) and airconditioner amplifier assy (A/C ECU). Theft Warning ECU Assy (Theft Deterrent ECU) T4 Air Conditioner Amplifier Assy (A/C ECU) A10 Combination Meter C11 H45691 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2267 05-2078 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM (1) (2) Disconnect the connectors of the theft warning ECU, master switch and air conditioner amplifier. Check the continuity between terminal T4-31 (MPX1) of the theft warning ECU vehicle’s side connector and terminal C11-21 (MPX-) of the master switch vehicle’s side connector. (3) Check the continuity between terminal T4-31 (MPX1) of the theft warning ECU vehicle’s side connector and terminal A10-9 (MPX-) of the air conditioner amplifier vehicle’s side connector. Standard: Continuity NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2 (a) CHECK THEFT WARNING ECU ASSY Inspect the theft warning ECU assy (theft deterrent ECU) (power source input). (1) Disconnect the theft warning ECU connector. (2) Check the voltage between terminal T4-2 (+B1) and T4-8 (+B2) of the theft warning ECU and the body ground. Standard: 10 - 14 V 4 T4 B50657 NG REPAIR OR REPLACE FUSE HARNESS AND CONNECTOR OR WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2268 05-2079 DIAGNOSTICS 3 (a) - MULTIPLEX COMMUNICATION SYSTEM CHECK THEFT WARNING ECU ASSY Inspect the theft warning ECU assy (theft deterrent ECU) (body ground). (1) Disconnect the theft warning ECU connector. (2) Check the continuity between terminal T4-29 (E) of the theft warning ECU vehicle’s side connector and the body ground. Standard: Continuity T4 B50657 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE THEFT WARNING ECU ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2269 05-2080 DIAGNOSTICS DTC B1271 - MULTIPLEX COMMUNICATION SYSTEM 05242-04 COMBINATION METER ECU COMMUNICATION STOP CIRCUIT DESCRIPTION B1271 will be output when the communication between the combination meter assy (meter ECU) and multiplex network body ECU stops for more than 10 seconds. DTC No. B1271 DTC Detecting Condition No communication from meter ECU for more than 10 seconds Trouble Area
Combination meter assy (meter ECU)
Wire harness 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2270 05-2081 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM WIRING DIAGRAM F7 FL Block Assy Engine Room J/B 1 2I D.C.C. W W 3 FL Main 1 ECM DOME ECU-B Battery MPX2 E6 29 3 2A 4 2A GR W-L IC3 5 1 IL2 BR 10 1G 1 Instrument Panel J/B SB Combination Meter Assy (Meter ECU) 9 C12 2 MPX+ C11 B 1K L-G 22 E2 C11 12 C11 B1 V R W-B MPX21 C11 3 3D 10 3E Center J/B 9 3F 1 L-G Center J/B Y 3E Center J/B IL2 11 V 11 4D 12 3J 13 3F W-B IB G 6 4H V IK3 12 Air Conditioner Amplifer Assy (A/C ECU) 9 A10 MPX- B78731 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2271 05-2082 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 (a) CHECK CONTINUITY OF COMMUNICATION LINE Inspect the wire harness between the ECM, combination meter assy (meter ECU) and air conditioner amplifier assy (A/C ECU). ECM Combination Meter Assy (Meter ECU) E6 E5 Air Conditioner Amplifier Assy (A/C ECU) C12 A10 C11 H45689 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2272 05-2083 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM (1) (2) Disconnect the connectors of the meter assy, ECM and air conditioner amplifier. Inspect the continuity between terminal C12-9 (MPX+) of the meter assy vehicle’s side connector and terminal E6-29 (MPX2) of the ECM vehicle’s side connector. Standard: Symbols (Terminal No.) Specified Condition MPX+ (C12-9) ⇔ MPX2 (E6-29) (equipped with 1MZ-FE) Continuity MPX+ (C12-9) ⇔ MPX2 (E6-29) (equipped with 2AZ-FE) Continuity (3) Inspect the continuity between terminal C11-21 (MPX-) of the meter assy vehicle’s side connector and terminal A10-9 (MPX-) of the air conditioner amplifier vehicle’s side connector. Standard: Continuity NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2 (a) CHECK COMBINATION METER ASSY Inspect the combination meter assy (meter ECU) (power source input). C11 B51838 (1) Disconnect the meter assy connector C11. (2) Inspect the voltage of each terminal of the vehicle’s side connector. Standard: Symbols (Terminal No.) Condition Specified Condition B (C11-2) ⇔ Body ground Constant 10 - 14 V B1 (C11-12) ⇔ Body ground Constant 10 - 14 V HINT: If the value is not as specified, there may be a malfunction in the vehicle’s side connector. NG REPAIR OR REPLACE FUSE HARNESS AND CONNECTOR OR WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2273 05-2084 DIAGNOSTICS 3 (a) - MULTIPLEX COMMUNICATION SYSTEM CHECK COMBINATION METER ASSY Inspect the combination meter assy (meter ECU) (body ground). C11 B51839 (1) (2) Disconnect the meter assy connector C11. Inspect the continuity between terminal C11-22 (E2) of the vehicle’s side connector and the body ground. Standard: Continuity NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE COMBINATION METER ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2274 05-2085 DIAGNOSTICS DTC - MULTIPLEX COMMUNICATION SYSTEM 05243-03 B1273/73 SLIDING ROOF ECU COMMUNICATION STOP CIRCUIT DESCRIPTION B1273/73 will be output when the communication between the sliding roof drive gear sub-assy (sliding roof ECU) and the MPX body ECU stops for more than 10 seconds. DTC No. DTC Detecting Condition Trouble Area B1273/73 No communication from sliding roof ECU for more than 10 seconds
Sliding roof drive gear sub-assy (sliding roof ECU)
Wire harness 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2275 05-2086 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM WIRING DIAGRAM S20 Sliding Roof Drive Gear Sub-assy (Sliding Roof ECU) 2 IE1 L 1 E B MPX1 W-B 7 10 W IE1 8 Y W-B Passenger Side J/ B 1H S/ROOF 8 IE1 6 5 4D Instrument Panel J/B GR 1 1A 6 4M B GR GR 2 F7 FL Block Assy 1 IL2 FL Main 1 W-B Instrument Panel J/B Assy W-B 1 4N W-B 4 1E 29 MPX2 Battery W-B IA C12 Combination Meter (Meter ECU) 4L 14 1D SB 9 MPX+ 7 IC E6 ECM H45687 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2276 05-2087 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 (a) CHECK CONTINUITY OF COMMUNICATION LINE Inspect the wire harness between the ECM, sliding roof drive gear sub-assy (sliding roof ECU) and combination meter assy (meter ECU). ECM E6 Combination Meter Assy (Meter ECU) Sliding Roof Drive Gear Sub-Assy (Sliding Roof ECU) C12 S20 H45690 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2277 05-2088 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM (1) (2) Disconnect the connectors of the sliding roof ECU, ECM and meter assy. Inspect the continuity between terminal S20-10 (MPX1) of the sliding roof ECU vehicle’s side connector and terminal E6-29 (MPX2) of the ECM vehicle’s side connector. Standard: Symbols (Terminal No.) Specified Condition MPX1 (S20-10) ⇔ MPX2 (E6-29) (equipped with 1MZ-FE) Continuity MPX1 (S20-10) ⇔ MPX2 (E6-29) (equipped with 2AZ-FE) Continuity (3) Inspect the continuity between terminal S20-10 (MPX1) of the sliding roof ECU vehicle’s side connector and terminal C12-9 (MPX+) of the meter assy vehicle’s side connector. Standard: Continuity NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2 CHECK SLIDING ROOF DRIVE GEAR SUB-ASSY (a) S20 Inspect the sliding roof drive gear sub-assy (sliding roof ECU). (1) Disconnect the sliding roof ECU connector. (2) Inspect the voltage of each terminal of the vehicle’s side connector. B51840 Standard: Symbols (Terminal No.) B (S20-1) ⇔ Body ground Condition Specified Condition Constant 10 - 14 V NG REPAIR OR REPLACE FUSE HARNESS AND CONNECTOR OR WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2278 05-2089 DIAGNOSTICS 3 - MULTIPLEX COMMUNICATION SYSTEM CHECK SLIDING ROOF DRIVE GEAR SUB-ASSY (a) S20 Inspect the sliding roof drive gear sub-assy (sliding roof ECU). (1) Disconnect the sliding roof ECU connector. (2) Inspect the voltage of each terminal of the vehicle’s side connector. B51841 Standard: Symbols (Terminal No.) E (S20-7) ⇔ Body ground Condition Specified Condition Constant Continuity NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE SLIDING ROOF DRIVE GEAR SUB-ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2279 05-2044 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM 0523T-05 DIAGNOSTIC TROUBLE CODE CHART 1. BODY ECU DIAGNOSTIC TROUBLE CODE DTC Code Lamp Code Diagnostic Item Diagnostic Result B1200 Normal code Normal Normal B1211 11 Power window regulator master switch assy (door ECU) communication stop No communication from door ECU for more than 10 seconds B1214 - Communication bus +B battery system short Communication circuit and +B battery system short B1215 - Communication bus (body ground) short Communication bus and body ground short B1241 41 Body ECU switch circuit diagnosis Switch is ON or stuck B1261 - ECM communication stop No communication from ECM for more than 10 seconds B1262 62 Airconditioner amplifier assy (A/C ECU) communication stop No communication from A/C ECU for more than 10 seconds B1269 69 Theft warning ECU assy (theft deterrent ECU) communication stop No communication from theft warning ECU for more than 10 seconds B1271 - Combination meter assy (meter ECU) communication stop No communication from meter ECU for more than 10 seconds B1273 73 Sliding roof drive gear sub-assy (sliding roof ECU) communication stop No communication from sliding roof ECU for more then 10 seconds 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2234 05-2040 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM MULTIPLEX COMMUNICATION SYSTEM 0523R-05 HOW TO PROCEED WITH TROUBLESHOOTING HINT: Troubleshoot in accordance with the procedure on the following pages. 1 VEHICLE BROUGHT TO WORKSHOP 2 SYMPTOM CHECK 3 INSPECT COMMUNICATION FUNCTION OF LARGE-SCALE MULTIPLEX COMMUNICATION SYSTEM (BEAN) (a) Check that there is no abnormality in the communication system by inspecting the communication function of the multiplex communication system with the hand-held tester. (1) (ECU communication stop, communication line abnormal) With code output, proceed to A. (2) (ECU communication stop, communication line abnormal) Without code output, proceed to B. B GO TO SECTION OF EACH SYSTEM A 4 (a) (b) (c) DIAGNOSTIC TROUBLE CODE CHECK (See page 05-2044 ) Check a DTC and note it if a code is output. Delete the DTC. Check if the DTC will be output once again, when the problem symptom is simulated based on the noted code. (1) When no code is output (symptom check and simulation is possible), proceed to A. (2) When no code is output (symptom check and simulation is impossible), proceed to B. (3) When the code is output, proceed to C. B GO TO PROBLEM SIMULATION (See page 01-26 ) C Go to step 7 A 5 (a) (b) PROBLEM SYMPTOMS TABLE (See page 05-2050 ) Without applicable symptoms, proceed to A. With applicable symptoms, proceed to B. B Go to step 7 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2230 05-2041 DIAGNOSTICS 6 (a) (b) - MULTIPLEX COMMUNICATION SYSTEM PERFORM TROUBLESHOOTING IN THE FOLLOWING METHOD, DEPENDING ON MALFUNCTION SYMPTOM Pre-check (See page 05-2042 ) Terminals of ECU (See page 05-2046 ) 7 ADJUSTMENT, REPAIR OR REPLACEMENT END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2231 05-2045 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM 0523U-04 LOCATION Sliding Roof Drive Gear Sub-Assy (Sliding Roof ECU) Theft Warning ECU Assy (Theft Deterrent ECU) ECM Combination Meter Assy (Meter ECU) Multiplex Network Body ECU Power Window Regulator Master Switch Assy (Door ECU) Airconditioner Amplifier Assy (A/C ECU) B51250 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2235 05-2042 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM 0523S-03 PRE-CHECK 1. (a) MULTIPLEX COMMUNICATION SYSTEM (BEAN) The BEAN communication line is used for the body, meters and air conditioning controls. Since the line is loop-shaped, the communication can be kept by the line that is not open even if a part of the line becomes open for some reasons. In case that the line becomes short (bus-down) for some reasons, however, all the BEAN communication will be impossible and some DTC will be output. HINT: When a bus-down occurs, the communication from the related ECU will stop. Therefore, an outputs of a DTC will be impossible. So, perform a DTC (SAE code) inspection with the hand-held tester. 2. COMMUNICATION FUNCTION INSPECTION (a) Inspect the battery positive voltage. Standard: 10 - 14 V (b) Perform a DTC check of the body ECU by connecting the hand-held tester to the DLC3 and turning the ignition switch ON. (1) Check that the DTCs of the ECU unconnected and also a short-circuit in the communication bus are not output. 3. INSPECT OUTPUT OF DTC BY DOOR OPEN INDICATOR (a) Inspect the battery positive voltage. Standard: 10 - 14 V (when engine stopped) (b) Check the DTC output. NOTICE: No abnormality exists in all the following items; door open indicator LED, wire harness, courtesy lamp switch’s contact condition, multiplex network body ECU, etc. (1) Check that the door open indicator will be on when any of the doors is opened. HINT: In case that the indicator will not be on, the following problems are possible reasons; door open indicator LED defective, wire harness short, courtesy light switch’s contact condition defective, multiplex network body ECU defective, etc. (2) Using SST (diagnosis check wire), make a shortcircuit between terminals TC (13) and CG (4) of the DLC3 connector. SST 09843-18040 NOTICE: Do not make a short-circuit in any other positions. DLC3 TC CG B61051 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2232 05-2043 DIAGNOSTICS (3) - MULTIPLEX COMMUNICATION SYSTEM Turn the ignition (starter) switch ON and read the number of blinks of the door open indicator. HINT: When 2 or more codes are output simultaneously, the display will be started from the smallest numbered code. Normal output (DTC not output) Repeated DTCs 11 and 41 output ON OFF 1.0 sec. 0.5 sec. 2.5 sec. 0.5 sec. 4.5 sec. 1.5 sec. B51822 (4) When the DTC of the ECU unconnected is displayed, perform an inspection depending on the troubleshooting. HINT:



4. (a) (b) When the communication bus is defective, the door open indicator in the meter will not be on. Therefore no DTC will be output. When other DTCs are output, refer to the DTC chart and applicable section. When no normal output is output even in the normal condition, problems, such as a short-circuit between terminals TC and CG, meter fuses defective, etc., may exist. When the door open indicator is always on, the wire harness might be short-circuited. INSPECT OUTPUT OF DTC WITH HAND-HELD TESTER Inspect the battery positive voltage. Standard: 10 - 14 V Inspect the DTC monitor code output. (1) Connect the hand-held tester to the DLC3 and turn the ignition (starter) switch ON, then check the DTC. HINT: When the DTC check is impossible, check the following items.
ECU data monitor is possible (multiplex network body ECU is defective).
The display shows a communication error (refer to the new diagnostic system and operations when an error occurred). (See page 01-26 ) (2) When the display shows DTCs that the ECU is unconnected and the communication bus is defective, perform an inspection depending on the troubleshooting. HINT: When other DTCs are output, refer to the DTC chart and applicable section. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2233 05-2050 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM 0523W-04 PROBLEM SYMPTOMS TABLE 1. TROUBLESHOOTING FOR EACH PROBLEM SYMPTOM NOTICE: Confirm the problem symptom and make an inspection depending on the applicable flow chart. Problem Symptom Suspected Area See Page B1211/11 (no communication from driver door ECU for more than 10 seconds) 1. Power window regulator master switch assembly 2. Wire harness 05-2051 05-2051 B1214 (short in communication circuit and +B power source system) 1. 2. 3. 4. 5. 6. 7. 8. Power window regulator master switch assembly ECM Air conditioning amplifier assembly Combination meter assembly Theft warning ECU Sliding roof drive gear Wire harness MPX body ECU 05-2056 05-2056 05-2056 05-2056 05-2056 05-2056 05-2056 05-2056 B1215 (short in communication circuit and body ground) 1. 2. 3. 4. 5. 6. 7. 8. Power window regulator master switch assembly ECM Air conditioning amplifier assembly Combination meter assembly Theft warning ECU Sliding roof drive gear Wire harness MPX body ECU 05-2056 05-2056 05-2056 05-2056 05-2056 05-2056 05-2056 05-2056 B1261 (no communication from ECM for more than 10 seconds) 1. ECM 2. Wire harness 05-2065 05-2065 B1262/62 (no communication from A/C ECU for more than 10 seconds) 1. Air conditioning amplifier assembly 2. Wire harness 05-2070 05-2070 B1269/69 (no communication from theft deterrent ECU for more than 10 seconds) 1. Theft warning ECU 2. Wire harness 05-2075 05-2075 B1271 (no communication from combination meter ECU for more than 10 seconds) 1. Combination meter assembly 2. Wire harness 05-2080 05-2080 B1273/73 (no communication from sliding roof control ECU for more than 10 seconds) 1. Sliding roof drive gear 2. Wire harness 05-2085 05-2085 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2240 05-2046 DIAGNOSTICS - MULTIPLEX COMMUNICATION SYSTEM 0523V-05 TERMINALS OF ECU 1. (a) MULTIPLEX NETWORK BODY ECU Check the body ECU. (1) Disconnect the body ECU connectors B9 and B12. (2) Check the voltage or continuity of each terminal of the vehicle’s side connectors. B11 B12 B9 B10 B51823 Standard: Symbols (Terminal No.) Wiring Color GND1 (B12-7) ⇔ Body ground W-B ⇔ - Constant Condition Continuity Specified Condition GND2 (B9-2) ⇔ Body ground W-B ⇔ - Constant Continuity BECU (B12-9) ⇔ GND1 (B12-7) G ⇔ W-B Constant 10 - 14 V BDR1 (B12-4) ⇔ GND1 (B12-7) B ⇔ W-B Constant 10 - 14 V HINT: If the value is not as specified, the vehicle’s side may be defective. 2. P5 (a) POWER WINDOW REGULATOR MASTER SWITCH ASSY (DOOR ECU) Check the master switch. (1) Disconnect the master switch connector. (2) Check the voltage or continuity of each terminal of the vehicle’s side connector. B51239 Standard: Symbols (Terminal No.) Wiring Color Condition Specified Condition GND (P5-2) ⇔ Body ground W-B ⇔ - Constant Continuity CPUB (P5-9) ⇔ GND (P5-2) L ⇔ W-B Constant 10 - 14 V BDR (P5-10) ⇔ GND (P5-2) G ⇔ W-B Constant 10 - 14 V HINT: If the value is not as specified, the vehicle’s side may be defective. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2236 05-2047 DIAGNOSTICS 3. (a) - MULTIPLEX COMMUNICATION SYSTEM COMBINATION METER ASSY (METER ECU) Check the meter. (1) Disconnect the meter connector C11. (2) Check the voltage or continuity of each terminal of the vehicle’s side connector. C12 C11 B51824 Standard: Symbols (Terminal No.) Wiring Color E2 (C11-22) ⇔ Body ground W-B ⇔ - Constant Condition Continuity Specified Condition B (C11-2) ⇔ E2 (C11-22) LG ⇔ W-B Constant 10 - 14 V B2 (C11-12) ⇔ E2 (C11-22) V ⇔ W-B Constant 10 - 14 V HINT: If the value is not as specified, the vehicle’s side may be defective. 4. AIR CONDITIONER AMPLIFIER ASSY (A/C ECU) (a) Check the air conditioner amplifier. (1) Disconnect the air conditioner amplifier connector A10. (2) Check the voltage or continuity of each terminal of the vehicle’s side connector. A11 A10 B51825 Standard: Symbols (Terminal No.) Wiring Color GND (A10-11) ⇔ Body ground W-B ⇔ - Constant Condition Continuity Specified Condition +B (A10-12) ⇔ GND (A10-11) W ⇔ W-B Constant 10 - 14 V HINT: If the value is not as specified, the vehicle’s side may be defective. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2237 05-2048 DIAGNOSTICS 5. (a) - MULTIPLEX COMMUNICATION SYSTEM THEFT WARNING ECU ASSY (THEFT DETERRENT ECU) Check the theft warning ECU. (1) Disconnect the connector. (2) Check the voltage or continuity of each terminal of the vehicle’s side connector. T4 B50657 Standard: Symbols (Terminal No.) Wiring Color E (T4-29) ⇔ Body ground W-B ⇔ - Constant Condition Continuity Specified Condition +B1 (T4-2) ⇔ E (T4-29) O ⇔ W-B Constant 10 - 14 V +B2 (T4-3) ⇔ E (T4-29) L ⇔ W-B Constant 10 - 14 V 6. (a) ECM Inspect the ECM operation. (1) Check the voltage or continuity of each terminal of the vehicle’s side connectors. NOTICE:
The inspection should be started from the back side of the connector with the ECM connector being connected.
Before the measurement, check the power source voltage (10 - 14 V when IG ON) and body ground (5 Ω or less between each ground terminal and the engine body, when IG OFF). E7 E9 E8 E6 E5 A53766 Standard: Symbols (Terminal No.) Wiring Color BATT (E5-3) ⇔ E1 (E9-1(*1)) BR ⇔ BR Constant 9 - 14 V +B (E5-1) ⇔ E1 (E7-1(*2)) W ⇔ BR Engine stopped, ignition switch ON 9 - 14 V +B2 (E5-2) ⇔ E1 (E9-1(*1), E7-1(*2)) W ⇔ BR Engine stopped, ignition switch ON 9 - 14 V E1 ⇔ Body ground E7 (E7-1)*2 ⇔ Body ground BR ⇔ - Continuity Constant (E9-1)*1 Condition Specified Condition *1:2AZ-FE *2:3MZ-FE 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2238 05-2049 DIAGNOSTICS 7. S20 (a) - MULTIPLEX COMMUNICATION SYSTEM SLIDING ROOF DRIVE GEAR SUB-ASSY (SLIDING ROOF ECU) Check the sliding roof ECU. (1) Disconnect the sliding roof ECU connector. (2) Check the voltage or continuity between each terminal of the vehicle’s side connectors. B51247 Standard: Symbols (Terminal No.) Wiring Color E (S20-7) ⇔ Body ground W-B ⇔ - Constant Condition Continuity Specified Condition B (S20-1) ⇔ E (S20-7) L ⇔ W-B Constant 10 - 14 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2239 05-1912 DIAGNOSTICS DTC - POWER WINDOW CONTROL SYSTEM 0523I-02 B1221/21 POWER WINDOW SWITCH CIRCUIT ON DRIVER DOOR CIRCUIT DESCRIPTION This DTC is output when any switch of the power window regulator master switch assy (door ECU) is ON. DTC No. B1221/21 DTC Detecting Condition Trouble Area Any switch of the power window regulator master switch is ON Power window regulator master switch assy (door ECU) INSPECTION PROCEDURE 1 (a) CHECK POWER WINDOW REGULATOR MASTER SWITCH ASSY Check if code B1221/21 will disappear but only B1211/11 (communication stop) will be output when the master switch connector is disconnected. (1) B1221/21 code output, proceed to A. (2) B1211/11 code output, proceed to B. B REPLACE POWER WINDOW MASTER SWITCH ASSY REGULATOR A REPLACE MULTIPLEX NETWORK BODY ECU 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2102 05-1913 DIAGNOSTICS - POWER WINDOW CONTROL SYSTEM 0523H-03 DTC B1231/31 JAM PROTECTION LIMIT SWITCH CIRCUIT ON DRIVER DOOR DTC B1232/32 JAM PROTECTION PULSE SWITCH CIRCUIT ON DRIVER DOOR CIRCUIT DESCRIPTION This DTC is output when the power window regulator motor assy malfunctions. DTC No. DTC Detecting Condition B1231/31 Open in power window regulator motor assy LH limit switch system
Power window regulator motor assy LH
Wire harness Trouble Area B1232/32 Open or short in power window regulator motor assy LH pulse sensor system
Power window regulator motor assy LH
Wire harness WIRING DIAGRAM P5 Power Window Regulator Master Switch Assy (Door ECU) P6 Power Window Regulator Motor Assy Front LH PLS 6 W 15 LMT 2 O 5 E 3 R 13 PLS LMT SGND B60591 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2103 05-1914 DIAGNOSTICS - POWER WINDOW CONTROL SYSTEM INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (a) Power Window Regulator Master Switch Assy (Door ECU) (b) Power Window Regulator Motor Assy LH Disconnect the connectors of the power window regulator master switch assy and power window regulator motor assy LH. Check the continuity between the master switch and regulator motor. Standard: Item Symbols (Terminal No.) Master switch ⇔ Regulator motor Specified Condition Limit switch LMT (5) ⇔ LMT (2) SGND (13) ⇔ E (3) Continuity Pulse sensor PLS (15) ⇔ PLS (6) SGND (13) ⇔ E (3) Continuity NG B51843 REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE POWER WINDOW REGULATOR MOTOR ASSY LH (DRIVER SIDE) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2104 05-1929 DIAGNOSTICS - POWER WINDOW CONTROL SYSTEM 0523N-06 REMOTE OPERATION VIA MASTER SWITCH IS IMPOSSIBLE IN THE OTHER DOOR (OPERATION VIA EACH DOOR SWITCH IS POSSIBLE) CIRCUIT DESCRIPTION When the ignition switch is ON, the master switch (door ECU) sends a remote switch signal for the other seats multiply to the body ECU, then the body ECU drives the power window motor for the other seats. NOTICE: The power window system has a function with a large-scale multiplex communications. First of all, inspect the communication function depending on the ”how to proceed with troubleshooting”, and check that there is no abnormality in the communication system. Then finally proceed with the troubleshooting. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2119 05-1930 DIAGNOSTICS - POWER WINDOW CONTROL SYSTEM WIRING DIAGRAM P5 Power Window Regulator Master Switch Assy (Door ECU) MPX1 MPX2 8 7 Communication Line 6 B10 10 B9 MPX2 MPX1 7 GND1 B12 Multiplex Network Body ECU PU 21 B10 PD 20 B10 RLD 13 B11 RLU 14 B11 RRU 9 B11 LG W O RRD 8 B11 BR W-B Passenger Side J/B 11 4H B 11 IN2 GR 4 IN2 Y LG 4 5 17 IA1 5 IA1 R P 4 BB1 9 BB1 L-O 7 IO2 GR R L-O 5 4 1 1 1 W-B 2 IN1 1 4N 5 P12 SU SD Power Window Regulator Switch Assy Rear (Rear RH) E 4L LG-B P11 SU SD Power Window Regulator Switch Assy Rear (Rear LH) E 7 9 BC1 4 BC1 LG-B 4 P10 SU SD Power Window Regulator Switch Assy (Passenger Side) 16 IO2 E W-B 12 BB1 W-B 12 BC1 W-B 10 4L Passenger Side J/B 1 4N W-B 7 W-B W-B W-B W-B 4L W-B IC BA BB IC B78735 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2120 05-1931 DIAGNOSTICS - POWER WINDOW CONTROL SYSTEM INSPECTION PROCEDURE 1 (a) CHECK HAND-HELD TESTER Monitor code (1) Using the hand-held tester, inspect the monitor code of the door ECU. HINT:

The monitor code shows the switch condition when a DTC is output. When a monitor code is indicated while the switch is not operated, the switch is detected in being stuck. When a monitor code is not indicated while the switch is operated, it is detected that the switch contact condition is bad. DTC Code Item B1221/21 Driver’s side switch 1 (operating) Monitor Item Any switch of the power window regulator master switch is ON NG Go to step 3 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2121 05-1932 DIAGNOSTICS 2 - POWER WINDOW CONTROL SYSTEM CHECK MULTIPLEX NETWORK BODY ECU (a) Inspect the output of the body ECU. (1) Inspect the voltage between terminal 7 (GND1) and each terminal of the door which body ECU is inoperative. B12 B9 B10 B11 B51823 Standard: Symbols (Terminal No.) Condition Specified Condition PU (B10-21) ⇔ GND1 (B12-7) Ignition switch ON, master switch passenger side switch OFF → UP (manual operation) 0 V → 10 - 14 V PD (B10-20) ⇔ GND1 (B12-7) Ignition switch ON, master switch passenger side switch OFF → DOWN (manual operation) 0 V → 10 - 14 V RRU (B11-9) ⇔ GND1 (B12-7) Ignition switch ON, master switch rear RH side switch OFF → UP (manual operation) 0 V → 10 - 14 V RRD (B11-8) ⇔ GND1 (B12-7) Ignition switch ON, master switch rear RH side switch OFF → DOWN (manual operation) 0 V → 10 - 14 V RLU (B11-14) ⇔ GND1 (B12-7) Ignition switch ON, master switch rear LH side switch OFF → UP (manual operation) 0 V → 10 - 14 V RLD (B11-13) ⇔ GND1 (B12-7) Ignition switch ON, master switch rear LH side switch OFF → DOWN (manual operation) 0 V → 10 - 14 V HINT:


When an output to the passenger door is normal, proceed to OK-A. When outputs to both rear doors are normal, proceed to OK-B. When an output to either of the passenger door and both rear doors are abnormal, proceed to NG. OK-B NG Go to step 4 REPLACE MULTIPLEX NETWORK BODY ECU OK-A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2122 05-1933 DIAGNOSTICS 3 - POWER WINDOW CONTROL SYSTEM CHECK POWER WINDOW REGULATOR SWITCH ASSY (PASSENGER SIDE) (a) Check the continuity. (1) Check the continuity between each terminal of the connectors. B31305 Standard: Switch Operation 4 Measuring Condition Specified Condition Not operated Terminal 4 ⇔ Terminal 1 Continuity Not operated Terminal 5 ⇔ Terminal 1 Continuity OK REPAIR OR CONNECTOR REPLACE NG REPLACE POWER SWITCH ASSY HARNESS WINDOW AND REGULATOR CHECK POWER WINDOW REGULATOR SWITCH ASSY REAR (REAR RH AND LH) (a) Check the continuity. (1) Check the continuity between each terminal of the connectors. B31305 Standard: Switch Operation Measuring Condition Specified Condition Not operated Terminal 4 ⇔ Terminal 1 Continuity Not operated Terminal 5 ⇔ Terminal 1 Continuity OK REPAIR OR CONNECTOR REPLACE HARNESS NG REPLACE POWER WINDOW SWITCH ASSY REAR AND REGULATOR 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2123 05-1920 DIAGNOSTICS - POWER WINDOW CONTROL SYSTEM 0523Q-04 WINDOWS CANNOT BE OPERATED VIA REGULATOR SWITCH AT EACH SEAT CIRCUIT DESCRIPTION With the ignition switch ON and the window lock switch at NORMAL (except driver side), each regulator switch drives each power window motor. NOTICE: The power window system has a function with a large-scale body multiplex communications. First of all, inspect the communication function depending on the ”how to proceed with troubleshooting”, and check that there is no abnormality in the communication system. Then finally proceed with the troubleshooting. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2110 05-1921 DIAGNOSTICS - POWER WINDOW CONTROL SYSTEM WIRING DIAGRAM P10 Power Window Regulator Switch Assy (Passenger Side) 3 IN1 BR G 7 V 4 7 4L Regulator Motor Assy 10 4L GR 2 IN1 W-B W-B GR Front RH 5 1 4N IC U Power Window Passenger Side J/B W-B 3 P7 +B 11 IA1 GR Instrument Panel J/B Assy 6 W-B 1 D E P11 Power Window Regulator Switch Assy Rear (Rear LH) 1 L-W BB1 +B 7 R D FR DOOR 12 1D P RR DOOR 3 1H D RR DOOR 1A 5 4 G BA 1 L 10 IO1 6 12 W-B BB1 W-B 8 1D 3 P8 Power Window Regulator Motor Assy Rear LH P 1 To Battery D E P12 Power Window Regulator Switch Assy Rear (Rear RH) 1 L-W +B BC1 7 R 5 U 3 P9 Power Window Regulator Motor Assy Rear RH 4 G W-B 6 12 W-B BC1 1 U D E BB B78734 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2111 05-1922 DIAGNOSTICS - POWER WINDOW CONTROL SYSTEM INSPECTION PROCEDURE 1 (a) CHECK FUSE Check whether the regulator switch fuses D FR DOOR 25 A, P RR DOOR 20 A and D RR DOOR 20 A of inoperative seats are normal. HINT:




If If If If If the the the the the fuse for the passenger side door is normal, proceed to OK-A. fuse for the rear RH and LH doors is normal, proceed to OK-B. fuse for the passenger side door is defective, proceed to NG-A. fuse for the rear RH door is defective, proceed to NG-B. fuse for the rear LH door is defective, proceed to NG-C. OK-B Go to step 6 NG-A REPLACE FUSE (D FR DOOR 25 A) NG-B REPLACE FUSE (P RR DOOR 20 A) NG-B REPLACE FUSE (D RR DOOR 20 A) OK-A 2 CHECK POWER WINDOW REGULATOR SWITCH ASSY (PASSENGER SIDE) (a) 8 7 6 5 4 Inspect the power source voltage. (1) Disconnect the regulator switch connector. (2) Check the voltage between terminal 7 (B) of the regulator switch vehicle’s side connector and the body ground. Standard: 10 - 14 V with ignition switch ON NG B51844 REPAIR OR CONNECTOR REPLACE HARNESS AND OK 3 CHECK POWER WINDOW REGULATOR SWITCH ASSY (PASSENGER SIDE) (a) 8 7 6 5 4 Inspect the GND. (1) Disconnect the regulator switch connector. (2) Check the continuity between terminal 1 (E) of the regulator switch vehicle’s side connector and the body ground. Standard: Continuity (constant) NG B51845 REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2112 05-1923 DIAGNOSTICS 4 - POWER WINDOW CONTROL SYSTEM CHECK POWER WINDOW REGULATOR MOTOR ASSY RH (PASSENGER SIDE) (a) 8 7 6 5 4 B51846 Inspect the motor operation. (1) Disconnect the regulator switch connector. (2) Inspect the door glass operation when the battery voltage is applied between terminals 3 (U) and 6 (D) of the regulator switch vehicle’s side connector. Standard: Measuring Condition Operational Direction Battery positive - Terminal 3 (U) Battery negative - Terminal 6 (D) Upward Battery positive - Terminal 6 (D) Battery negative - Terminal 3 (U) Downward OK REPLACE POWER SWITCH ASSY WINDOW Author
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: REGULATOR NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) 2113 05-1924 DIAGNOSTICS 5 - POWER WINDOW CONTROL SYSTEM INSPECT POWER WINDOW REGULATOR MOTOR ASSY RH (PASSENGER SIDE) (a) Driving Axis Counterclockwise Inspect the operation of the front LH power window regulator motor assembly. (1) Check that the motor operates smoothly when the battery voltage is applied to each terminal of the connector. Standard: Measuring Condition Clockwise B51847 Operational Direction Battery positive - Terminal 4 Battery negative - Terminal 5 Clockwise rotation toward driving axis Battery positive - Terminal 5 Battery negative - Terminal 4 Counterclockwise rotation toward driving axis (b) Inspect the PTC operation inside the power window regulator motor. NOTICE: The inspection should be performed with the power window regulator and door glass installed to the vehicle. (1) Set a DC 400 A probe of the electrical tester in the wire harness of terminal 1 or 2. NOTICE: Match the arrow mark of the probe with the current direction. (2) Set the door glass in the fully closed position. (3) When 60 seconds have elapsed after the door glass is fully closed, check now long the current takes to charge, from approximately 16 - 34 A into 1 A or less, when the power window switch is turned UP once again. Standard: Approximately 4 - 90 seconds (4) When approximately 60 seconds have elapsed after the inspection of the current cut-off, check that the door glass goes down when the power window regulator switch is turned DOWN. 6 OK REPAIR OR CONNECTOR REPLACE NG REPLACE POWER MOTOR ASSY RH HARNESS WINDOW AND REGULATOR CHECK POWER WINDOW REGULATOR SWITCH ASSY REAR (REAR RH AND LH) (a) 8 7 6 5 4 B51844 Inspect the power source voltage. (1) Disconnect the regulator switch connector. (2) Check the voltage between terminal 7 (+B) of the regulator switch vehicle’s side connector and the body ground. Standard: 10 - 14 V with ignition switch ON NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2114 05-1925 DIAGNOSTICS 7 POWER WINDOW CONTROL SYSTEM CHECK POWER WINDOW REGULATOR SWITCH ASSY REAR (REAR RH AND LH) (a) 8 7 6 5 4 B51845 8 - Inspect the GND. (1) Disconnect the regulator switch connector. (2) Check the continuity between terminal 1 (E) of the regulator switch vehicle’s side connector and the body ground. Standard: Continuity (constant) NG REPAIR OR CONNECTOR REPLACE HARNESS OK-A Go to step 8 (In case Rear RH side) OK-B Go to step 10 (In case Rear LH side) AND CHECK POWER WINDOW REGULATOR MOTOR ASSY RH (REAR RH) (a) 8 7 6 5 4 B51846 Inspect the motor operation. (1) Disconnect the regulator switch connector. (2) Inspect the door glass operation when the battery voltage is applied between terminals 3 (U) and 6 (D) of the regulator switch vehicle’s side connector. Standard: Measuring condition Operational direction Battery positive - Terminal 3 (U) Battery negative - Terminal 6 (D) Upward Battery positive - Terminal 6 (D) Battery negative - Terminal 3 (U) Downward OK REPLACE POWER WINDOW SWITCH ASSY REAR REGULATOR NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2115 05-1926 DIAGNOSTICS 9 - POWER WINDOW CONTROL SYSTEM INSPECT POWER WINDOW REGULATOR MOTOR ASSY RH (REAR RH) (a) Driving Axis Clockwise Inspect the operation of the power window regulator motor assy RH (Rear RH side). (1) Check that the motor operates smoothly when the battery voltage is applied to each terminal of the connector. Standard: Measuring Condition Counterclockwise B51848 Operational Direction Battery positive - Terminal 5 Battery negative - Terminal 4 Clockwise rotation toward driving axis Battery positive - Terminal 4 Battery negative - Terminal 5 Counterclockwise rotation toward driving axis (b) Inspect the PTC operation inside the power window regulator motor. NOTICE: The inspection should be performed with the power window regulator and door glass installed to the vehicle. (1) Set a DC 400 A probe of the electrical tester in the wire harness of terminal 1 or 2. NOTICE: Match the arrow mark of the probe with the current direction. (2) Set the door glass in the fully closed position. (3) When 60 seconds have elapsed after the door glass is fully closed, check now long the current takes to charge, from approximately 16 - 34 A into 1 A or less, when the power window switch is turned UP once again. Standard: Approximately 4 - 90 seconds (4) When approximately 60 seconds have elapsed after the inspection of the current cut-off, check that the door glass goes down when the power window regulator switch is turned DOWN. OK REPAIR OR CONNECTOR REPLACE NG REPLACE POWER MOTOR ASSY RH HARNESS WINDOW AND REGULATOR 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2116 05-1927 DIAGNOSTICS 10 - POWER WINDOW CONTROL SYSTEM CHECK POWER WINDOW REGULATOR MOTOR ASSY LH (REAR LH) (a) 8 7 6 5 4 B51846 Inspect the motor operation. (1) Disconnect the regulator switch connector. (2) Inspect the door glass operation when the battery voltage is applied between terminals 3 (U) and 6 (D) of the regulator switch vehicle’s side connector. Standard: Measuring condition Operational direction Battery positive - Terminal 3 (U) Battery negative - Terminal 6 (D) Upward Battery positive - Terminal 6 (D) Battery negative - Terminal 3 (U) Downward OK REPLACE POWER WINDOW SWITCH ASSY REAR REGULATOR NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2117 05-1928 DIAGNOSTICS 11 - POWER WINDOW CONTROL SYSTEM INSPECT POWER WINDOW REGULATOR MOTOR ASSY LH (REAR LH) (a) Driving Axis Counterclockwise Clockwise B51849 Inspect the operation of the power window regulator motor assy LH (Rear LH side). (1) Check that the motor operates smoothly when the battery voltage is applied to each terminal of the connector. Standard: Measuring condition Operational direction Battery positive - Terminal 4 Battery negative - Terminal 5 Clockwise rotation toward driving axis Battery positive - Terminal 5 Battery negative - Terminal 4 Counterclockwise rotation toward driving axis (b) Inspect the PTC operation inside the power window regulator motor. NOTICE: The inspection should be performed with the power window regulator and door glass installed to the vehicle. (1) Set a DC 400 A probe of the electrical tester in the wire harness of terminal 1 or 2. NOTICE: Match the arrow mark of the probe with the current direction. (2) Set the door glass in the fully closed position. (3) When 60 seconds have elapsed after the door glass is fully closed, check now long the current takes to charge, from approximately 16 - 34 A into 1 A or less, when the power window switch is turned UP once again. Standard: Approximately 4 - 90 seconds (4) When approximately 60 seconds have elapsed after the inspection of the current cut-off, check that the door glass goes down when the power window regulator switch is turned DOWN. NG REPLACE POWER MOTOR ASSY LH WINDOW REGULATOR OK REPAIR OR REPLACE HARNESS AND CONNECTOR 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2118 05-1915 DIAGNOSTICS - POWER WINDOW CONTROL SYSTEM 0523O-03 DRIVER POWER WINDOW DOES NOT OPERATE CIRCUIT DESCRIPTION The power window regulator master switch assy (door ECU) controls the driver side power window by itself and drives the driver side power window motor. NOTICE: The power window system has a function with a large-scale multiplex communication. First of all, inspect the communication function depending on ”how to proceed with troubleshooting” and confirm that the communication system has no abnormality. Then finally perform the troubleshooting. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2105 05-1916 DIAGNOSTICS - POWER WINDOW CONTROL SYSTEM WIRING DIAGRAM P5 Power Window Regulator Master Switch Assy (Door ECU) Instrument Panel J/B Assy 10 1G To Battery G 7 1C IG1 3 1D BR 2 IB2 L 9 1 1D W 3 IB2 Y 20 4 I15 Ignition Switch Assy IG1 P FR DOOR 6 1K Y 8 IL1 3 IB1 V G 10 CPUB SIG BDR AM1 2 W 6 1C AM1 2 1 To Battery 1 1A P6 Power Window Regulator Motor Assy Front LH V U 4 D 1 GR 5 11 2 UP DN GND W-B 2 IB1 W-B 8 4L 7 4L Passenger Side J/B 1 4N W-B W-B IC B78733 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2106 05-1917 DIAGNOSTICS - POWER WINDOW CONTROL SYSTEM INSPECTION PROCEDURE 1 (a) CHECK FUSE Check if the P FR DOOR 20 A, ECU B 7.5 A and IG1 7.5 A fuses are normal. NG REPLACE FUSE OK 2 CHECK POWER WINDOW REGULATOR MASTER SWITCH ASSY (a) Check the power source voltage. (1) Disconnect the master switch connector. (2) Check the voltage of each terminal of the vehicle’s side connector of the master switch. B51850 Standard: Symbols (Terminal No.) Condition Specified Condition CPUB (9) ⇔ Body ground Constant 10 - 14 V BDR (10) ⇔ Body ground Constant 10 - 14 V SIG (20) ⇔ Body ground Ignition switch OFF → ON 0 V → 10 - 14 V NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 3 CHECK POWER WINDOW REGULATOR MASTER SWITCH ASSY (a) B51851 Check the GND. (1) Disconnect the master switch connector. (2) Check the continuity between terminal 2 (GND) of the vehicle’s side connector of the master switch and the body ground. Standard: Continuity (constant) NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2107 05-1918 DIAGNOSTICS 4 - POWER WINDOW CONTROL SYSTEM CHECK POWER WINDOW REGULATOR MOTOR ASSY LH (DRIVER’S SIDE) (a) (b) B51852 Disconnect the master switch connector. Inspect the door glass operation when the battery voltage is applied between terminals 1 (UP) and 11 (DN) of the vehicle’s side connector of the master switch. Standard: Measuring Condition Operational Direction Battery positive - Terminal 1 (UP) Battery negative - Terminal 11 (DN) Upward Battery positive - Terminal 11 (DN) Battery negative - Terminal 1 (UP) Downward OK REPLACE POWER WINDOW MASTER SWITCH ASSY REGULATOR NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2108 05-1919 DIAGNOSTICS 5 - POWER WINDOW CONTROL SYSTEM INSPECT POWER WINDOW REGULATOR MOTOR ASSY LH (DRIVER SIDE) (a) Inspect the power window regulator motor assy LH (Driver side) operation. NOTICE:
Do not apply the battery voltage, because the pulse sensor and limit switch could be damaged if the battery voltage is applied to terminals 2, 3 and 6 of the power window regulator motor connector.
Be sure to reset the power window regulator motor (initial position setting of limit switch) when the driver’s side power window regulator motor is installed to the regulator. (1) Check that the motor operates smoothly when the Driving Axis battery positive voltage is applied to each terminal of the connector. Standard: Measuring Condition Counterclockwise Clockwise Operational Direction Battery positive - Terminal 5 Battery negative - Terminal 4 Clockwise Battery positive - Terminal 4 Battery negative - Terminal 5 Counterclockwise B51847 (b) Inspect the PTC operation inside the power window regulator motor. NOTICE: The inspection should be performed with the power window regulator and door glass installed to the vehicle. (1) Set a DC 400 A probe of the electrical tester in the wire harness of terminal 4 or 5. NOTICE: Match the arrow mark of the probe with the current direction. (2) Set the door glass in the fully closed position. (3) When 60 seconds have elapsed after the door glass is fully closed, check now long the current takes to charge, from approximately 16 - 34 A into 1 A or less, when the power window switch is turned UP once again. Standard: Approximately 4 - 90 seconds (4) When approximately 60 seconds have elapsed after the inspection of the current cut-off, check that the door glass goes down when the power window regulator switch is turned DOWN. NG REPLACE POWER MOTOR ASSY LH WINDOW REGULATOR OK REPAIR OR REPLACE HARNESS AND CONNECTOR 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2109 05-1904 DIAGNOSTICS - POWER WINDOW CONTROL SYSTEM 0523F-02 CUSTOMER PROBLEM ANALYSIS CHECK POWER WINDOW CONTROL SYSTEM Check Sheet Inspector’s name: Registration No. Registration Year Customer’s Name Frame No. Date Vehicle Brought in / / Date Problem First Occurred /   Constant  Once only Weather   Fine  Cloudy Various/Others Outdoor Temperature  Hot  Warm  Cold (Approx. Frequency Problem Occurs Weather Conditions When Problem Occurred km miles Odometer Reading  Diagnosis code is output / Sometimes ( times per  Rainy  Snowy  Cool C ( F))  B1221/21  B1231/31 day, month)  B1232/32  AUTO UP/AUTO DOWN is impossible  Operation interlocked with key is impossible Malfunction Symptoms  Operation after key-OFF is impossible  Remote operation by the master switch is impossible in a switch  Passenger Side  Rear RH Side  Rear LH Side  Operation by a switch of each seat is impossible in a switch  Passenger Side Condition when recovered normal Condition when problem occurred  IG ON Yes No  Rear RH Side  Engine Started  IG OFF ON  (  Rear LH Side  ( ) Switch operated ) Switch operated  Others ( ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2094 05-1908 DIAGNOSTICS - POWER WINDOW CONTROL SYSTEM 0523J-02 DIAGNOSTIC TROUBLE CODE CHART 1. DIAGNOSTIC TROUBLE CODE Door ECU (driver side) DTC Code Item Diagnosis B1231/31 Driver side jam protection limit switch malfunctions Power window regulator motor assy RH open in limit switch system B1232/32 Driver side jam protection sensor malfunctions Power window regulator motor assy RH open or short in pulse sensor system 2. MONITOR CODE HINT:
The monitor code shows the switch condition when a DTC is output.
When a monitor code is indicated while the switch is not operated, the switch is detected in being stuck. When a monitor code is not indicated while the switch is operated, it is detected that the switch contact condition is bad. DTC Code B1221/21 Item Driver side switch 1 (operating) Monitor Item Any switch of the power window regulator master switch is ON 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2098 05-1902 DIAGNOSTICS - POWER WINDOW CONTROL SYSTEM 0523E-02 HOW TO PROCEED WITH TROUBLESHOOTING HINT: Troubleshoot in accordance with the procedure on the following pages. 1 VEHICLE BROUGHT TO WORKSHOP 2 CUSTOMER PROBLEM ANALYSIS CHECK AND SYMPTOM CHECK (See page 05-1904 ) 3 INSPECT COMMUNICATION FUNCTION OF LARGE-SCALE MULTIPLEX COMMUNICATION SYSTEM (BEAN) (a) Check that there is no abnormality in the communication system by inspecting the communication function of the multiplex communication system with the hand-held tester. (1) (ECU unconnected, communication line abnormal) Without code output, proceed to A. (2) (ECU unconnected, communication line abnormal) With code output, proceed to B. B GO TO MULTIPLEX COMMUNICATION SECTION (See page 05-2044 ) A 4 (a) DIAGNOSTIC TROUBLE CODE CHECK (See page 05-1908 ) Check the diagnostic trouble code. (1) Without code output, proceed to A. (2) With code output, proceed to B. B Go to step 7 A 5 (a) (b) PROBLEM SYMPTOMS TABLE (See page 05-191 1) Without applicable symptoms, proceed to A. With applicable symptoms, proceed to B. B Go to step 7 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2092 05-1903 DIAGNOSTICS 6 (a) - POWER WINDOW CONTROL SYSTEM PERFORM TROUBLESHOOTING IN THE FOLLOWING METHOD, DEPENDING ON MALFUNCTION SYMPTOM Pre-check (See page 05-1905 ) (1) Check with hand-held tester (ECU data monitor). (2) Check with hand-held tester (Active test). Terminals of ECU (See page 05-1909 ) (b) 7 ADJUSTMENT, REPAIR OR REPLACEMENT END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2093 05-1907 DIAGNOSTICS - POWER WINDOW CONTROL SYSTEM 0523K-02 LOCATION Un-lock Warning Switch Assy Multiplex Network Body ECU Power Window Regulator Master Switch Assy (Door ECU) Power Window Regulator Motor Assy RH Power Window Regulator Switch Assy Front Door Window Regulator Sub-assy RH Power Window Regulator Motor Assy RH Rear Door Window Regulator Sub-assy RH Power Window Regulator Motor Assy LH Front Door Window Regulator Sub-assy LH Power Window Regulator Switch Assy Rear Power Window Regulator Switch Assy Rear Front Door Courtesy Lamp Switch Assy Rear Door Window Regulator Sub-assy LH Power Window Regulator Motor Assy LH B51238 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2097 05-1901 DIAGNOSTICS - POWER WINDOW CONTROL SYSTEM POWER WINDOW CONTROL SYSTEM 0523D-02 PRECAUTION 1. (a) NOTICES OF INSPECTION WITH REMOVAL AND INSTALLATION PROCEDURES Before performing operations related to the front door lock assy RH and door lock cylinder, disconnect the battery terminal or the connectors of the power window regulator master switch assy. CAUTION: If the operation is performed with the connectors being connected, the door control switch (interlocked with key) inside the door lock might be unexpectedly actuated, which results in injury. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2091 05-1905 DIAGNOSTICS - POWER WINDOW CONTROL SYSTEM 0523G-02 PRE-CHECK 1. POWER WINDOW OPERATION MODE HINT: The initial condition that the customizing function by the hand-held tester is not chosen is shown. Standard: Power window operation Ignition switch ON Ignition switch OFF Operative after key-OFF Ignition switch OFF Inoperative after key-OFF Manual UP Operative Jam protection function operative Inoperative Manual DOWN Operative Operative Inoperative Jam protection function operative Jam protection function operative Inoperative Operative Operative Inoperative UP operation interlocked with key Inoperative Jam protection function operative Jam protection function operative DOWN operation interlocked with key Inoperative Operative Operative AUTO UP AUTO DOWN 2. (a) POWER WINDOW FAIL-SAFE FUNCTION When an abnormality is detected in the limit switch and pulse sensor for operating the jam protection function (DTC: B1231/31, B1232/32), the following power window operations will be prohibited by the fail-safe function. Standard: Power window operation Ignition switch ON Ignition switch OFF Operative after key-OFF Ignition switch OFF Inoperative after key-OFF Manual UP Operative Operation prohibited - Manual DOWN Operative Operation prohibited - AUTO UP Operation prohibited Operation prohibited - AUTO DOWN Operation prohibited Operation prohibited - UP operation interlocked with key - Operation prohibited Operation prohibited DOWN operation interlocked with key - Operation prohibited Operation prohibited HINT: In case of normal limit switch, the prohibition (fail-safe function) will be cancelled by fully opening the door glass that is fully closed by the manual operation, then AUTO operations will be possible. 3. CHECK HAND-HELD TESTER (a) ECU Data Monitor: (1) The ECU data monitor will indicate if the part is normal or malfunctioning. Standard: Door ECU (driver side) (switch condition) Item Driver side power window AUTO switch Jam protection limit switch Inspecting condition Standard value Pressed → Not pressed ON/OFF Power window fully open → fully closed ON/OFF 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2095 05-1906 DIAGNOSTICS - POWER WINDOW CONTROL SYSTEM Door ECU (driver side) (jam protection threshold) Item Inspecting condition Standard value Window full-close position → 1/4 open position Power window is going UP by manual operation OK/CAUTION* Window 1/4 open position → 2/4 open position Power window is going UP by manual operation OK/CAUTION* Window 2/4 open position → 3/4 open position Power window is going UP by manual operation OK/CAUTION* Window 3/4 open position → full-open position Power window is going UP by manual operation OK/CAUTION* HINT: * : ”CAUTION” is indicated when something is detected in being caught in the window. (b) Active Test: (1) The active test will indicate if the part is normal or malfunctioning. Standard: Door ECU (driver side) Item Power window Operation UP/DOWN (c) Customizing Function (reference): (1) Using the hand-held tester, select a setting from the following items on the power window. Standard: Door ECU (driver side) Item Setting Power window UP operation interlocked with door With/Without function Power window DOWN operation interlocked with door With/Without function 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2096 05-191 1 DIAGNOSTICS - POWER WINDOW CONTROL SYSTEM 0523M-03 PROBLEM SYMPTOMS TABLE Problem Symptom Suspected Area See Page B1221/21 (Door ECU SW ON) 1. Power window regulator master switch assy (door ECU) 05-1912 B1231/31 (Driver side jam protection limit switch malfunctions) 1. Power window regulator motor assy LH 05-1913 B1232/32 (Driver side jam protection sensor malfunctions) 1. Power window regulator motor assy LH 05-1913 AUTO UP/AUTO DOWN does not operate (only driver side) 1. Power window regulator master switch assy (door ECU) 2. Power window regulator motor assy LH 05-1913 05-1913 Power window operation is impossible by operation interlocked with key (only driver side) 1. Front door lock assy RH 2. Power window regulator master switch assy (door ECU) 05-1957 05-1909 Operation is impossible after key-OFF (only driver side) 1. Front door courtesy lamp switch assy 2. Multiplex network body ECU 05-1957 05-1909 Driver’s side power window does not operate 1. 2. 3. 4. 5. 6. P FR DOOR 20 A fuse ECU-B 7.5 A fuse IG1 7.5 A fuse Power window regulator master switch assy (door ECU) Power window regulator motor assy RH Wire harness 05-1915 05-1915 05-1915 05-1915 05-1915 05-1915 Window operation via regulator switch for each seat is impossible 1. 2. 3. 4. 5. 6. 7. 8. 9. P FR DOOR 20 A fuse D FR DOOR 25 A fuse D RR DOOR 20 A fuse P RR DOOR 20 A fuse Power window regulator master switch assy (door ECU) Power window regulator switch assy Power window regulator motor assy RH Power window regulator motor assy LH Wire harness 05-1920 05-1920 05-1920 05-1920 05-1920 05-1920 05-1920 05-1920 05-1920 Remote operation of other seat via master switch is impossible 1. Power window regulator master switch assy (door ECU) 2. Multiplex network body ECU 3. Wire harness 05-1929 05-1929 05-1929 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2101 05-1909 DIAGNOSTICS - POWER WINDOW CONTROL SYSTEM 0523L-04 TERMINALS OF ECU 1. P5 (a) (b) CHECK POWER WINDOW REGULATOR MASTER SWITCH ASSY (DOOR ECU) Disconnect the P5 master switch connector. Check the voltage or continuity of each terminal of the wire harness side connector. B51239 Standard: Symbols (Terminal No.) Wiring Color GND (P5-2) ⇔ Body ground W-B ⇔ - Constant Condition Continuity Specified Condition CPUB (P5-9) ⇔ GND (P5-2) L ⇔ W-B Constant 10 - 14 V SIG (P5-20) ⇔ GND (P5-2) Y ⇔ W-B Ignition switch OFF → ON 0 V → 10 - 14 V BDR (P5-10) ⇔ GND (P5-2) G ⇔ W-B Constant 10 - 14 V DN (P5-11) ⇔ UP (P5-1) GR ⇔ V Constant Continuity LMT (P5-5) ⇔ SGND (P5-13) O⇔R Driver side door glass fully closed No continuity LMT (P5-5) ⇔ SGND (P5-13) O⇔R Driver side door glass opened by 4 mm (0.16 in.) or more Continuity KUL (P5-14) ⇔ LSWE (P5-3) Y ⇔ LG Driver side door lock cylinder be in neutral by key → UNLOCK No continuity → Continuity KL (P5-4) ⇔ LSWE (P5-3) G ⇔ LG Driver side door lock cylinder be in neutral by key → LOCK No continuity → Continuity If the result is not as specified, the wire harness side may malfunction. (1) Reconnect the P5 switch connector, and check the voltage of each terminal of the connector. Standard: Symbols (Terminal No.) Wiring Color Condition Specified Condition UP (P5-1) ⇔ GND (P5-2) V ⇔ W-B Ignition switch ON, master switch driver’s side switch OFF → UP (manual operation) 0 V → 10 - 14 V UP (P5-1) ⇔ GND (P5-2) V ⇔ W-B Ignition switch ON, driver side door glass fully opened → master switch driver side switch UP (auto operation) → door glass fully closed 0 V → 10 - 14 V → 0 V DN (P5-11) ⇔ GND (P5-2) GR ⇔ W-B Ignition switch ON, master switch driver’s side switch OFF → DOWN (manual operation) 0 V → 10 - 14 V DN (P5-11) ⇔ GND (P5-2) GR ⇔ W-B Ignition switch ON, driver side door glass fully closed → master switch driver side switch OFF → DOWN (auto operation) → door glass fully opened 0 V → 10 - 14 V → 0 V PWS (P5-6) ⇔ GND (P5-2) B ⇔ W-B Ignition switch ON, window lock switch LOCK → NORMAL 0 V → 10 - 14 V If the result is not as specified, the master switch may malfunction. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2099 05-1910 DIAGNOSTICS 2. (a) (b) - POWER WINDOW CONTROL SYSTEM CHECK MULTIPLEX NETWORK BODY ECU Disconnect the body ECU connectors B9, B10, B11 and B12. Check the voltage or continuity of each terminal of the wire harness side connector. B11 B12 B9 B10 B51823 Standard: Symbols (Terminal No.) Wiring Color Condition Specified Condition GND1 (B12-7) ⇔ Body ground W-B ⇔ - Constant Continuity GND2 (B9-2) ⇔ Body ground W-B ⇔ - Constant Continuity BECU (B12-9) ⇔ GND1 (B12-7) G ⇔ W-B Constant 10 - 14 V BDR1 (B12-4) ⇔ GND1 (B12-7) B ⇔ W-B Constant 10 - 14 V IG (B9-5) ⇔ GND1 (B12-7) BR ⇔ W-B Ignition switch OFF → ON 0 V → 10 - 14 V DCTY (B11-1 1) ⇔ GND1 (B12-7) B ⇔ W-B Driver door fully closed → Opened No continuity → Continuity KSW (B10-2) ⇔ GND1 (B12-7) G ⇔ W-B No key in ignition key cylinder → Key inserted No continuity → Continuity If the result is not as specified, the wire harness side may malfunction. (c) Reconnect the ECU connectors, and check the voltage of each terminal of the connectors. Standard: Symbols (Terminal No.) Wiring Color Condition Specified Condition PU (B10-21) ⇔ GND1 (B12-7) B ⇔ W-B Ignition switch ON, master switch passenger side switch OFF → UP (manual operation) 0 V → 10 - 14 V PD (B10-20) ⇔ GND1 (B12-7) GR ⇔ W-B Ignition switch ON, master switch passenger side switch OFF → DOWN (manual operation) 0 V → 10 - 14 V RRU (B11-9) ⇔ GND1 (B12-7) LG ⇔ W-B Ignition switch ON, master switch rear RH side switch OFF → UP (manual operation) 0 V → 10 - 14 V RRD (B11-8) ⇔ GND1 (B12-7) BR ⇔ W-B Ignition switch ON, master switch rear RH side switch OFF → DOWN (manual operation) 0 V → 10 - 14 V RLU (B11-14) ⇔ GND1 (B12-7) O ⇔ W-B Ignition switch ON, master switch rear LH side switch OFF → UP (manual operation) 0 V → 10 - 14 V RLD (B11-13) ⇔ GND1 (B12-7) W ⇔ W-B Ignition switch ON, master switch rear LH side switch OFF → DOWN (manual operation) 0 V → 10 - 14 V If the result is not as specified, the door ECU or communication line may malfunction. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2100 05-2145 DIAGNOSTICS - CRUISE CONTROL SYSTEM 05IQQ-01 DIAGNOSIS SYSTEM 1. DESCRIPTION The ECU controls the cruise control system of the vehicle. The data and DTCs relating to the cruise control system can be read from the DLC3 of the vehicle. If no DTCs are output when checking for DTCs, there may be a problem with the combination meter or the multiplex communication system. Use the hand-held tester or SST to check and solve the problem. SST 09843-18040 2. (a) 1 2 3 4 5 6 7 8 CHECK THE DLC3 The vehicle’s ECM uses ISO 9141-2 for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 9141-2 format. 9 10 11 12 13 14 15 16 DLC3 F40034 Symbols (Terminals No.) Terminal Description Condition Specified Condition SIL(7) - SG(5) Bus ”+” line During transmission Pulse generation CG(4) - Body ground Chassis ground Always Below 1 Ω SG(5) - Body ground Signal ground Always Below 1 Ω BAT(16) - Body ground Battery positive Always 11 to 16 V HINT: If the display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the hand-held tester to the DLC3, turned the ignition switch to the ON position and operated the tester, there is a problem on either the vehicle side or the tool side.
If communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle.
If communication is still impossible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool’s instruction manual. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2335 05-2146 DIAGNOSTICS 3. (a) (b) CRUISE main indicator light I39348 CRUISE CONTROL SYSTEM CHECK THE INDICATOR Turn the ignition switch to the ON position. Check that the CRUISE main indicator light comes on when the cruise control main switch ON-OFF button is pushed on, and that the indicator light goes off when the ON-OFF button is pushed off. HINT: If there is a problem with the indicator, inspect the cruise main indicator light circuit (see page 05-2165 ). HINT: If a malfunction occurs in the vehicle speed sensors, stop lamp switch assy or other related parts during cruise control driving, and the ECM actuates AUTO CANCEL of the cruise control and then the CRUISE main indicator light starts to blink, informing the driver of the malfunction. At the same time, data of the malfunction is stored as a diagnostic trouble code, or DTC. Indicator Light 1.5 sec. - 0.5 sec. ON OFF BE4034 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2336 05-2149 DIAGNOSTICS - CRUISE CONTROL SYSTEM 05IQT-02 DATA LIST/ACTIVE TEST 1. (a) DATA LIST While the hand-held tester is connected to the DLC3 and with the ignition switch turned to the ON position, the CRUISE CONTROL data list can be displayed. Follow the prompts on the tester screen to access the data list. CC (ECM): Item Measurement Item / Display (Range) Normal Condition Diagnostic Note VEHICLE SPD Vehicle speed / min.: 0 km/h (0 mph), max.: 255 km/h (158 mph) Actual vehicle speed - MEMORY SPD Cruise control memorized speed / min.: 36 km/h (22.5 mph), max.: 200 km/h (125 mph) Actual stored vehicle speed - THROTTLE Required throttle opening angle / min.: 0
, max.: 84
Actual required throttle opening - CRUISE CONTROL Cruise control system active condition / ON or OFF ON : Cruise control activated OFF : Cruise control inactivated - MAIN SW (MAIN) Main SW signal (Main CPU) / ON or OFF ON : Main SW ON (Pushed on) OFF: Main SW OFF (Pushed off) *1 MAIN SW (SUB) Main SW signal (Sub CPU) / ON or OFF ON : Main SW ON (Pushed on) OFF: Main SW OFF (Pushed off) *1 CCS INDICATOR M Cruise indicator signal (Main CPU) / ON or OFF ON: CRUISE main indicator light is on OFF: CRUISE main indicator light is off - CCS INDICATOR S Cruise indicator signal (Sub CPU) / ON or OFF ON: CRUISE main indicator light is on OFF: CRUISE main indicator light is off - CANCEL SW CANCEL SW signal / ON or OFF ON : CANCEL SW ON OFF : CANCEL SW OFF - SET/COAST SW -/SET SW signal / ON or OFF ON : -/SET SW ON OFF : -/SET SW OFF - RES/ACC SW +/RES SW signal / ON or OFF ON : +/RES SW ON OFF : +/RES SW OFF - STP LIGHT SW2-M Stop lamp SW signal (Main CPU) / ON or OFF ON : Brake pedal depressed OFF : Brake pedal released - STP LIGHT SW2-S Stop lamp SW signal (Sub CPU) / ON or OFF ON : Brake pedal depressed OFF : Brake pedal released - STP LIGHT SW1-S Stop light SW signal (Sub CPU) / ON or OFF ON : Brake pedal depressed OFF : Brake pedal released - SHIFT D POS PNP SW signal (D position) / ON or OFF ON : Shift D position OFF : Except shift D position - HINT: *1 is OK but cruise indicator not turn on → CRUISE MAIN indicator or wire harness or ECM failure 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2339 05-2150 DIAGNOSTICS - CRUISE CONTROL SYSTEM 2. ACTIVE TEST HINT: Performing the ACTIVE TEST using the hand-held tester allows components such as the relay, VSV, and actuator to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one way to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) According to the display on the tester, perform the ”ACTIVE TEST”. HINT: The ignition switch must be turned to the ON position to proceed ACTIVE TEST using the hand-held tester. COMBINATION METER ASSY: Item Vehicle Condition / Test Details Diagnostic Note CRUISE INDIC ”CRUISE” indicator is ON / OFF - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2340 05-2147 DIAGNOSTICS - CRUISE CONTROL SYSTEM 05IQR-01 DTC CHECK/CLEAR 1. (a) TC (b) DLC3 CG DTC CHECK (USING SST CHECK WIRE) Using SST check wire, connect terminals TC and CG of the DLC3. SST 09843-18040 Turn the ignition switch to the ON position. C52361 (c) Normal System Code 0.25 sec. 0.25 sec. ON (d) OFF 2. (a) Read and record any DTCs from the CRUISE main indicator light on the combination meter. As examples, refer to the chart on the left for the indications of the normal system code and code 52. Refer to the Diagnostic Trouble Code Chart (see page 05-2153 ) for DTC information. DTC CLEAR (USING SST CHECK WIRE) Remove the battery cable or ECU-IG fuse. Code 52 0.5 sec. 0.5 sec. 1.5 sec. 2.5 sec. ON OFF Code 52 I03610 3. (a) (b) (c) 4. (a) (b) (c) DTC CHECK (USING HAND-HELD TESTER) Connect the hand-held tester to the DLC3. Turn the ignition switch to the ON position. Read the DTCs on the tester screen. DTC CLEAR (USING HAND-HELD TESTER) Connect the hand-held tester to the DLC3. Turn the ignition switch to the ON position. Clear the DTCs following the prompts on the tester screen. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2337 05-2148 DIAGNOSTICS - CRUISE CONTROL SYSTEM 05IQS-01 FAIL-SAFE CHART 1. If the following conditions are detected while the cruise control is in operation, the system clears the stored vehicle speed in the ECM and cancels the cruise control operation. Vehicle Condition Auto Cancel Condition Re-operation Condition The CRUISE main indicator light blinks.
There is an open or short in the stop lamp switch circuit.
There is a problem with the vehicle speed signal.
There is a problem with the throttle position sensor and motor. Push the ON-OFF button of the cruise control main switch on again. The CRUISE main indicator light blinks.
There is a problem with the input circuit of the stop lamp switch circuit.
There is a problem with the cancel circuit.
Turn the ON-OFF button of the cruise control main switch on again.
Turn the ignition switch off. The CRUISE main indicator light goes off.
Vehicle speed is lower than the low speed limit (approx. 40 km/h (approx. 25 mph)) while running with the cruise control on.
Vehicle speed is lower than the stored speed by 16 km/h (approx. 9.9 mph) or more. Push the cruise control main switch to -/SET. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2338 05-2155 DIAGNOSTICS DTC - CRUISE CONTROL SYSTEM 05IQX-02 P0571/52 STOP LIGHT SWITCH CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION When the brake pedal is depressed, the stop lamp switch assy sends a signal to the ECM. When the ECM receives this signal, it cancels the cruise control. Fail-safe function operates to enable normal driving even if there is a malfunction in the stop lamp signal circuit. The cancel condition occurs when positive battery voltage is applied to terminal STP. When the brake is applied, battery positive voltage is normally applied to terminal STP of the ECM through the STOP fuse and the stop lamp switch assy, and the ECM turns the cruise control off. DTC No. P0571/52 DTC Detection Condition The malfunction code is output when the voltage of the STP terminal and that of the ST1- terminal on the ECM are less than 1 V for 0.5 sec. or more. Trouble Area
Stop lamp switch assy
Stop lamp switch assy circuit
ECM 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2345 05-2156 DIAGNOSTICS - CRUISE CONTROL SYSTEM WIRING DIAGRAM J3 *1 J6 *2 J/C S15 STOP LAMP SWITCH ECM P P E E 12 E6 ST1- V 4 3 Passenger Side J/B 3 4L B 1 2 12 4M BR 19 E6 STP Instrument Panel J/B Y 1 1E STOP 1 1A 6 1G IGN 1 1C B Passenger Side J/B 1 4E 4 4M W F7 FL BLOCK I15 IGNITION SW AM2 L-Y 10 1 IC1 Y 7 AM2 GR IG2 6 ALT W 1 2 FL MAIN BATTERY *1: 3MZ-FE *2: 2AZ-FE I39315 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2346 05-2157 DIAGNOSTICS - CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 READ VALUE OF HAND-HELD TESTER (a) (b) (c) Connect the hand-held tester to the DLC3. Turn the ignition switch to the ON position, and turn the hand-held tester main switch on. Select the item ”STP LIGHT SW2-M”, ”STP LIGHT SW2-S” or ”STP LIGHT SW1-S” in the DATA LIST, and read its value displayed on the hand-held tester. (d) Check that the stop lamp comes on when the brake pedal is depressed, and goes off when the brake pedal is released. ECM: Item Measurement Item / Display (Range) Normal Condition Diagnostic Note STP LIGHT SW2-M Stop lamp SW signal (Main CPU) / ON or OFF ON : Brake pedal depressed OFF : Brake pedal released - STP LIGHT SW2-S Stop lamp SW signal (Sub CPU) / ON or OFF ON : Brake pedal depressed OFF : Brake pedal released - STP LIGHT SW1-S Stop lamp SW signal (Sub CPU) / ON or OFF ON : Brake pedal depressed OFF : Brake pedal released - OK: When brake pedal operation is performed, the standard values will be above. NG Go to step 2 OK REPLACE ECM (SEE PAGE 10-24 ) 2 INSPECT STOP LAMP SWITCH ASSY 2 Pushed in ⇔ Free 4 (a) (b) 1 3 I04062 Disconnect the stop lamp switch assy connector. Measure the resistance according to the value(s) in the table below. Standard: Switch condition Tester connection Switch pin free 1-2 Below 1 Ω Switch pin free 3-4 10 kΩ or higher Switch pin pushed in 1-2 10 kΩ or higher Switch pin pushed in 3-4 Below 1 Ω NG Specified value REPLACE STOP LAMP SWITCH ASSY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2347 05-2158 DIAGNOSTICS 3 - CRUISE CONTROL SYSTEM CHECK HARNESS AND CONNECTOR Stop Lamp Switch Wire Harness Side Connector Front View: (a) S15 I39310 Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition S15-2 - Body ground Always 10 to 16 V S15-3 - Body ground Ignition SW ON 10 to 16 V NG REPAIR OR REPLACE HARNESS OR CONNECTOR (STOP LAMP SWITCH - BATTERY) OK 4 INSPECT ECM Wire Harness View: (a) (b) (c) (d) E6 Reconnect the stop lamp switch connector. Disconnect the E6 connector from the ECM. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Pedal condition Tester connection Specification Depressed E6-19 (STP) Body ground 10 to 16 V Released E6-19 (STP) Body ground Below 1 V Depressed E6-12 (ST1-) Body ground Below 1 V Released E6-12 (ST1-) Body ground 10 to 16 V ST1 STP NG I36982 REPAIR OR REPLACE HARNESS OR CONNECTOR (STOP LAMP SWITCH - ECM) OK REPLACE ECM (SEE PAGE 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2348 05-2159 DIAGNOSTICS DTC - CRUISE CONTROL SYSTEM 05B34-05 P0607/54 INPUT SIGNAL CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION This DTC indicates the internal abnormalities of the ECM. DTC No. P0607/54 Detection Item The ECM has a supervisory CPU and a control ECU inside. When each input STP signal is different for 0.15 sec. or more, this trouble code is output. This trouble code is output after 0.4 sec. has passed from the time the cruise cancel input signal (STP input) is input into the ECM. Trouble Area
ECM HINT: The ECM receives signals from each sensor to control all the functions of the cruise control with the microcomputer. When a trouble code is detected, fail-safe remains on until the ignition switch is turned off. INSPECTION PROCEDURE 1 REPLACE ECM (SEE PAGE 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2349 05-2143 DIAGNOSTICS - CRUISE CONTROL SYSTEM 05IQP-02 ROAD TEST 1. (a) PROBLEM SYMPTOM CONFIRMATION Inspect the SET function. (1) Push the ON-OFF button on. (2) Drive at the required speed (40 km/h (25 mph) or higher). (3) Push the cruise control main switch to -/SET. (4) After releasing the switch, check that the vehicle cruises at the set speed. (b) Inspect the ACC (+) switch. (1) Push the ON-OFF button on. (2) Drive at the required speed (40 km/h (25 mph) or higher). (3) Push the cruise control main switch to -/SET. (4) Check that vehicle speed increases while the cruise control main switch is pushed to +/RES, and that the vehicle cruises at the newly set speed when the switch is released. (5) Momentarily push the cruise control main switch to +/RES and then immediately release it. Check that vehicle speed increases by approximately 1.6 km/h (1.0 mph) (Tap-up function). (c) Inspect the COAST (-) function. (1) Push the ON-OFF button on. (2) Drive at the required speed (40 km/h (25 mph) or higher). (3) Push the cruise control main switch to -/SET. (4) Check that vehicle speed decreases while the cruise control main switch is pushed to -/SET, and the vehicle cruises at the newly set speed when the switch is released. (5) Momentarily push the cruise control main switch to -/SET , and then immediately release it. Check that vehicle speed decreases by approximately 1.6 km/h (1.0 mph) (Tap-down function). (1) (3) I33808 (3) (1) I33808 (1) (3) I33808 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2333 05-2144 DIAGNOSTICS Inspect the CANCEL function. (1) Push the ON-OFF button on. (2) Drive at the required speed (40 km/h (25 mph) or higher). (3) Push the cruise control main switch to -/SET. (4) When doing one of the followings, check that the cruise control system is cancelled and that the normal driving mode is reset.
Depressing the brake pedal
Moving the shift lever to any position except D
Pushing the ON-OFF button off
Pulling the cruise control main switch to CANCEL (e) Inspect the RES (RESUME) function. (1) Push the ON-OFF button on. (2) Drive at the required speed (40 km/h (25 mph) or higher). (3) Push the cruise control main switch to -/SET. (4) When doing one of the followings, check that the cruise control system is cancelled and that the normal driving mode is reset.
Depressing the brake pedal
Moving the shift lever to any position except D
Pulling the cruise control main switch to CANCEL (5) After pushing the cruise control main switch to +/RES at a driving speed of more than 40 km/h (25 mph), check that the vehicle restores the speed prior to the cancellation. (3) I33808 (1) I33808 CRUISE CONTROL SYSTEM (d) (1) (4) - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2334 05-2138 DIAGNOSTICS - CRUISE CONTROL SYSTEM 05IQL-01 SYSTEM DESCRIPTION 1. CRUISE CONTROL SYSTEM The computer which controls the cruise control system is combined with the ECM, and the actuator uses the throttle position sensor and motor. A microcomputer is built into the ECM to control functions including: ON-OFF , SET/COAST, RESUME/ACCEL, CANCEL, vehicle speed operation, motor output control, and overdrive control.
The ECM compares the driving vehicle speed from the speed sensor with the stored vehicle speed set through the cruise control main switch assy. The ECM instructs the throttle valve motor of the throttle position sensor and motor to close the valve when the driving vehicle speed is greater than the stored vehicle speed, and instructs it to open the valve when the driving speed is less than the stored speed.
The ECM receives signals such as ON-OFF, SET/COAST, RESUME/ACCEL, and CANCEL from the cruise control main switch assy and executes them.
The ECM turns on the indicator in the combination meter based upon the ON signal from the cruise control main switch assy.
The ECM cancels the cruise control system when it detects that the brake pedal is depressed, based on the stop lamp switch signal.
The ECM cancels the cruise control system when it detects that the shift position is changed from D to N, based on the park/neutral position switch assy signal. 2. LIMIT CONTROL (a) Low speed limit The lowest possible limit of the speed setting range is set at approximately 40 km/h (25 mph). The cruise control system cannot be set when the driving vehicle speed is below the low speed limit. Cruise control operation will be automatically canceled and the stored vehicle speed will be erased when the vehicle speed goes below the low speed limit while the cruise control is in operation. (b) High speed limit The highest possible limit of the speed setting range is set at approximately 200 km/h (125 mph). The cruise control system cannot be set when the driving vehicle speed is over the high speed limit. Speed up using RESUME/ACCEL with the cruise control main switch assy also cannot be set beyond the high speed limit. 3. OPERATION OF CRUISE CONTROL The cruise control main switch operates seven functions: SET, COAST(-), TAP-DOWN, RESUME, ACCEL(+), TAP-UP and CANCEL. The SET, TAP-DOWN and COAST functions, and the RESUME, TAP-UP and ACCEL functions are operated with the same switch. The cruise control main switch assy is an automatic return type switch which turns on only while operating it in each arrow direction and turns off after releasing it. (a) SET CONTROL Vehicle speed is stored and constant speed control is maintained when pushing the switch to -/SET while driving with the cruise control main switch ON-OFF button on (the CRUISE main indicator light is on), and the vehicle speed is within the set speed range (between the low and high speed limits). (b) COAST CONTROL The ECM makes the cruise control demanding throttle opening angle zero degrees and decelerates the vehicle (the throttle valve is not fully closed due to idle speed control, etc.) when -/SET on the cruise control main switch is pressed and held while the cruise control system is in operation. Vehicle speed, when the cruise control main switch is released from -/SET, is stored and constant speed control is maintained. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2328 05-2139 DIAGNOSTICS - CRUISE CONTROL SYSTEM (c) TAP-DOWN CONTROL When tapping down on the cruise control main switch to -/SET (for approx. 0.5 second) while the cruise control system is in operation, the stored vehicle speed decreases each time by approximately 1.6 km/h (1.0 mph). However, when the difference between the driving and the stored vehicle speed is more than 5 km/h (approx. 3.1 mph), the vehicle speed, when the cruise control main switch is released from -/SET, will be stored and constant speed control is maintained. (d) ACCELERATION CONTROL The throttle valve motor of the throttle position sensor and motor is instructed by the ECM to open the valve when +/RES on the cruise control main switch is pressed and held while the cruise control system is in operation. Vehicle speed, when the cruise control main switch is released from +/RES, is stored and the vehicle is controlled at a constant speed. (e) TAP-UP CONTROL When tapping up on the cruise control main switch to +/RES (for approx. 0.5 second) while the cruise control system is in operation, the stored vehicle speed increases each time by approximately 1.6 km/h (1.0 mph). However, when the difference between the driving and the stored vehicle speed is more than 5 km/h (approx. 3.1 mph), the stored vehicle speed will not be changed. (f) RESUME CONTROL If cruise control operation was cancelled with the stop lamp switch or the CANCEL switch, and if driving speed is within the limit range, pushing the cruise control main switch to +/RES restores vehicle speed memorized at the time of cancellation, and maintains constant speed control. (g) MANUAL CANCEL CONTROL Doing any of the following cancels the cruise control system while in operation. (The stored vehicle speed in the ECM is maintained.)
Depressing the brake pedal
Moving the shift lever to any position except D
Pushing the cruise control main switch to CANCEL
Pushing the cruise control main switch ON-OFF button off (The stored vehicle speed in the ECM is not maintained.) 4. AUTO CANCEL (FAIL-SAFE) This system has an automatic cancellation function (fail-safe) (for details, see page 05-2148 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2329 05-2142 DIAGNOSTICS - CRUISE CONTROL SYSTEM 05IQO-01 CUSTOMER PROBLEM ANALYSIS CHECK CRUISE CONTROL SYSTEM Check Sheet Inspector’s name: VIN Production Date Customer’s Name Licence Plate No. Date Vehicle Brought in / / Date Problem Occurred Condition of Frequency Problem Occurrence Problem Occurs /  Continuous /  Intermittent ( Vehicle Speed when Problem Occurred Symptoms km mile Odometer Reading times a day) km mile  Auto cancel occurs
Driving condition  City driving  Freeway  Uphill  Downhill
After cancel occurred, did the driver activate cruise control again?  Yes  No  Cancel does not occur  With brake ON  Except shifting into D position  When control SW turns to CANCEL position  Cruise control malfunction  Slip to acceleration side  Slip to deceleration side  Hunting occurs  Switch malfunction  SET  ACCEL(+)  COAST(-)  RESUME  CANCEL  CRUISE MAIN indicator light  Remains ON 1st Time  Normal System Code  Trouble Code (Code ) 2nd Time  Normal System Code  Trouble Code (Code )  Does not light up  Blinks DTC Check 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2332 05-2153 DIAGNOSTICS - CRUISE CONTROL SYSTEM 05IQV-01 DIAGNOSTIC TROUBLE CODE CHART HINT:

Using SST 09843-18040, connect terminals TC and CG of the DLC3. If a trouble code is displayed during the DTC check, check the circuit listed for that code. For details of each code, refer to the ”See page” under respective ”DTC No.” in the DTC chart. DTC No. (See Page) Circuit Inspection Trouble Area P0500/21 (05-2154 ) Vehicle Speed Sensor Circuit Malfunction
Vehicle speed sensor
Vehicle speed sensor signal circuit
ECM P0503/23 (05-2154 ) Vehicle Speed Sensor Circuit Malfunction
Vehicle speed sensor
Vehicle speed sensor signal circuit
ECM P0571/52 (05-2155 ) Stop Light Switch Circuit Malfunction
Stop lamp switch assy
Stop lamp switch assy circuit
ECM P0607/54 (05-2159 ) Input Signal Circuit Malfunction
ECM Author
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: 2343 05-2140 DIAGNOSTICS - CRUISE CONTROL SYSTEM 05IQN-02 HOW TO PROCEED WITH TROUBLESHOOTING The hand-held tester can be used at steps 4, 5, 6, and 11. 1 VEHICLE BROUGHT TO WORK SHOP 2 CUSTOMER PROBLEM ANALYSIS (SEE PAGE 05-2142 ) 3 PROBLEM SYMPTOM CONFIRMATION 4 CHECK BODY MULTIPLEX COMMUNICATION SYSTEM (SEE PAGE 05-2040 ) (a) Check for output DTCs. HINT: The ECM of this system is connected to the multiplex communication system. Therefore, before starting troubleshooting, make sure to check that there is no trouble in the multiplex communication system. MULTIPLEX SYSTEM DTC IS OUTPUT (PROCEED TO ”BODY MULTIPLEX COMMUNICATION SYSTEM”) NO MULTIPLEX SYSTEM DTC (GO TO STEP 5) 5 DTC CHECK AND CLEAR (SEE PAGE 05-2147 ) 6 DTC CHECK (OTHER THAN MULTIPLEX DTC) (SEE PAGE 05-2147 ) TROUBLE CODE (GO TO STEP 7) NORMAL SYSTEM CODE (GO TO STEP 8) 7 DTC CHART (SEE PAGE 05-2153 ) GO TO STEP 11 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2330 05-2141 DIAGNOSTICS 8 - CRUISE CONTROL SYSTEM PROBLEM SYMPTOM SIMULATION SYMPTOM DOES NOT OCCUR (GO TO STEP 9) SYMPTOM OCCURS (GO TO STEP 10) 9 SYMPTOM SIMULATION (SEE PAGE 01-26 ) 10 PROBLEM SYMPTOMS TABLE (SEE PAGE 05-2152 ) 11 CIRCUIT INSPECTION (SEE PAGE 05-2154 - 05-2166 ) 12 TERMINALS OF ECM (SEE PAGE 05-2151 ) 13 IDENTIFICATION OF PROBLEM 14 REPAIR OR REPLACE 15 CONFIRMATION TEST END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2331 05-2154 DIAGNOSTICS - CRUISE CONTROL SYSTEM 05IQW-02 DTC P0500/21 VEHICLE SPEED SENSOR CIRCUIT MALFUNCTION DTC P0503/23 VEHICLE SPEED SENSOR CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION 3MZ-FE: See page 05-578 . 2AZ-FE: See page 05-216 . DTC No. DTC Detection Condition Trouble Area P0500/21 This trouble code is output when the vehicle speed signal from the vehicle speed sensor is cut for 0.14 sec. or more while the cruise control is in operation.
Vehicle speed sensor
Vehicle speed sensor signal circuit
ECM P0503/23 Momentary interruption and noise are detected when a rapid change of vehicle speed occurs while the cruise control is in operation.
Vehicle speed sensor
Vehicle speed sensor signal circuit
ECM WIRING DIAGRAM 3MZ-FE: See page 05-578 . 2AZ-FE: See page 05-216 . INSPECTION PROCEDURE 3MZ-FE: See page 05-578 . 2AZ-FE: See page 05-216 . Author
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: 2344 05-2137 DIAGNOSTICS - CRUISE CONTROL SYSTEM 05IQK-01 LOCATION Park/neutral Position Switch Combination Meter ECM Spiral Cable Sub-assy Skid Control ECU Instrument Panel J/B
STOP Fuse
IGN Fuse Cruise Control Main Switch DLC3 Stop Lamp Switch I39351 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2327 05-2136 DIAGNOSTICS - CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM 05IQZ-01 PRECAUTION 1. (a) (b) (c) (d) (e)




Pay attention to the following points when inspecting the cruise control system. Push the cruise control main switch ON-OFF button off when not using the cruise control. Be careful of vehicle speed increase when driving downhill with the cruise control on. RESUME/ACCEL operation, after canceling the cruise control, works as RESUME, and works as ACCEL while the cruise control system is in operation. Push the cruise control main switch ON-OFF button off and reset the cruise control if the CRUISE main indicator light blinks while the cruise control system is in operation. When the cruise control cannot be set by this procedure or cancelled immediately after setting, there may be a malfunction in the system. Do not use the cruise control system where the road conditions are as follows: Heavy traffic Steep downhill Sharp turns Icy or snowy roads Slippery roads 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2326 05-2152 DIAGNOSTICS - CRUISE CONTROL SYSTEM 05IQU-02 PROBLEM SYMPTOMS TABLE If a normal system code is displayed during the DTC check but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. HINT: Inspect the ”Fuse” and ”Relay” before confirming the suspected areas as shown in the chart below. Inspect each malfunction circuit in numerical order for the corresponding symptom. If the malfunction still exists even after checking and confirming that all the circuits are normal, replace the ECM. Symptom Suspected Area See page Main switch cannot be turned ON. (Cruise indicator light in combination meter does not come on.) 3. Cruise control switch circuit 4. CRUISE main indicator light circuit 5. ECM 05-2160 05-2165 10-24 Vehicle speed setting cannot be done. (Although indicator light in combination meter comes on when the main switch is turned ON, it goes off when vehicle speed is set.) 1. Cruise control switch circuit 2. ECM 05-2160 10-24 1. Cruise control switch circuit 2. Stop lamp switch circuit 3. Park/neutral position switch circuit 05-2160 05-2155 05-1036 05-922 05-1109 05-981 05-1868 10-24 Setting cannot be done. (Indicator light in combination meter comes on when the main switch is turned ON and they remain ON while setting.) 4. Transmission control switch circuit U151E/U151F U241E/U141F U151E/U151F U241E/U141F 5. Combination meter system 6. ECM 1. Cruise control switch circuit 2. Vehicle speed sensor circuit While the vehicle is driven with cruise control, the set control is cancelled. (Indicator light and CRUISE remain ON.) 3. Stop lamp switch circuit 4. CRUISE main indicator light circuit 5. Park/neutral position switch circuit 3MZ-FE 2AZ-FE U151E/U151F U241E/U141F 6. ECM 2. ECM 05-578 05-216 10-24 Setting cannot be cancelled. (When Coast, Acceleration, Resume, Set speed change and Control switch are operated.) 1. Cruise control switch circuit 2. ECM 05-2160 10-24 DTC is not output, or is output when should not be. 1. Diagnosis circuit 2. ECM 05-2166 10-24 CRUISE MAIN indicator light does not come on. 1. 2. 3. 4. 05-2160 05-2165 10-24 71-18 Hunting (Speed is not constant.) 1. Vehicle speed sensor circuit 3MZ-FE 2AZ-FE 05-2160 05-578 05-216 05-2155 05-2165 05-1036 05-922 10-24 Cruise control switch circuit CRUISE main indicator light circuit ECM Combination meter assy Author
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: 2342 05-2151 DIAGNOSTICS - CRUISE CONTROL SYSTEM 05B31-08 TERMINALS OF ECM E7 E8 E9 E6 E5 I30693 Symbols (Terminals No.) Wiring Color Terminal Description TC - E1 (E5-20 - E9-1) *1 (E5-20 - E7-1) *2 O - BR Ground Ignition switch ON → Connect terminals TC and CG of DLC3 10 to 16 V → Below 1 V STP - E1 (E6-19 - E9-1) *1 (E6-19 - E7-1) *2 BR - BR Stop lamp signal Ignition switch ON Depress brake pedal → Release brake pedal 10 to 16 V → Below 1 V Ignition switch ON CANCEL switch hold ON -/SET switch hold ON +/RES switch hold ON MAIN switch hold ON 10 to 16 V 6.6 to 11.4 V 4.5 to 8.1 V 2.3 to 4.5 V Below 1 V Ignition switch ON Depress brake pedal → Release brake pedal Below 1 V → 10 to 16 V CCS - E1 (E6-24 - E9-1) *1 (E6-24 - E7-1) *2 LG - BR Cruise control main switch circuit ST1- - E1 (E6-12 - E9-1) *1 (E6-12 - E7-1) *2 V - BR Stop lamp signal Condition Specified Condition *1: 2AZ-FE *2: 3MZ-FE 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2341 05-756 DIAGNOSTICS - TIRE PRESSURE WARNING SYSTEM 05IP2-01 AMBIENT TEMPERATURE SENSOR CIRCUIT CIRCUIT DESCRIPTION The ambient temperature sensor sends the outside temperature signal to the ECM. The ECM transmits the signal to the skid control ECU as a communication signal. The skid control ECU controls the tire pressure warning system, depending on the changes of the outside temperature. HINT: The signal sent from the ambient temperature sensor is also used in the A/C. WIRING DIAGRAM S27 Skid Control ECU With Actuator ENG+ 9 ENG- 23 ECM W-L W-G B-R 5 V 24 E5 R 30 E5 ENG- B 32 E6 TAM 28 E7 E2 IC4 18 IC4 5 IK3 A1 A/C Ambient Temp. Sensor BR 2 1 6 EB2 BR Short Connector 5 5 BR S29 S28 ENG+ F46778 INSPECTION PROCEDURE 1 (a) CHECK DIAGNOSTIC CODE OUTPUT Check if the normal code is output by air conditioning system (see page 05-1 117). OK: DTC is not output. NG REPAIR CIRCUIT INDICATED BY OUTPUT CODE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 946 05-757 DIAGNOSTICS 2 - TIRE PRESSURE WARNING SYSTEM CHECK HARNESS AND CONNECTOR(BRAKE ACTUATOR ASSY - ECM) (SEE PAGE 01-36 ) (a) Wire Harness Side: S27 ENG+ (b) (c) ENGWire Harness Side: ENG+ Disconnect the brake actuator assy S27 connector and ECM E5 connector. Measure the resistance between each terminal of brake actuator assy and ECM wire harness side connectors. Standard: Tester connection Specified condition S27-9 (ENG+) - E5-24 (ENG+) Below 1 Ω S27-23 (ENG-) - E5-30 (ENG-) Below 1 Ω Measure the resistance between each terminal of the brake actuator assy wire harness side connector and body ground. Standard: Tester connection Specified condition S27-9 (ENG+) - Body ground 10 kΩ or higher S27-23 (ENG-) - Body ground 10 kΩ or higher E5 F45562 F45165 ENGF45563 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 947 05-758 DIAGNOSTICS 3 - TIRE PRESSURE WARNING SYSTEM INSPECT ECM(ENG+, ENG- OUTPUT) (a) ECM: ENG+ E9 E1 E5 (b) (c) Connect the brake actuator assy S27 connector and ECM E5 connector. Remove the ECM with the connectors connected. Turn the ignition switch to the ON position. ENGA53769 Normal Signal Waveform: ENG + terminal (d) Using an oscilloscope, connect the terminals, as shown in the chart below. Tester Connection E5-24 (ENG+) - E9-1 (E1) (e) GND 1 V / Division 0.5 ms / Division F45157 Normal Signal Waveform: ENG- terminal With the engine idling, check the output waveform. OK: Signal waveform appears as shown in the illustration. HINT: As the vehicle speed increases, the waveform cycle narrows. (f) Using an oscilloscope, connect the terminals, as shown in the chart below. Tester Connection E5-30 (ENG-) - E9-1 (E1) (g) GND 1 V / Division 0.5 ms / Division F45158 With the engine idling, check the output waveform. OK: Signal waveform appears as shown in the illustration. HINT: As the engine speed increases, the waveform cycle narrows. NG REPLACE ECM OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 948 05-759 DIAGNOSTICS 4 - TIRE PRESSURE WARNING SYSTEM INSPECT AMBIENT TEMPERATURE SENSOR (a) Ambient Temperature Sensor: (b) A1 I30155 Remove the ambient temperature sensor and disconnect the A1 connector. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A1-1 - A1-2 50
F (10
C) 3.00 to 3.73 kΩ A1-1 - A1-2 59
F (15
C) 2.45 to 2.88 kΩ A1-1 - A1-2 68
F (20
C) 1.95 to 2.30 kΩ A1-1 - A1-2 77
F (25
C) 1.60 to 1.80 kΩ A1-1 - A1-2 86
F (30
C) 1.28 to 1.47 kΩ A1-1 - A1-2 95
F (35
C) 1.00 to 1.22 kΩ A1-1 - A1-2 104
F (40
C) 0.80 to 1.00 kΩ A1-1 - A1-2 113
F (45
C) 0.65 to 0.85 kΩ A1-1 - A1-2 122
F (50
C) 0.50 to 0.70 kΩ A1-1 - A1-2 131
F (55
C) 0.44 to 0.60 kΩ A1-1 - A1-2 140
F (60
C) 0.36 to 0.50 kΩ HINT: As the temperature increases, the resistance decreases (see the chart below). NOTICE: Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. 4.0 3.5 3.0 2.5 Resistance (kΩ) MIX 2.0 MAX 1.5 1.0 5.0 0.0 0 20 40 68 104 60
C 140
F Temperature (
C) I38777 NG REPLACE AMBIENT TEMPERATURE SENSOR OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 949 05-760 DIAGNOSTICS 5 - TIRE PRESSURE WARNING SYSTEM CHECK HARNESS AND CONNECTOR(ECM - AMBIENT TEMPERATURE SENSOR) (SEE PAGE 01-36 ) (a) (b) Wire harness side: Disconnect the ECM E6 and E7 connectors. Measure the resistance according to the value(s) in the table below. Standard: A1 Wire harness side: Condition Specified condition E6-32 (TAM) - A1-2 Always Below 1 Ω E7-28 (E2) - A1-1 Always Below 1 Ω E6-32 (TAM) - Body ground Always 10 kΩ or higher E7-28 (E2) - Body ground Always 10 kΩ or higher E6 E7 E2 Tester connection NG TAM F46780 REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE ECM (SEE PAGE 10-9 OR 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 950 05-744 DIAGNOSTICS - TIRE PRESSURE WARNING SYSTEM 05EZ0-02 DIAGNOSIS SYSTEM 1. (a) BAT SIL DLC3 CG C52361 DIAGNOSTIC SYSTEM Inspect the battery voltage. Battery voltage: 11 to 14 V If voltage is below 11 V, recharge the battery before proceeding. (b) Check the DLC3. The vehicle’s skid control ECU uses ISO 9141-2 for communication. The terminal arrangement of the DLC3 complies with SAE J1962 and matches with the ISO 9141-2 format. Verify conditions listed in the table below: Terminal No. Terminal name Connection / Voltage or Resistance Condition 7 SIL Bus + Line / Pulse generation During transmission 4 CG Chassis Ground to Body Ground / 1 Ω or less Always 16 BAT Battery Positive to Body Ground / 10 to 14 V Always HINT: If the hand-held tester displays ”UNABLE TO CONNECT TO VEHICLE” when the cable of the hand-held tester is properly connected to the DLC3, the ignition switch is turned to the ON position and the tester is operated, there is either a problem on the vehicle side or tester side.
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 on the original vehicle.
If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tester itself. In this case, consult the Service Department listed in the tester’s instruction manual. 2. (a) (b) CHECK WARNING LAMP Turn the ignition switch to the LOCK position. When the ignition switch is turned to the ON position, the lamp should come on for 3 to 4 seconds and then go off. HINT: If the tire pressure warning lamp has a defect, check the tire pressure warning lamp output patterns and the problem symptoms table (see page 05-740 ). Tire Pressure Warning Lamp Lamp Output Pattern: Ignition Switch ON ON OFF 3 to 4 Sec. F46775 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 934 05-745 DIAGNOSTICS 3. - TIRE PRESSURE WARNING SYSTEM TIRE PRESSURE WARNING LAMP CHART: Priority 1 Condition Ignition switch is in the ON position. Tire Pressure Warning Lamp Output Pattern Tire pressure warning lamp comes on for 3 seconds when the ignition switch is turned to the ON position. (However, during initialization, the lamp comes on for 4 seconds.) 3 or 4 Sec. ON OFF Ignition Switch ON 2 System abnormal 1 Tire pressure warning lamp signal is open. HINT: When the tire pressure warning lamp drive signal circuit opens due to a skid control ECU malfunction, communication error, open circuit in the wire harness, etc., the tire pressure warning lamp comes on. (Active Lamp Circuit) 3 System abnormal 2 ABS system malfunction Speed sensor malfunction Stop lamp switch assy malfunction HINT: The skid control ECU monitors the speed sensor signal and the stop lamp switch signal, and the tire pressure warning lamp blinks. 4 (When in test mode) Tire pressure warning reset switch is turned on during test mode. (Press and hold the tire pressure warning reset switch.) Tire pressure warning lamp comes on ON OFF Signal Circuit Open Tire pressure warning lamp blinks (Comes on and goes off repeatedly at 0.5 second intervals.) 0.5 Sec. ON OFF Malfunction Occurs 0.5 Sec. HINT: (When the skid control ECU detects a system abnormal 2 malfunction, check the ABS DTCs and proceed to the pages on which the ABS DTCs are described.) Tire pressure warning lamp comes on when the tire pressure warning reset switch is turned on. Switch Operating ON OFF Switch ON 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 935 05-746 DIAGNOSTICS Priority 5 - Condition Initialization mode is received. HINT: See step 3 for initialization procedure. TIRE PRESSURE WARNING SYSTEM Tire Pressure Warning Lamp Output Pattern Tire pressure warning lamp blinks 3 times (Comes on and goes off repeatedly at 1 second intervals.) ON 1 Sec. Switch ON OFF 3 Sec. 6 Failure to initialize when driving the vehicle. HINT: 3 conditions will indicate this pattern: 1. New vehicle from factory 2. ECM replacement 3. Failure to initialize 1 Sec. Tire pressure warning lamp blinks (Comes on and goes off repeatedly at 0.25 second intervals.) 0.25 Sec. ON OFF 0.25 Sec. 7 Outputs tire air pressure check result. HINT: The result is output only when driving at 19 mph (35 km/h) or more. Tire pressure is judged to be normal: Warning light is OFF: ON OFF Tire pressure is judged to be low: Warning light comes on: ON OFF Judging Low Tire Pressure HINT: When the skid control ECU does not operate properly, the ABS warning lamp comes on as an ABS system malfunction. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 936 05-747 DIAGNOSTICS - TIRE PRESSURE WARNING SYSTEM 05EZ1-02 DATA LIST/ACTIVE TEST 1. DATA LIST HINT: By accessing the DATA LIST displayed by the hand-held tester, you can read the value of the switches and sensors without removing any parts. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. (a) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Following the display on the tester, select the ”DATA LIST”. ABS: Item Measurement Item / Range (Display) Normal Condition Diagnostic Note STOP LIGHT SW Stop light switch / ON or OFF ON: Brake pedal depressed OFF: Brake pedal released WHEEL SPD FR Front right wheel speed reading / min.: 0 km/h (0 mph) max.: 326.4 km/h (202 mph) Actual wheel speed Speed indicated on speedometer WHEEL SPD FL Front left wheel speed reading / min.: 0 km/h (0 mph) max.: 326.4 km/h (202 mph) Actual wheel speed Speed indicated on speedometer WHEEL SPD RR Rear right wheel speed reading / min.: 0 km/h (0 mph) max.: 326.4 km/h (202 mph) Actual wheel speed Speed indicated on speedometer WHEEL SPD RL Rear left wheel speed reading / min.: 0 km/h (0 mph) max.: 326.4 km/h (202 mph) Actual wheel speed Speed indicated on speedometer VEHICLE SPD Vehicle speed reading / min.: 0 km/h (0 mph) max.: 326.4 km/h (202 mph) Actual vehicle speed EFI COM EFI communication open detection / Normal or Open Normal - TEST MODE Test mode / NORMAL or TEST NORMAL: Normal mode TEST: During test mode - #CODES Number of DTC recorded / min.: 0, max.: 255 Min.: 0, Max.: - - - Speed indicated on speedometer 2. ACTIVE TEST HINT: Perform the ACTIVE TEST using the hand-held tester to operate the ABS warning lights. Performing the ACTIVE TEST is one of the methods to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Following the display on the tester, perform the ”ACTIVE TEST”. ABS: Item ABS WARN LIGHT Vehicle Condition / Test Details Diagnostic Note ABS warning light / ON or OFF - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 937 05-736 DIAGNOSTICS - TIRE PRESSURE WARNING SYSTEM 05EYX-02 INITIALIZATION NOTICE:  This system requires initializing after changing tires or wheels, or after rotating the tires.  Be sure to adjust the tire air pressure to the specified value before initialization. 1. (a) INITIALIZING THE TIRE PRESSURE WARNING SYSTEM Check and adjust the tire pressure to the specified value. Specified Value (b) (c) Tire Pressure Warning Reset Switch Tire Pressure Warning Lamp Lamp Output Pattern:
Receipt of the Initialization Signal Keep pressing the switch for 3 sec. 1 Sec. ON OFF 3 Sec. 1 Sec.
Failure of Initialization 0.25 Sec. ON OFF 0.25 Sec. F46772 Front 210 kpa (2.1 kgf/cm2, 30 psi) Rear 210 kpa (2.1 kgf/cm2, 30 psi) With the vehicle stopped, turn the ignition switch to the ON position. Press and hold the tire pressure warning reset switch until the tire pressure warning lamp blinks 3 times at 1 second intervals. HINT: If the tire pressure warning lamp does not blink, perform the initialization again. (with the ignition switch off, perform the procedure above starting at step 1-(b).) (d) Drive the vehicle at 19 mph (30 km/h) or more, to complete the initialization of the skid control ECU. (It takes more than one hour.) HINT: If the tire pressure warning lamp blinks at 0.25 second intervals while the vehicle is being driven, the initialization may have failed. If so, perform the initialization again. (Turn the ignition switch off and retry from step 1-(a).) (e) After initialization is completed, the skid control ECU monitors the tire pressure by using the wheel speed sensors. (f) To verify the system has been initialized check the length of time the tire pressure warning lamp is on after turning the ignition switch to the ON position.  Not initialized: 4 sec.  Initialized: 3 sec. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 926 05-733 DIAGNOSTICS - TIRE PRESSURE WARNING SYSTEM 05CLA-03 SYSTEM DESCRIPTION 1. (a) TIRE PRESSURE WARNING SYSTEM DESCRIPTION The tire pressure warning system informs the driver if it detects a low tire pressure. When the tire pressure warning system detects low tire pressure in any of the 4 wheels, which affects safe driving the tire pressure warning lamp comes on. Specified Value Front 210 kpa (2.1 kgf/cm2, 30 psi) Rear 210 kpa (2.1 kgf/cm2, 30 psi) (b) Tire pressure warning system is controlled by the skid control ECU. HINT: When the tire pressure reset switch is push, the tire pressure warning lamp goes off. 2. (a) TIRE PRESSURE WARNING DISPLAY FUNCTION The tire pressure warning lamp comes on, according to the condition of the tire pressure warning system, as shown in the DIAGNOSIS SYSTEM (see page 05-744 ). Tire Pressure Warning Lamp F46769 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 923 05-732 DIAGNOSTICS - TIRE PRESSURE WARNING SYSTEM 05EYW-02 SYSTEM DIAGRAM Tire Pressure Warning Reset Switch Ambient Temperature Sensor ECM Skid Control ECU Right Front Speed Sensor Left Front Speed Sensor Right Rear Speed Sensor Left Rear Speed Sensor Stop Lamp Switch Assy Combination Meter Assy (Tire Pressure Warning Lamp) F46771 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 922 05-748 DIAGNOSTICS - TIRE PRESSURE WARNING SYSTEM 05IOZ-02 STOP LAMP SWITCH CIRCUIT CIRCUIT DESCRIPTION When the stop lamp switch is ON (brake pedal depressed), the skid control ECU suspends the tire pressure warning system. WIRING DIAGRAM S15 Stop Light SW Passenger Side J/B 3 4L B 2 S27 Skid Control ECU With Actuator 1 11 4A B 22 IC4 G-Y 27 STP Instrument Panel J/B Y 1 1E STOP 1 1A B W-B 32 A J4 J/C F7 FL Block FL MAIN ALT W 1 Battery GND1 B 2 W-B EA W-B EB F46776 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 938 05-749 DIAGNOSTICS - TIRE PRESSURE WARNING SYSTEM INSPECTION PROCEDURE 1 (a) CHECK STOP LAMP SWITCH OPERATION Check that the stop lamp comes on when the brake pedal is depressed, and goes off when the brake pedal is released. OK: Stop lamp functions normally. NG Go to step 3 OK 2 CHECK HARNESS AND CONNECTOR(BRAKE ACTUATOR ASSY - STOP LAMP SWITCH ASSY) (SEE PAGE 01-36 ) Wire Harness Side: (a) (b) STP S27 GND1 Disconnect the brake actuator assy connector. Measure the voltage according to the value(s) in the table below. Standard: Switch condition Tester connection Specified condition Brake pedal depressed S27-27 (STP) S27-32 (GND1) 10 to 14 V Brake pedal released S27-27 (STP) S27-32 (GND1) Below 1.5 V F45562 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-740 ) 3 CHECK REAR COMBINATION LAMP ASSY LH NG REPLACE REAR COMBINATION LAMP ASSY LH OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 939 05-750 DIAGNOSTICS 4 TIRE PRESSURE WARNING SYSTEM INSPECT STOP LAMP SWITCH ASSY Stop Lamp Switch Assy: 2 Free - 1 (a) (b) Disconnect the stop lamp switch assy S15 connector. Measure the resistance according to the value(s) in the table below. Standard: Switch condition Tester connection Specified condition Switch pin free 1-2 Below 1 Ω Switch pin pushed in 1-2 10 kΩ or higher Pushed In F45894 NG REPLACE STOP LAMP SWITCH ASSY OK 5 CHECK HARNESS AND CONNECTOR(BRAKE ACTUATOR ASSY - STOP LAMP SWITCH ASSY) (SEE PAGE 01-36 ) Wire Harness Side: (a) (b) (c) STP S27 GND1 F45562 Connect the stop lamp switch assy S15 connector. Disconnect the brake actuator assy connector. Measure the voltage according to the value(s) in the table below. Standard: Switch condition Tester connection Specified condition Brake pedal depressed S27-27 (STP) S27-32 (GND1) 10 to 14 V Brake pedal released S27-27 (STP) S27-32 (GND1) Below 1.5 V NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-740 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 940 05-752 DIAGNOSTICS - TIRE PRESSURE WARNING SYSTEM 05IP0-02 TIRE PRESSURE WARNING RESET SWITCH CIRCUIT CIRCUIT DESCRIPTION Receiving the signal from the tire pressure warning reset switch, the skid control ECU indicates initialization of the tire pressure warning system. WIRING DIAGRAM P22 Tire Pressure Warning Reset Switch Passenger Side J/B W-B 7 4L 6 W-B 4J 2 1 SB S27 Skid Control ECU With Actuator 2 B-Y IC4 41 INIT J4 J/C W-B A W-B 32 GND1 W-B IC EB EA F46777 INSPECTION PROCEDURE 1 CHECK TIRE PRESSURE WARNING RESET SWITCH (SEE PAGE 05-737 ) OK: Tire pressure warning reset switch functions normally. NG Go to step 2 OK CORRECT TIRE PRESSURE TO THE SPECIFIED PRESSURE, THEN INITIALIZE THE SYSTEM 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 942 05-753 DIAGNOSTICS 2 - TIRE PRESSURE WARNING SYSTEM INSPECT TIRE PRESSURE WARNING RESET SWITCH Tire Pressure Warning Reset Switch: (a) (b) Disconnect the tire pressure warning reset switch P22 connector. Measure the resistance according to the value(s) in the table below. Standard: ON OFF 2 Switch condition Specified condition ON Below 1 Ω OFF 10 kΩ or higher 1 F44158 NG REPLACE TIRE PRESSURE WARNING RESET SWITCH OK 3 CHECK HARNESS AND CONNECTOR(TIRE PRESSURE WARNING RESET SWITCH - BRAKE ACTUATOR ASSY) (SEE PAGE 01-36 ) (a) Wire Harness Side: (b) (c) S27 GND1 INIT Reconnect the tire pressure warning reset switch P22 connector. Disconnect the brake actuator assy connector. Measure the resistance according to the value(s) in the table below. Standard: Switch condition Tester connection Specified condition ON S27-41 (INIT) S27-32 (GND1) Below 1 Ω OFF S27-41 (INIT) S27-32 (GND1) 10 kΩ or higher F45562 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-740 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 943 05-751 DIAGNOSTICS - TIRE PRESSURE WARNING SYSTEM 05EZ4-02 ABS SYSTEM MALFUNCTION CIRCUIT DESCRIPTION The skid control ECU outputs DTCs when a speed sensor malfunction occurs or there is an open in the stop lamp switch assy circuit of the ABS system. If ABS system has a malfunction, tire pressure warning system will not function. INSPECTION PROCEDURE 1 (a) CHECK DIAGNOSTIC TROUBLE CODE OUTPUT Check that the normal code is output by ABS system (see page 05-765 ). OK: DTC is not output. NG REPAIR CIRCUIT INDICATED BY OUTPUT CODE OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-740 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 941 05-754 DIAGNOSTICS - TIRE PRESSURE WARNING SYSTEM 05IP1-03 TIRE PRESSURE WARNING LAMP CIRCUIT CIRCUIT DESCRIPTION When the tire pressure decreases, the skid control ECU illuminates the tire pressure warning lamp on the combination meter assy. HINT: Refer to the ”TIRE PRESSURE WARNING LAMP CHART” section in the ”DIAGNOSIS SYSTEM” for the tire pressure warning lamp (see page 05-744 ). WIRING DIAGRAM S27 Skid Control ECU with Actuator ECM 30 E5 R 18 IC4 W-G 23 S27 ENG- 24 ENG+ E5 V 5 IC4 W-L 9 S27 ENG+ TRC+ 25 E5 Y 7 IC4 G-B TRC- 31 E5 G 19 IC4 Y-B ENG- MPX1 S27 TRC+ 22 Multiplex Communication Circuit MPX2 8 29 E6 S27 TRC- Combination Meter 9 C12 MPX+ 21 C11 MPX- 18 E6 F45964 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 944 05-755 DIAGNOSTICS - TIRE PRESSURE WARNING SYSTEM INSPECTION PROCEDURE 1 (a) (b) INSPECT COMBINATION METER ASSY(TIRE PRESSURE WARNING LAMP) Turn the ignition switch to the ON position. Check the tire pressure warning lamp. OK: Tire pressure warning lamp comes on for 3 or 4 seconds. NG REPLACE COMBINATION METER ASSY (SEE PAGE 71-18 ) OK 2 (a) CHECK DIAGNOSTIC CODE OUTPUT Check if the normal code is output by SFI system (see page 05-38 or 05-400 ). OK: No DTC output from SFI system. NG REPAIR CIRCUIT INDICATED BY OUTPUT CODE OK 3 (a) CHECK DIAGNOSTIC CODE OUTPUT Check if the normal code is output by VSC system (see page 05-765 ). OK: No DTC output from VSC system. NG REPAIR CIRCUIT INDICATED BY OUTPUT CODE OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-740 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 945 05-737 DIAGNOSTICS - TIRE PRESSURE WARNING SYSTEM 05EYY-02 TEST MODE PROCEDURE 1. (a) (b) TS (c) DLC3 TEST MODE (USING SST CHECK WIRE) Make sure the ignition switch off. Using SST, connect terminals TS and CG of the DLC3. SST 09843-18040 Turn the ignition switch to the ON position. CG C52361 S Tire Pressure Warning Reset Switch Lamp Output Pattern:
Normal Condition (d) Press the tire pressure warning reset switch. (e) Check that the tire pressure warning lamp comes on. HINT:  Unless (d) above is done, the tire pressure warning lamp remains off while in test mode.  When there is a problem with the tire pressure warning system, the tire pressure warning lamp blinks at 0.5 second intervals. If the lamp output result is not normal, proceed to the problem symptoms table or TS terminal circuit. Tire Pressure Warning Lamp OFF Switch Operating See page Problem symptoms table 05-740 TS and CG terminal circuit 05-873 (f) (g) Switch ON ON Item Turn the ignition switch off. Remove the SST from the DLC3. SST 09843-18040
System Malfunction 0.5 Sec. ON OFF 0.5 Sec. F46773 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 927 05-738 DIAGNOSTICS - TIRE PRESSURE WARNING SYSTEM (h) (i) (j) Turn the ignition switch to the ON position. Check that the tire pressure warning lamp goes off. Initialize the tire pressure warning system (see page 05-736 ). 2. (a) (b) (c) TEST MODE (USING THE HAND-HELD TESTER) Connect the hand-held tester to the DLC3. Turn the ignition switch to the ON position. Select ”SIGNAL CHECK”, and proceed checking with the hand-held tester. Tire Pressure Warning Lamp Lamp Output Pattern: Ignition Switch ON ON OFF 3 to 4 Sec. F46775 Hand-Held Tester DLC3 F46779 Tire Pressure Warning Reset Switch Lamp Output Pattern:
Normal Condition Switch ON ON OFF Tire Pressure Warning Lamp (d) Press the tire pressure warning reset switch. (e) Check that the tire pressure warning lamp comes on. HINT:  Unless (d) above is done, the tire pressure warning lamp remains off while in test mode.  When there is a problem with the tire pressure warning system, the tire pressure warning lamp blinks at 0.5 second intervals. If the lamp output result is not normal, proceed to the problem symptoms table (see page 05-740 ). (f) Turn the ignition switch off. Switch Operating
System Malfunction 0.5 Sec. ON OFF 0.5 Sec. F46773 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 928 05-739 DIAGNOSTICS (g) (h) (i) - TIRE PRESSURE WARNING SYSTEM Turn the ignition switch to the ON position. Check that the tire pressure warning lamp goes off. Initialize the tire pressure warning system (see page 05-736 ). Tire Pressure Warning Lamp Lamp Output Pattern: Ignition Switch ON ON OFF 3 to 4 Sec. F46775 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 929 05-735 DIAGNOSTICS - TIRE PRESSURE WARNING SYSTEM 05BW7-05 CUSTOMER PROBLEM ANALYSIS CHECK Inspector’s : Name Tire Pressure Warning System Check Sheet VIN Production Date Customer’s Name / / Licence Plate No. Date Vehicle Brought In / km miles Odometer Reading / Date Problem First Occurred / Frequency Problem Occurs Continuous / Intermittent ( times a day) In spite of abnormal low pressure of the tire pressure,the warning lamp does not come on. The warning lamp was on and the tire was filled up with air, but the warning lamp does not go off. Symptoms Tire Pressure Warning Lamp Abnormal Remains ON Does not Come on ABS Warning Lamp Normal Malfunction Code (Code ) ) RR ( ) RL ( ) Tire Pressure FR ( ) FL ( Tire Size Check Item Tire FR ( ) FL ( ) RR ( ) RL ( ) FR ( Tire Type ) FL ( ) RR ( ) RL ( ) FR ( Tire Wear Condition ) FL ( ) RR ( ) RL ( ) History of Changing Tires or Wheels When ( ) History of Rotating Tires When ( ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 925 05-734 DIAGNOSTICS - TIRE PRESSURE WARNING SYSTEM 05BW6-05 HOW TO PROCEED WITH TROUBLESHOOTING The hand-held tester can be used at steps 3, 6 and 9. 1 VEHICLE BROUGHT TO WORKSHOP 2 CUSTOMER PROBLEM ANALYSIS (SEE PAGE 05-735 ) 3 CHECK MULTIPLEX COMMUNICATION SYSTEM (SEE PAGE 05-2040 ) (a) Check that DTC is output. DTC IS OUTPUT (PROCEED TO ”MULTIPLEX COMMUNICATION SYSTEM”) DTC IS NOT OUTPUT (Go to step 4) 4 (a) (b) (c) CHECK TIRE PRESSURE WARNING LAMP CONDITION Turn the ignition switch to the ON position. Record the condition of the tire pressure warning lamp on the combination meter assy. Refer to the ”TIRE PRESSURE WARNING LAMP CHART” section of the DIAGNOSIS SYSTEM for checking the condition of the tire pressure warning lamp (see page 05-744 ). 5 PROBLEM SYMPTOMS TABLE (SEE PAGE 05-740 ) 6 CIRCUIT INSPECTION (SEE PAGE 05-748 to 05-756 ) 7 IDENTIFICATION OF PROBLEM 8 REPAIR 9 CONFIRMATION TEST END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 924 05-731 DIAGNOSTICS - TIRE PRESSURE WARNING SYSTEM 05CLC-04 LOCATION Right Rear Speed Sensor Brake Actuator Assy (Skid Control ECU) Right Front Speed Sensor Left Rear Speed Sensor 4WD: Left Rear Speed Sensor Ambient Temperature Sensor Left Front Speed Sensor Combination Meter Assy
Tire Pressure Warning Lamp
ABS Warning Lamp ECM Stop Lamp Switch Assy DLC3 Tire Pressure Warning Reset Switch F46770 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 921 05-729 DIAGNOSTICS - TIRE PRESSURE WARNING SYSTEM TIRE PRESSURE WARNING SYSTEM 05CL9-03 PRECAUTION 1. (a) TIRE PRESSURE WARNING SYSTEM PRECAUTION When the tire pressure warning lamp comes on, immediately check the air pressure of all tires and adjust to the specified pressure. Specified Value Tire Pressure Warning Lamp (b) F46769 (c) Front 210 kpa (2.1 kgf/cm2, 30 psi) Rear 210 kpa (2.1 kgf/cm2, 30 psi) This system requires initializing after changing tires or wheels, or after rotating the tires (see page 28-1 ). Set tire pressure within the specified range before initializing. If the tire air pressure is not within the specified range, the tire pressure warning system will not function. In the following cases, the system may not operate normally.
A compact spare tire, snow tires, or tire chains are used.
The tire pressure is excessively higher than specified, or tire pressure suddenly drops due to bursting or other causes.
The vehicle is driven on a slippery road surface such as rough or frozen roads.
The vehicle speed is 19 mph (30 km/h) or less or more than 62 mph (100 km/h) , and the driving duration is less than 5 minutes.
The tires differ in tread pattern or manufacture.
The tires are not the specified size.
The tread wear is very different among the installed tires.
Rapid acceleration/deceleration or sharp turns is continued.
Towing a trailer.
The loading is over the limit or imbalanced.
Initialization was not performed correctly after replacing or rotating tires or wheels.
The outside temperature is below 32F (0C) or above 104F (40C). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 919 05-730 DIAGNOSTICS 2. (a) (b) - TIRE PRESSURE WARNING SYSTEM FAIL-SAFE FUNCTION When a system malfunction occurs in the tire pressure warning system, the tire pressure warning lamp blinks. The result of this diagnosis is stored in the skid control ECU. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 920 05-740 DIAGNOSTICS - TIRE PRESSURE WARNING SYSTEM 05BWC-05 PROBLEM SYMPTOMS TABLE Check the circuits for each problem symptom in the order given in the table below, and proceed to the relevant troubleshooting page. HINT:
Inspect each circuit in numerical order for the corresponding symptom. If the malfunction still exists even after checking and confirming that all the circuits are normal, replace the brake actuator assy.
When a malfunction is found in the skid control ECU, replace the brake actuator assy.
When the tire pressure warning lamp blinks and the ABS warning lamp comes on, check the ABS system first. Symptom Suspect Area See page Tire pressure warning lamp does not come on after ignition switch is turned ON. 3. Tire pressure warning lamp circuit 4. Combination meter assy 5. Brake actuator assy 05-754 05-1868 - Tire pressure warning lamp remains on after ignition switch is turned ON. HINT:
System abnormal 1 is detected.
Low pressure is detected. 1. Check tire pressure and press the tire pressure reset switch a few seconds. 2. Tire pressure warning lamp circuit 3. Combination meter assy 4. Brake actuator assy 05-754 05-1868 - Tire pressure warning lamp blinks at 0.5 second intervals. HINT: System abnormal 2 is detected. 1. Stop lamp switch circuit 2. Vehicle speed sensor 3. ABS system malfunction 05-748 05-788 05-751 Tire pressure warning lamp blinks at 0.25 second intervals. HINT: ECU requires initialization. 1. Initialize the tire pressure warning system 2. Brake actuator assy 05-736 - ECU is initialized (tire pressure warning reset switch is ON), but tire pressure warning lamp does lit. 1. Check initialization 2. Tire pressure warning reset switch circuit 3. Brake actuator assy 05-736 05-752 - Tire pressure warning lamp comes on while driving, but lamp goes off without supplying tire air pressure. 1. Check tire pressure warning lamp 2. Tire pressure warning lamp circuit 3. Combination meter assy 4. Brake actuator assy HINT: Tire pressure may be affected by the driving environment. When any of the detected pressures reach standard tire pressure value, the warning lamp may go off. 05-744 05-744 05-754 - Tire pressure warning lamp comes on, but tire air pressure is within the standard value. 1. Check if vehicle has the appropriate size tire. 2. Ambient temperature sensor circuit 3. Tire pressure warning lamp circuit 4. Combination meter assy 5. Brake actuator assy HINT:
Using inappropriate size tires, or not using the indicated tires.
Tire pressure is not adjusted at initialization. 05-756 05-754 05-1868 - - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 930 05-741 DIAGNOSTICS - TIRE PRESSURE WARNING SYSTEM Tire pressure warning lamp remains off, even when tire air pressure decreased. 1. Check if vehicle has the appropriate size tires. 2. Ambient temperature sensor circuit 3. Tire pressure warning lamp circuit 4. Combination meter assy 5. Brake actuator assy HINT:
Using inappropriate size tires.
Tire pressure may be affected by the driving environment. Since tire pressure decreases in cold weather, the pressure warning lamp may come on.
Tire pressure is not adjusted at initialization. 05-756 05-754 05-1868 - Tire pressure warning lamp comes on while driving, and lamp remains lit after correcting tire pressure. 1. 2. 3. 4. 5. 6. 05-744 05-754 05-1868 05-756 - Test mode cannot be completed. 1. ABS system malfunction 2. TS terminal circuit 3. Brake actuator assy Press the tire pressure reset switch a few seconds. Check tire pressure warning lamp Tire pressure warning lamp circuit Combination meter assy Ambient temperature sensor circuit Brake actuator assy 05-751 05-873 - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 931 05-742 DIAGNOSTICS - TIRE PRESSURE WARNING SYSTEM 05IOX-02 TERMINALS OF ECU SKID CONTROL ECU: S27 F45156 Symbols (Terminals No.) Wiring Color Terminal Description Condition Specified Condition TRC+ (8) - TRC- (22) G-B - Y-B ECM communication output Ignition switch ON ENG+ (9) - GND1 (32) W-L - W-B ECM serial communication line (+) input signal Ignition switch ON and vehicle speed 30 km/h (19 mph) or more D/G (13) - GND1 (32) GR-B - W-B Diagnosis tester communication line Ignition switch ON ENG- (23) - GND1 (32) W-G - W-B ECM serial communication line (-) input signal Ignition switch ON and engine idle speed STP (27) - GND1 (32) G-Y - W-B Stop lamp switch assy input signal Brake pedal depressed STP (27) - GND1 (32) G-Y - W-B Stop lamp switch assy input signal Brake pedal released GND1 (32) - Body ground W-B Body ground Ground Always Below 1 Ω INIT (41) - GND1 (32) B-Y - W-B Tire pressure warning reset switch signal Ignition switch ON and tire pressure warning reset switch ON Below 3 V INIT (41) - GND1 (32) B-Y - W-B Tire pressure warning reset switch signal Ignition switch ON and tire pressure warning reset switch OFF 10 to 14 V Pulse generation Pulse generation (See wave form 1) 10 to 14 V Pulse generation (See wave form 2) 10 to 14 V Below 1.5 V Wave form 1: Reference Item Condition Terminal ENG+ - GND1 Tool setting 1 V / DIV, 0.5 ms / DIV Vehicle condition Engine idle speed GND F45157 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 932 05-743 DIAGNOSTICS - TIRE PRESSURE WARNING SYSTEM Wave form 2: Reference Item Condition Terminal ENG- - GND1 Tool setting 1 V / DIV, 0.5 ms / DIV Vehicle condition Engine idle speed GND F45158 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 933 05-2131 DIAGNOSTICS - CAN COMMUNICATION SYSTEM 05IR7-02 CHECK CAN BUS LINE (CAN-L) FOR SHORT TO GND CIRCUIT DESCRIPTION A short to GND is suspected in the CAN bus line when there is continuity between terminals 4 (CG) and 14 (CANL) of the DLC3. Symptom Trouble Area
Short to GND in CAN bus line (CANL)
Skid control ECU
Steering sensor
Yaw rate sensor There is continuity between terminals 4 (CG) and 14 (CANL) of DLC3. WIRING DIAGRAM S14 Steering Sensor J16 J/C CANH VSC Y 10 10 CANL 2 STRG L 12 IC4 B W 13 IC4 W 8 VSC STRG 21 W 9 ESS Skid Control ECU With Actuator 19 11 S27 CANH 25 S27 CANL W-B Y1 Yaw Rate Sensor CANH CANL 1 GND 12 IO2 G 13 IO2 W B 3 W 2 9 20 YAW YAW D3 DLC3 CANH CANL W-B B 11 DLC3 6 W 14 22 W-B DLC3 1 S27 GND2 32 S27 GND1 Passenger Side J/B CG W-B 4 6 4C 1 4N W-B 3 4C 1 4N W-B J19 J/C W-B W-B A A BF J4 J/C IC EH EB A G30963 Author
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: 2321 05-2132 DIAGNOSTICS - CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK CAN BUS LINE FOR SHORT TO GND(DLC3 SUB BUS LINE, CAN-L) (a) Disconnect the wire harness connector (J16) from the junction connector. (b) Measure the resistance according to the value(s) in the table below. Standard: Junction Connector: J16 CANH CANL G26430 G25476 DLC3: CG 1 2 3 4 D3 5 6 7 8 Tester connection Condition Specified value D3-4 (CG) D3-14 (CANL) Ignition SW OFF 1 MΩ or more 9 10 11 12 13 14 15 16 CANL G25474 C81825 NG G26206 REPAIR OR REPLACE DLC3 SUB BUS LINE OR CONNECTOR (CAN-L) OK 2 (a) CONNECTION OF CONNECTORS Reconnect the wire harness connector (J16) to the junction connector. Author
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: 2322 05-2133 DIAGNOSTICS 3 - CAN COMMUNICATION SYSTEM CHECK CAN BUS LINE FOR SHORT TO GND(SKID CONTROL ECU, CAN-L) DLC3: (a) CG D3 (b) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Disconnect the connector (S27) from the skid control ECU. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value D3-4 (CG) D3-14 (CANL) Ignition SW OFF 3 kΩ or more CANL G25474 C81825 G26206 OK REPLACE SKID CONTROL ACTUATOR (SEE PAGE 32-37 ) ECU WITH NG 4 CHECK CAN BUS LINE FOR SHORT TO GND(STEERING SENSOR, CAN-L) DLC3: CG 1 2 3 4 (a) (b) (c) D3 5 6 7 8 9 10 11 12 13 14 15 16 Reconnect the connector (S27) to the skid control ECU. Disconnect the connector (S14) from the steering sensor. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value D3-4 (CG) D3-14 (CANL) Ignition SW OFF 3 kΩ or more CANL G25474 C81825 G26206 OK REPLACE STEERING SENSOR (SEE PAGE 32-48 ) NG 5 CHECK CAN BUS LINE FOR SHORT TO GND(YAW RATE SWENSOR, CAN-L) DLC3: CG 1 2 3 4 (a) (b) (c) D3 5 6 7 8 9 10 11 12 13 14 15 16 G25474 C81825 Reconnect the connector (S14) to the steering sensor. Disconnect the connector (Y1) from the yaw rate sensor. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value D3-4 (CG) D3-14 (CANL) Ignition SW OFF 3 kΩ or more CANL G26206 OK REPLACE YAW RATE SENSOR (SEE PAGE 32-46 ) NG Author
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: 2323 05-2134 DIAGNOSTICS 6 - CAN COMMUNICATION SYSTEM CHECK CAN BUS LINE FOR SHORT TO GND(SKID CONTROL ECU - JUNCTION CONNECTOR, CAN-L) (a) (b) Junction Connector: J16 (c) CANH Reconnect the connector (Y1) to the yaw rate sensor. Disconnect the wire harness connector (J16) from the junction connector. Disconnect the connector (S27) from the skid control ECU. CANL G26430 G25476 (d) Skid Control ECU Connector Front View: S27 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value S27-25 (CANL) S27-32 (GND1) Ignition SW OFF 1 MΩ more NG GND1 CANL E69126 REPAIR OR REPLACE CAN MAIN BUS LINE OR CONNECTOR (SKID CONTROL ECU - JUNCTION CONNECTOR, CAN-L) OK Author
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: 2324 05-2135 DIAGNOSTICS 7 CAN COMMUNICATION SYSTEM CHECK CAN BUS LINE FOR SHORT TO GND(STEERING SENSOR - JUNCTION CONNECTOR, CAN-L) Steering Sensor Wire Harness View: S14 ESS CANL G24991 - G26210 (a) (b) Disconnect the connector (S14) from the steering sensor. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value S14-2 (ESS) S14-9 (CANL) Ignition SW OFF 1 MΩ more HINT: Check the wire harness connector connected to the junction connector while disconnecting them. NG REPAIR OR REPLACE CAN MAIN BUS LINE OR CONNECTOR (STEERING SENSOR - JUNCTION CONNECTOR, CAN-L) OK REPAIR OR REPLACE YAW RATE SENSOR SUB BUS LINE OR CONNECTOR (CAN-L) Author
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: 2325 05-2109 DIAGNOSTICS - CAN COMMUNICATION SYSTEM 05DY7-11 CHECK CAN MAIN BUS LINE FOR DISCONNECTION CIRCUIT DESCRIPTION The CAN main bus line and DLC3 sub bus line may have a disconnection when the resistance between terminals 6 (CANH) and 14 (CANL) of the DLC3 is more than 69 Ω. Symptom Trouble Area Resistance between terminals 6 (CANH) and 14 (CANL) of DLC3 is more than 69 Ω .
CAN main bus line
Skid control ECU
Steering sensor WIRING DIAGRAM S14 Steering Sensor CANH CANL Skid Control ECU with Actuator J16 J/C Y 10 STRG 10 W 9 21 STRG VSC L 12 IC4 B 11 S27 CANH W 13 IC4 W 25 S27 CANL 8 VSC 19 G30960 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2299 05-21 10 DIAGNOSTICS - CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK DLC3 DLC3: D3 1 2 3 4 5 (a) (b) Turn the ignition switch to the LOCK position. Measure the resistance according to the value(s) in the table below. Result: CANH 6 7 8 9 10 11 12 13 14 15 16 G25474 C81825 CANL G26206 Tester connection Condition Specified value Result D3-6 (CANH) D3-14 (CANL) Ignition SW OFF 108 to 132 Ω A D3-6 (CANH) D3-14 (CANL) Ignition SW OFF 132 Ω or more B NOTICE: When the measured value is 132 Ω or more and the CAN communication system diagnostic code is output, there may be a fault besides disconnection of the DLC3 sub bus line. For that reason, troubleshooting should be performed again from ”How to proceed with troubleshooting” after repairing the trouble area. B REPAIR OR REPLACE DLC3 SUB BUS LINE OR CONNECTOR (CAN-H, CAN-L) A 2 (a) READ OUTPUT DTC Read the output diagnostic codes. Standard: U0073/94, U0123/62, U0124/95 and U0126/63 are output simultaneously. A Only U0126/63 is output. B NOTICE: Diagnostic codes other than the CAN communication system diagnostic codes (U0073/94, U0123/62, U0124/95, U0126/63) may be output simultaneously with the CAN codes. B Go to step 4 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2300 05-21 11 DIAGNOSTICS 3 - CAN COMMUNICATION SYSTEM CHECK CAN MAIN BUS LINE FOR DISCONNECTION(SKID CONTROL ECU JUNCTION CONNECTOR) Skid Control ECU Connector Front View: CANH CANL (a) S27 E69126 (b) Disconnect the connector (S27) from the skid control ECU. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value S27-11 (CANH) S27-25 (CANL) Ignition SW OFF 108 to 132 Ω NG REPAIR OR REPLACE CAN MAIN BUS LINE OR CONNECTOR (SKID CONTROL ECU - JUNCTION CONNECTOR) OK REPLACE SKID CONTROL ECU WITH ACTUATOR (SEE PAGE 32-37 ) 4 CHECK CAN MAIN BUS LINE FOR DISCONNECTION(STEERING SENSOR JUNCTION CONNECTOR) Steering Sensor Wire Harness View: S14 G24991 CANH CANL G26210 (a) (b) (c) Turn the ignition switch to the LOCK position. Disconnect the connector (S14) from the steering sensor. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value S14-10 (CANH) S14-9 (CANL) Ignition SW OFF 108 to 132 Ω NG REPAIR OR REPLACE CAN MAIN BUS LINE OR CONNECTOR (STEERING SENSOR - JUNCTION CONNECTOR) OK REPLACE STEERING SENSOR (SEE PAGE 32-48 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2301 05-21 12 DIAGNOSTICS - CAN COMMUNICATION SYSTEM 05IR3-02 CHECK CAN BUS LINES FOR SHORT CIRCUIT CIRCUIT DESCRIPTION The CAN bus lines are considered to be shorted when the resistance between terminals 6 (CANH) and 14 (CANL) of the DLC3 is below 54 Ω. Symptom Trouble Area Resistance between terminals 6 (CANH) and 14 (CANL) of DLC3 is below 54 Ω.
Short in CAN bus lines
Skid control ECU
Steering sensor
Yaw rate sensor WIRING DIAGRAM S14 Steering Sensor CANH CANL Skid Control ECU with Actuator J16 J/C Y 10 10 STRG W 21 STRG 9 VSC L 12 IC4 B 11 S27 CANH W 13 IC4 W 25 S27 CANL 8 VSC 19 Y1 Yaw Rate Sensor CANH CANL B 3 W 2 12 IO2 G 13 IO2 W 9 20 YAW YAW G30961 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2302 05-21 13 DIAGNOSTICS - CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK CAN BUS LINES FOR SHORT(DLC3 SUB BUS LINE) Junction Connector: (a) (b) Turn the ignition switch to the LOCK position. Disconnect the wire harness connector (J16) from the junction connector. (c) Measure the resistance according to the value(s) in the table below. Standard: J16 CANH CANL G26430 G25476 DLC3: D3 1 2 3 CANH 4 5 6 7 8 9 10 11 12 13 14 15 16 Tester connection Condition Specified value D3-6 (CANH) D3-14 (CANL) Ignition SW OFF 1 MΩ or more CANL G25474 C81825 G26206 NG REPAIR OR REPLACE DLC3 SUB BUS LINE OR CONNECTOR (CAN-H, CAN-L) OK 2 CHECK CAN BUS LINES FOR SHORT(SKID CONTROL ECU - JUNCTION CONNECTOR) Skid Control ECU Connector Front View: (a) CANH CANL S27 (b) E69126 Disconnect the connector (S27) from the skid control ECU. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value S27-11 (CANH) S27-25 (CANL) Ignition SW OFF 1 MΩ or more HINT: Check the wire harness connector connected to the junction connector while disconnecting it. NG REPAIR OR REPLACE CAN MAIN BUS LINE OR CONNECTOR (CAN-H, CAN-L) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2303 05-21 14 DIAGNOSTICS 3 - CAN COMMUNICATION SYSTEM INSPECT SKID CONTROL ECU WITH ACTUATOR(CANH - CANL) (a) Skid Control ECU: CANH CANL G26199 G28087 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value 11 (CANH) - 25 (CANL) Ignition SW OFF 108 to 132 Ω NG REPLACE SKID CONTROL ACTUATOR (SEE PAGE 32-37 ) ECU WITH OK 4 CHECK CAN BUS LINES FOR SHORT(STEERING SENSOR - JUNCTION CONNECTOR) Steering Sensor Wire Harness View: (a) (b) S14 G24991 CANH CANL G26210 Disconnect the connector (S14) from the steering sensor. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value S14-10 (CANH) S14-9 (CANL) Ignition SW OFF 1 MΩ or more HINT: Check the wire harness connector connected to the junction connector while disconnecting it. NG REPAIR OR REPLACE STEERING SENSOR SUB BUS LINE OR CONNECTOR (CAN-H, CAN-L) OK 5 INSPECT STEERING SENSOR(CANH - CANL) (a) Steering Sensor: G25475 G24692 CANH CANL G26209 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value 10 (CANH) - 9 (CANL) Ignition SW OFF 108 to 132 Ω NG REPLACE STEERING SENSOR (SEE PAGE 32-48 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2304 05-21 15 DIAGNOSTICS 6 - CAN COMMUNICATION SYSTEM CHECK CAN BUS LINES FOR SHORT(YAW RATE SENSOR SUB BUS LINE) (a) (b) Yaw Rate Sensor Connector Front View: Y1 CANL CANH G26359 Disconnect the connector (Y1) from the yaw rate sensor. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value Y1-3 (CANH) Y1-2 (CANL) Ignition SW OFF 1 MΩ or more HINT: Check the wire harness connector connected to the junction connector while disconnecting it. NG REPAIR OR REPLACE YAW RATE SENSOR SUB BUS LINE OR CONNECTOR (CAN-H, CAN-L) OK REPLACE YAW RATE SENSOR (SEE PAGE 32-46 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2305 05-21 16 DIAGNOSTICS - CAN COMMUNICATION SYSTEM 05IR4-03 CHECK CAN BUS LINE (CAN-H) FOR SHORT TO +B CIRCUIT DESCRIPTION A short to +B is suspected in the CAN bus line when there is continuity between terminals 16 (BAT) and 6 (CANH) of the DLC3. Symptom Trouble Area
Short to +B in CAN bus line (CANH)
Skid control ECU
Steering sensor
Yaw rate sensor There is continuity between terminals 16 (BAT) and 6 (CANH) of DLC3. WIRING DIAGRAM S14 Steering Sensor J16 J/C VSC CANH Y 10 CANL 3 BAT Skid Control ECU With Actuator STRG 10 9 12 IC4 B W 13 IC4 W 8 VSC W L 21 STRG 19 D3 DLC3 CANH CANL B G YAW 9 DLC3 11 6 W YAW 14 22 DLC3 W 20 11 S27 CANH 25 S27 CANL Y1 Yaw Rate Sensor 12 IO2 B 13 IO2 W 3 2 CANH CANL Instrument Panel J/B 10 1E W BAT 16 J17 J/C P P E E 10 1G B BR 5 IC3 4 2A W-L Engine Room J/B W W 3 ALT 1 1A 9 1D F7 FL Block 1 FL MAIN OBD 1 2I 2 SHORT PIN ECU-B 31 S27 +BS B 8 Battery G30962 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2306 05-21 17 DIAGNOSTICS - CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK CAN BUS LINE FOR SHORT TO +B(DLC3 SUB BUS LINE, CAN-H) (a) Disconnect the wire harness connector (J16) from the junction connector. (b) Measure the resistance according to the value(s) in the table below. Standard: Junction Connector: J16 CANH CANL G26430 G25476 DLC3: D3 1 2 CANH 3 4 5 6 7 8 Tester connection Condition Specified value D3-6 (CANH) D3-16 (BAT) Ignition SW OFF 1 MΩ or more 9 10 11 12 13 14 15 16 NG BAT G25474 C81825 G26206 REPAIR OR REPLACE DLC3 SUB BUS LINE OR CONNECTOR (CAN-H) OK 2 (a) CONNECTION OF CONNECTORS Reconnect the wire harness connectors (J16) to the junction connector. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2307 05-21 18 DIAGNOSTICS 3 - CAN COMMUNICATION SYSTEM CHECK CAN BUS LINE FOR SHORT TO +B(SKID CONTROL ECU, CAN-H) (a) DLC3: D3 CANH (b) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 BAT G25474 C81825 G26206 Disconnect the connector (S27) from the skid control ECU. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value D3-6 (CANH) D3-16 (BAT) Ignition SW OFF 1 MΩ or more OK REPLACE SKID CONTROL ACTUATOR (SEE PAGE 32-37 ) ECU WITH NG 4 CHECK CAN BUS LINE FOR SHORT TO +B(STEERING SENSOR, CAN-H) DLC3: D3 1 2 3 4 (a) (b) (c) CANH 5 6 7 8 9 10 11 12 13 14 15 16 BAT G25474 C81825 G26206 Reconnect the connector (S27) to the skid control ECU. Disconnect the connector (S14) from the steering sensor. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value D3-6 (CANH) D3-16 (BAT) Ignition SW OFF 1 MΩ or more OK REPLACE STEERING SENSOR (SEE PAGE 32-48 ) NG 5 CHECK CAN BUS LINE FOR SHORT TO +B(YAW RATE SENSOR, CAN-H) DLC3: D3 1 2 3 4 (a) (b) (c) CANH 5 6 7 8 9 10 11 12 13 14 15 16 G25474 C81825 BAT G26206 Reconnect the connector (S14) to the steering sensor. Disconnect the connector (Y1) from the yaw rate sensor. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value D3-6 (CANH) D3-16 (BAT) Ignition SW OFF 1 MΩ or more OK REPLACE YAW RATE SENSOR (SEE PAGE 32-46 ) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2308 05-21 19 DIAGNOSTICS 6 - CAN COMMUNICATION SYSTEM CHECK CAN BUS LINE FOR SHORT TO +B(SKID CONTROL ECU - JUNCTION CONNECTOR, CAN-H) (a) (b) Junction Connector: (c) J16 CANH Reconnect the connector (Y1) to the yaw rate sensor. Disconnect the wire harness connector (J16) from the junction connector. Disconnect the connector (S27) from the skid control ECU. CANL G26430 G25476 Skid Control ECU Connector Front View: (d) CANH S27 +BS Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value S27-11 (CANH) S27-31 (+BS) Ignition SW OFF 1 MΩ or more NG E69126 REPAIR OR REPLACE CAN MAIN BUS LINE OR CONNECTOR (SKID CONTROL ECU - JUNCTION CONNECTOR, CAN-H) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2309 05-2120 DIAGNOSTICS 7 CAN COMMUNICATION SYSTEM CHECK CAN BUS LINE FOR SHORT TO +B(STEERING SENSOR - JUNCTION CONNECTOR, CAN-H) Steering Sensor Wire Harness View: S14 BAT CANH G24991 - G26210 (a) (b) Disconnect the connector (S14) from the steering sensor. Measure the resistance according to the values in the table below. Standard: Tester connection Condition Specified value S14-10 (CANH) S14-3 (BAT) Ignition SW OFF 1 MΩ or more HINT: Check the wire harness connector connected to the junction connector while disconnecting it. NG REPAIR OR REPLACE CAN MAIN BUS LINE OR CONNECTOR (STEERING SENSOR - JUNCTION CONNECTOR, CAN-H) OK REPAIR OR REPLACE YAW RATE SENSOR SUB BUS LINE OR CONNECTOR (CAN-H) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2310 05-2121 DIAGNOSTICS - CAN COMMUNICATION SYSTEM 05IR5-03 CHECK CAN BUS LINE (CAN-L) FOR SHORT TO +B CIRCUIT DESCRIPTION A short to the +B is suspected in the CAN bus line when there is continuity between terminals 16 (BAT) and 14 (CANL) of the DLC3. Symptom Trouble Area
Short to +B in CAN bus line (CANL)
Skid control ECU
Steering sensor
Yaw rate sensor There is continuity between terminals 16 (BAT) and 14 (CANL) of DLC3. WIRING DIAGRAM S14 Steering Sensor J16 J/C VSC CANH Y 10 CANL 3 BAT Skid Control ECU With Actuator STRG 10 9 12 IC4 B W 13 IC4 W 8 VSC W L 21 STRG 19 D3 DLC3 CANH CANL B 11 6 DLC3 W G YAW 9 YAW 14 22 DLC3 W 20 11 S27 CANH 25 S27 CANL Y1 Yaw Rate Sensor 12 IO2 B 13 IO2 W 3 2 CANH CANL Instrument Panel J/B 10 1E W BAT 16 J17 J/C P P E E 10 1G B BR 5 IC3 4 2A W-L Engine Room J/B W 3 ALT 1 1A 9 1D F7 FL Block 1 FL MAIN OBD 1 2I 2 SHORT PIN ECU-B 31 S27 +BS B 8 Battery G30962 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2311 05-2122 DIAGNOSTICS - CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK CAN BUS LINE FOR SHORT TO +B(DLC3 SUB BUS LINE, CAN-L) (a) Disconnect the wire harness connector (J16) from the junction connector. (b) Measure the resistance according to the value(s) in the table below. Standard: Junction Connector: J16 CANH CANL G26430 G25476 DLC3: D3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 CANL G25474 C81825 BAT G26206 Tester connection Condition Specified value D3-14 (CANL) D3-16 (BAT) Ignition SW OFF 1 MΩ or more NG REPAIR OR REPLACE DLC3 SUB BUS LINE OR CONNECTOR (CAN-L) OK 2 (a) CONNECTION OF CONNECTORS Reconnect the wire harness connector (J16) to the junction connector. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2312 05-2123 DIAGNOSTICS 3 - CAN COMMUNICATION SYSTEM CHECK CAN BUS LINE FOR SHORT TO +B(SKID CONTROL ECU, CAN-L) (a) DLC3: D3 (b) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 CANL G25474 C81825 BAT G26206 Disconnect the connector (S27) from the skid control ECU. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value D3-14 (CANL) D3-16 (BAT) Ignition SW OFF 1 MΩ or more OK REPLACE SKID CONTROL ACTUATOR (SEE PAGE 32-37 ) ECU WITH NG 4 CHECK CAN BUS LINE FOR SHORT TO +B(STEERING SENSOR, CAN-L) DLC3: (a) (b) (c) D3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 CANL G25474 C81825 BAT G26206 Reconnect the connector (S27) to the skid control ECU. Disconnect the connector (S14) from the steering sensor. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value D3-14 (CANL) D3-16 (BAT) Ignition SW OFF 1 MΩ or more OK REPLACE STEERING SENSOR (SEE PAGE 32-48 ) NG 5 CHECK CAN BUS LINE FOR SHORT TO +B(YAW RATE SENSOR, CAN-L) DLC3: (a) (b) (c) D3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 G25474 C81825 CANL BAT Reconnect the connector (S14) to the steering sensor. Disconnect the connector (Y1) from the yaw rate sensor. Measure the resistance according to the value(s) in the table below. Tester connection Condition Specified value D3-14 (CANL) D3-16 (BAT) Ignition SW OFF 1 MΩ or more OK G26206 REPLACE YAW RATE SENSOR (SEE PAGE 32-46 ) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2313 05-2124 DIAGNOSTICS 6 - CAN COMMUNICATION SYSTEM CHECK CAN BUS LINE FOR SHORT TO +B(SKID CONTROL ECU - JUNCTION CONECTOR, CAN-L) (a) (b) Junction Connector: J16 (c) CANH Reconnect the connector (Y1) to the yaw rate sensor. Disconnect the wire harness connector (J16) from the junction connector. Disconnect the connector (S27) from the skid control ECU. CANL G26430 G25476 (d) Skid Control ECU Connector Front View: S27 +BS Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value S27-25 (CANL) S27-31 (+BS) Ignition SW OFF 1 MΩ or more NG CANL E69126 REPAIR OR REPLACE CAN MAIN BUS LINE OR CONNECTOR (SKID CONTROL ECU - JUNCTION CONNECTOR, CAN-L) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2314 05-2125 DIAGNOSTICS 7 CAN COMMUNICATION SYSTEM CHECK CAN BUS LINE FOR SHORT TO +B(STEERING SENSOR - JUNCTION CONNESTOR, CAN-L) Steering Sensor Wire Harness View: BAT CANL (a) (b) S14 G24991 - G26210 Disconnect the connector (S14 ) from the steering sensor. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value S14-9 (CANL) S14-3 (BAT) Ignition SW OFF 1 MΩ or more HINT: Check the wire harness connector connected to the junction connector while disconnecting it. NG REPAIR OR REPLACE CAN MAIN BUS LINE OR CONNECTOR (STEERING SENSOR - JUNCTION CONNECTOR, CAN-L) OK REPAIR OR REPLACE YAW RATE SENSOR SUB BUS LINE OR CONNECTOR (CAN-L) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2315 05-2126 DIAGNOSTICS - CAN COMMUNICATION SYSTEM 05IR6-03 CHECK CAN BUS LINE (CAN-H) FOR SHORT TO GND CIRCUIT DESCRIPTION A short to GND is suspected in the CAN bus line when there is continuity between terminals 4 (CG) and 6 (CANH) of the DLC3. Symptom Trouble Area There is continuity between terminals 4 (CG) and 6 (CANH) of DLC3.
Short to GND in CAN bus line (CANH)
Skid control ECU
Steering sensor
Yaw rate sensor WIRING DIAGRAM S14 Steering Sensor J16 J/C CANH VSC Y 10 10 CANL 2 STRG L 12 IC4 B W 13 IC4 W 8 VSC STRG 21 W 9 ESS Skid Control ECU With Actuator 19 11 S27 CANH 25 S27 CANL W-B Y1 Yaw Rate Sensor CANH CANL 1 GND 12 IO2 G 13 IO2 W B 3 W 2 9 20 YAW YAW D3 DLC3 CANH CANL W-B B 11 DLC3 6 W 14 22 W-B DLC3 1 S27 GND2 32 S27 GND1 Passenger Side J/B CG W-B 4 6 4C 1 4N W-B 3 4C 1 4N W-B J19 J/C W-B W-B A A BF J4 J/C IC EH EB A G30963 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2316 05-2127 DIAGNOSTICS - CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK CAN BUS LINE FOR SHORT TO GND(DLC3 SUB BUS LINE, CAN-H) (a) Disconnect the wire harness connector (J16) from the junction connector. (b) Measure the resistance according to the value(s) in the table below. Standard: Junction Connector: J16 CANH CANL G26430 G25476 DLC3: CG 1 2 3 4 CANH D3 5 6 7 8 Tester connection Condition Specified value D3-4 (CG) D3-6 (CANH) Ignition SW OFF 1 MΩ or more 9 10 11 12 13 14 15 16 NG G25474 C81825 G26206 REPAIR OR REPLACE DLC3 SUB BUS LINE OR CONNECTOR (CAN-H) OK 2 (a) CONNECTION OF CONNECTORS Reconnect the wire harness connector (J16) to the junction connector. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2317 05-2128 DIAGNOSTICS 3 - CAN COMMUNICATION SYSTEM CHECK CAN BUS LINE FOR SHORT TO GND(SKID CONTROL ECU, CAN-H) DLC3: CG (a) CANH D3 (b) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 G25474 C81825 G26206 Disconnect the connector (S27) from the skid control ECU. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value D3-4 (CG) D3-6 (CANH) Ignition SW OFF 3 kΩ or more OK REPLACE SKID CONTROL ACTUATOR (SEE PAGE 32-37 ) ECU WITH NG 4 CHECK CAN BUS LINE FOR SHORT TO GND(STEERING SENSOR, CAN-H) DLC3: CG 1 2 3 4 D3 5 6 (a) (b) (c) CANH 7 8 9 10 11 12 13 14 15 16 G25474 C81825 G26206 Reconnect the connector (S27) to the skid control ECU. Disconnect the connector (S14) from the steering sensor. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value D3-4 (CG) D3-6 (CANH) Ignition SW OFF 3 kΩ or more OK REPLACE STEERING SENSOR (SEE PAGE 32-48 ) NG 5 CHECK CAN BUS LINE FOR SHORT TO GND(YAW RATE SENSOR, CAN-H) DLC3: CG 1 2 3 4 D3 5 6 (a) (b) (c) CANH 7 8 9 10 11 12 13 14 15 16 G25474 C81825 G26206 Reconnect the connector (S14) to the steering sensor. Disconnect the connector (Y1) from the yaw rate sensor. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value D3-4 (CG) D3-6 (CANH) Ignition SW OFF 3 kΩ or more OK REPLACE YAW RATE SENSOR (SEE PAGE 32-46 ) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2318 05-2129 DIAGNOSTICS 6 - CAN COMMUNICATION SYSTEM CHECK CAN BUS LINE FOR SHORT TO GND(SKID CONTROL ECU - JUNCTION CONNECTOR, CAN-H) (a) (b) Junction Connector: J16 (c) CANH Reconnect the connector (Y1) to the yaw rate sensor. Disconnect the wire harness connector (J16) from the junction connector. Disconnect the connector (S27) from the skid control ECU. CANL G26430 G25476 Skid Control ECU Connector Front View: (d) CANH S27 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value S27-11 (CANH) S27-32 (GND1) Ignition SW OFF 1 MΩ or more NG GND1 E69126 REPAIR OR REPLACE CAN MAIN BUS LINE OR CONNECTOR (SKID CONTROL ECU - JUNCTION CONNECTOR, CAN-H) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2319 05-2130 DIAGNOSTICS 7 CAN COMMUNICATION SYSTEM CHECK CAN BUS LINE FOR SHORT TO GND(STEERING SENSOR - JUNCTION CONNECTOR, CAN-H) Steering Sensor Wire Harness View: S14 ESS CANH G24991 - G26210 (a) (b) Disconnect the connector (S14) from the steering sensor. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value S14-2 (ESS) S14-10 (CANH) Ignition SW OFF 1 MΩ or more HINT: Check the wire harness connector connected to the junction connector while disconnecting it. NG REPAIR OR REPLACE CAN MAIN BUS LINE OR CONNECTOR (STEERING SENSOR - JUNCTION CONNECTOR, CAN-H) OK REPAIR OR REPLACE YAW RATE SENSOR SUB BUS LINE OR CONNECTOR (CAN-H) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2320 05-2102 DIAGNOSTICS - CAN COMMUNICATION SYSTEM 05DY5-04 CHECK CAN BUS LINE CIRCUIT DESCRIPTION When any DTC for the CAN communication is output, first measure the resistance between the terminals of DLC3 to specify the trouble area. WIRING DIAGRAM S14 Steering Sensor CANH CANL Skid Control ECU with Actuator J16 J/C Y 10 10 STRG W 21 STRG 9 VSC L 12 IC4 B W 13 IC4 W 8 VSC 19 11 S27 CANH 25 S27 CANL Y1 Yaw Rate Sensor CANH CANL B 3 W 2 12 IO2 G 13 IO2 W 9 20 YAW YAW D3 DLC3 CANH CANL B 11 6 W 14 22 DLC3 DLC3 Passenger Side J/B CG 6 4C W-B 4 1 4N W-B Instrument Panel J/B BAT 10 1E W 16 F7 FL Block FL MAIN W 1 ALT OBD 1 1A B 2 IC Battery G30957 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2292 05-2103 DIAGNOSTICS - CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK CAN BUS LINE(MAIN BUS LINE FOR DISCONNECTION, BUS LINES FOR SHORT CIRCUIT) DLC3: D3 1 2 3 4 5 (a) (b) CANH 6 7 8 9 10 11 12 13 14 15 16 CANL G25474 C81825 G26206 Turn the ignition switch to the LOCK position. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value Result D3-6 (CANH) D3-14 (CANL) Ignition SW OFF 54 to 69 Ω OK D3-6 (CANH) D3-14 (CANL) Ignition SW OFF 69 Ω or more NG-A D3-6 (CANH) D3-14 (CANL) Ignition SW OFF 54 Ω or less NG-B NG-A CHECK CAN MAIN BUS LINE DISCONNECTION (SEE PAGE 05-2109 ) FOR NG-B CHECK CAN BUS LINES FOR SHORT CIRCUIT (SEE PAGE 05-21 12) OK 2 CHECK CAN BUS LINE (CAN-H) FOR SHORT TO +B (a) DLC3: CANH D3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value D3-6 (CANH) D3-16 (BAT) Ignition SW OFF 1 MΩ or more NG G25474 C81825 BAT CHECK CAN BUS LINE (CAN-H) FOR SHORT TO +B (SEE PAGE 05-21 16) G26206 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2293 05-2104 DIAGNOSTICS 3 - CAN COMMUNICATION SYSTEM CHECK CAN BUS LINE (CAN-L) FOR SHORT TO +B (a) DLC3: D3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Tester connection Condition Specified value D3-14 (CANL) D3-16 (BAT) Ignition SW OFF 1 MΩ or more NG CANL G25474 C81825 Measure the resistance according to the value(s) in the table below. Standard: BAT G26206 CHECK CAN BUS LINE (CAN-L) FOR SHORT TO +B (SEE PAGE 05-2121 ) OK 4 CHECK CAN BUS LINE (CAN-H) FOR SHORT TO GND DLC3: CG 1 2 3 4 5 (a) CANH D3 6 7 8 9 10 11 12 13 14 15 16 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value D3-4 (CG) D3-6 (CANH) Ignition SW OFF 3 kΩ or more NG G25474 C81825 G26206 CHECK CAN BUS LINE (CAN-H) FOR SHORT TO GND (SEE PAGE 05-2126 ) OK 5 CHECK CAN BUS LINE (CAN-L) FOR SHORT TO GND (a) CG DLC3: 1 2 D3 3 4 5 6 7 8 9 10 11 12 13 14 15 16 G25474 C81825 CANL Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value D3-4 (CG) D3-14 (CANL) Ignition SW OFF 3 kΩ or more NG G26206 CHECK CAN BUS LINE (CAN-L) FOR SHORT TO GND (SEE PAGE 05-2131 ) OK HOW TO PROCEED WITH TROUBLESHOOTING (SEE PAGE 05-2095 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2294 05-2105 DIAGNOSTICS - CAN COMMUNICATION SYSTEM 05IR2-02 STEERING SENSOR COMMUNICATION STOP MODE CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition U0126/63
When ECU terminal IG1 voltage is 9.5 V or more, data is not received from the steering sensor for more than 1 sec.
When ECU terminal IG1 voltage is 9.5 V or more, data can not be received from the steering sensor more than once within 5 sec. This situation repeatedly occurs more than 10 times. Trouble Area
Steering sensor
Power source of steering sensor WIRING DIAGRAM S14 Steering Sensor J16 J/C STRG STRG Y 10 10 W 9 21 CANH CANL Passenger Side J/B Y 4 4J 11 4C L 7 4L 3 4C W-B 1 2 IG1 ESS W-B Instrument Panel J/B 10 1D ECU-IG 1 1A AM1 F7 FL Block W 1 ALT B 2 1 I15 Ignition SW 7 1C G 6 1C W 4 IG1 AM1 2 2 FL MAIN IC Battery G30958 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2295 05-2106 DIAGNOSTICS - CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK WIRE HARNESS(IG1, ESS) Steering Sensor Wire Harness View: S14 G24991 (a) (b) (c) Turn the ignition switch to the LOCK position. Disconnect the connector (S14) from the steering sensor. Measure the resistance according to the value(s) in the table below. Standard: ESS Tester connection Condition Specified value IG1 S14-2 (ESS) Body ground Always Below 1 Ω G26210 (d) (e) Connect the connector (S14) to the steering sensor. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified value S14-1 (IG1) Body ground Ignition SW ON 10 to 14 V NOTICE: Perform the measurement from the back of the connector with the connector connected. NG REPAIR OR REPLACE WIRE HARNESS OR CONNECTOR OK REPLACE STEERING SENSOR (SEE PAGE 32-48 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2296 05-2107 DIAGNOSTICS - CAN COMMUNICATION SYSTEM 05DY8-04 YAW RATE SENSOR COMMUNICATION STOP MODE CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area U0123/62
When ECU terminal IG1 voltage is 9.5 V or more, data is not received from the yaw rate sensor for more than 1 sec.
When ECU terminal IG1 voltage is 9.5 V or more, data can not be received from the yaw rate sensor more than once within 5 sec .This situation repeatedly occurs more than 10 times.
Yaw rate sensor
Yaw rate sensor sub bus line
Power source of yaw rate sensor U0124/95
When ECU terminal IG1 voltage is 9.5 V or more, data is not received from the deceleration the sensor for more than 1 sec.
When ECU terminal IG1 voltage is 9.5 V or more, data can not be received from the deceleration sensor more than once within 5 sec. This situation repeatedly occurs more than 10 times.
Yaw rate sensor
Yaw rate sensor sub bus line
Power source of yaw rate sensor WIRING DIAGRAM Y1 Yaw Rate Sensor J16 J/C YAW YAW G 9 W 20 12 IO2 B 13 IO2 W 3 2 CANH CANL Passenger Side J/B 2 4C 4 4J Y 3 IO2 V 5 Instrument Panel J/B 10 1D ECU-IG 1 1A AM1 F7 FL Block W 1 B ALT 2 FL MAIN Battery 1 O IG I15 Ignition SW 7 1C G 6 1C W 4 IG1 2 AM1 2 J19 J/C W-B A W-B A 1 GND BF G30959 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2297 05-2108 DIAGNOSTICS - CAN COMMUNICATION SYSTEM INSPECTION PROCEDURE 1 CHECK CAN BUS LINE FOR DISCONNECTION(YAW RATE SENSOR SUB BUS LINE) (a) (b) (c) Yaw Rate Sensor Connector Front View: Y1 CANL Turn the ignition switch to the LOCK position. Disconnect the connector (Y1) from the yaw rate sensor. Measure the resistance according to the value(s) in the table below. Standard: CANH G26359 Tester connection Condition Specified value Y1-2 (CANL) Y1-3 (CANH) Ignition SW OFF 54 to 69 Ω NG REPAIR OR REPLACE YAW RATE SENSOR SUB BUS LINE OR CONNECTOR (CAN-H, CAN-L) OK 2 CHECK WIRE HARNESS(IG,GND) (a) Yaw Rate Sensor Connector Front View: Y1 GND IG G26359 (b) Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified value Y1-1 (GND) Body ground Always Below 1 Ω Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified value Y1-5 (IG) - Body ground Ignition SW ON 10 to 14 V NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE YAW RATE SENSOR (SEE PAGE 32-46 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2298 05-2090 DIAGNOSTICS - CAN COMMUNICATION SYSTEM CAN COMMUNICATION SYSTEM 05BYH-15 PRECAUTION 1. (a) 2. (a) HANDLING PRECAUTIONS ON STEERING SYSTEM Care must be taken when replacing parts. Incorrect replacement could affect the performance of the steering system and result in a driving hazard. HANDLING PRECAUTIONS ON SRS AIRBAG SYSTEM The HIGHLANDER is equipped with a SRS (Supplemental Restraint System), such as the driver airbag and front passenger airbag. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notice for the Supplemental Restraint System (see page 60-1 ). 3. (a) F45104 WIRE HARNESS REPAIR After repairing the wire bus line with solder, wrap the repaired part with vinyl tape. NOTICE:
The CANL bus line and CANH bus line must be installed together all the time. When installing, make sure to twist them.
The difference in length of the CANL bus line and CANH bus line should be within 100 mm (3.937 in.).
Untwisted parts around the connectors should be within 80 mm (3.150 in.). (b) Do not perform bypass wiring between the connectors. NOTICE: If you perform bypass wiring, the characteristic of the twisted wire harness will be lost. Bypass Wire F45105 4. (a) CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the back of the connector. F45106 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2280 05-2091 DIAGNOSTICS (b) Repair Wire - CAN COMMUNICATION SYSTEM If it is impossible to check resistance from the back of the connector, use a repair wire to check it. F45107 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2281 05-2093 DIAGNOSTICS - CAN COMMUNICATION SYSTEM 05DY2-04 SYSTEM DIAGRAM Serial Communication Line DLC3 Steering Sensor Skid Control ECU 120 Ω
10 % 120 Ω
10 % Junction Connector : CAN Main Bus Line (CAN-H) Yaw Rate Sensor : CAN Main Bus Line (CAN-L) : CAN Sub Bus Line (CAN-H) : CAN Sub Bus Line G26354 (CAN-L) HINT: The Skid Control ECU stores DTCs and performs DTC communication by receiving information from the Steering Sensor and Yaw Rate Sensor. These sensors cannot store DTCs or perform DTC communication. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2283 05-2096 DIAGNOSTICS - CAN COMMUNICATION SYSTEM 05BYQ-06 CUSTOMER PROBLEM ANALYSIS CHECK CAN Communication System Check Sheet Inspector’s : Name VIN / Production Date Customer’s Name / Licence Plate No. Date Vehicle Brought In / / km miles Odometer Reading Date Problem First Occurred / Continuously Frequency Problem Occurs / Intermittently ( times a day) 1st Time Normal System Code Trouble Code (Code ) 2nd Time Normal System Code Trouble Code (Code ) DTC Check 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2286 05-2094 DIAGNOSTICS - CAN COMMUNICATION SYSTEM 05DY3-12 DESCRIPTION 1. (a) (b) (c) (d) 2. (a) (b) 3. (a) (b) (c) 4. (a) 5. (a) (b) (c) BRIEF DESCRIPTION CAN (Controller Area Network) is a serial data communication system for real time application. It is a vehicle multiplex communication system which has a high communication speed (500 kbps) and the ability to detect malfunctions. The CAN performs the communication based on the differential voltage by pairing the CANH bus line and CANL bus line. The HIGHLANDER uses the CAN communication system for communication between the following ECU and sensors in the ABS with EBD & BA & TRC & VSC system. The CAN has two resistors of 120 Ω that are necessary for communication to the main bus line. DEFINITION OF TERMS Main bus line (1) Main bus line is a wire harness between the two terminus circuits on the bus (communication line). This is the main bus in the CAN communication system. Sub bus line (1) Sub bus line is a wire harness which diverges from the main bus line, which is the main bus of the CAN bus, to an ECU or sensor. ECU OR SENSORS WHICH COMMUNICATE THROUGH THE CAN COMMUNICATION SYSTEM Skid Control ECU Steering Sensor Yaw Rate Sensor DIAGNOSTIC CODES FOR THE CAN COMMUNICATION SYSTEM DTCs for CAN system are as follows: U0073/94, U0123/62, U0124/95, U0126/63 REMARKS FOR TROUBLESHOOTING Trouble in the CAN bus (communication line) can be checked from the DLC3 (except a wire break other than in the DLC3 sub bus line). By using the hand-held tester, DTCs for the CAN communication system can be checked through the DTC ISO 9141K-Line. The CAN communication system cannot detect the trouble in the DLC3 sub bus line even though the DLC3 is also connected to the CAN communication system. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2284 05-2101 DIAGNOSTICS - CAN COMMUNICATION SYSTEM 05BYL-13 DIAGNOSTIC TROUBLE CODE CHART 1. DTCs COMBINATION TABLE NOTICE: Complete ”CHECK CAN BUS LINE” (see page 05-2102 ), to confirm that there is no disconnection in the CAN main bus lines and there is no short circuit, short to +B or short to ground in the CAN bus lines. Then perform troubleshooting according to the DTC combination table. (a) Confirm the trouble mode according to the combination of output DTCs. Trouble Mode U0073/94 U0123/62 U0124/95 U0126/63 Skid control ECU communication stop mode Yaw rate sensor communication stop mode - Steering sensor communication stop mode - - - HINT:



(b) U0073/94, U0123/62, U0124/95 and U0126/63 are the DTCs in the CAN communication system. The above table shows combinations of these DTCs. ..... DTCs that are being output. - ...... DTCs that are not being output. Confirm the trouble mode by referring to the above. Then check the parts to be replaced and pages to proceed to, by referring to the below. Output Code See page and parts to be replaced Suspected Area Skid control ECU communication stop mode (U0073/94, U0123/62, U0124/95 and U0126/63 are output simultaneously) Skid control ECU Yaw rate sensor communication stop mode (U0123/62 and U0124/95 are output simultaneously)
Open circuit between yaw rate sensor and junction connector
Yaw rate sensor power source/internal malfunction 05-2107 Steering sensor communication stop mode (U0126/63 only)
Steering sensor power source/internal malfunction 05-2105 Replace skid control ECU 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2291 05-2095 DIAGNOSTICS - CAN COMMUNICATION SYSTEM 05BYJ-06 HOW TO PROCEED WITH TROUBLESHOOTING NOTICE: When DTCs other than U0073/94, U0123/62, U0124/95, U0126/63 are output, inspect and repair the trouble areas indicated by the DTCs. 1 CHECK CAN BUS LINE (SEE PAGE 05-2102 ) 2 CHECK AND CLEAR DTCs HINT: When checking the DTCs for the skid control ECU, proceed to page 05-765 3 CHECK DTC COMBINATION TABLE (SEE PAGE 05-2101 ) 4 CIRCUIT INSPECTION 5 IDENTIFICATION OF PROBLEM 6 REPAIR OR REPLACE 7 CONFIRMATION TEST END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2285 05-2092 DIAGNOSTICS - CAN COMMUNICATION SYSTEM 05BYM-06 LOCATION Skid Control ECU with Actuator Steering Sensor Junction Connector Yaw Rate Sensor DLC3 G30966 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2282 05-2097 DIAGNOSTICS - CAN COMMUNICATION SYSTEM 05IR1-01 TERMINALS OF ECU DLC3: CG 1 2 3 4 D3 5 1. (a) CANH 6 7 8 DLC3 Check DLC3. (1) Turn the ignition switch off. (2) Measure the resistance according to the value(s) in the table below. 9 10 11 12 13 14 15 16 CANL G25474 C81825 BAT G26206 Standard: Terminals Check item Condition D3-6 (CANH) - D3-14 (CANL) Resistance Ignition SW OFF 54 to 69 Ω D3-6 (CANH) - D3-16 (BAT) Resistance Ignition SW OFF More than 1 MΩ D3-14 (CANL) - D3-16 (BAT) Resistance Ignition SW OFF More than 1 MΩ D3-6 (CANH) - D3-4 (CG) Resistance Ignition SW OFF More than 3 kΩ D3-14 (CANL) - D3-4 (CG) Resistance Ignition SW OFF More than 3 kΩ Skid Control ECU: CANH G25167 CANL GND1 +BS 2. (a) Specified value SKID CONTROL ECU Check skid control ECU. (1) Turn the ignition switch off. (2) Disconnect the connector (S27) from the skid control ECU. (3) Measure the resistance according to the value(s) in the table below. G26428 Standard: Terminals Check item Condition Specified value 11 (CANH) - 25 (CANL) Resistance Ignition SW OFF 108 to 132 Ω 11 (CANH) - 32 (GND1) Resistance Ignition SW OFF More than 3 kΩ 25 (CANL) - 32 (GND1) Resistance Ignition SW OFF More than 3 kΩ 11 (CANH) - 31 (+BS) Resistance Ignition SW OFF More than 1 MΩ 25 (CANL) - 31 (+BS) Resistance Ignition SW OFF More than 1 MΩ 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2287 05-2098 DIAGNOSTICS (b) Skid Control ECU Connector Front View: S27 CANH +BS GND1 CANL - CAN COMMUNICATION SYSTEM Check the skid control ECU harness side connector (S27). (1) Turn the ignition switch off. (2) Disconnect the connector (S27) from the skid control ECU. (3) Measure the resistance according to the value(s) in the table below. E69126 Standard: Terminals Wiring Color Check item Condition Specified value S27-11 (CANH) - S27-25 (CANL) B-W Resistance Ignition SW OFF 108 to 132 Ω S27-11 (CANH) S27-32 (GND1) B - W-B Resistance Ignition SW OFF More than 3 kΩ S27-25 (CANL) - S27-32 (GND1) W - W-B Resistance Ignition SW OFF More than 3 kΩ S27-11 (CANH) - S27-31 (+BS) B-B Resistance Ignition SW OFF More than 1 MΩ S27-25 (CANL) - S27-31 (+BS) W-B Resistance Ignition SW OFF More than 1 MΩ 3. (a) Steering Sensor: G25475 G24692 CANH CANL BAT STEERING SENSOR Check steering sensor. (1) Turn the ignition switch off. (2) Disconnect the connector (S14) from the steering sensor. (3) Measure the resistance according to the value(s) in the table below. ESS G26209 Standard: Terminals Check item Condition 10 (CANH) - 9 (CANL) Resistance Ignition SW OFF 108 to 132 Ω 10 (CANH) - 2 (ESS) Resistance Ignition SW OFF More than 3 kΩ 9 (CANL) - 2 (ESS) Resistance Ignition SW OFF More than 3 kΩ 10 (CANH) - 3 (BAT) Resistance Ignition SW OFF More than 1 MΩ 9 (CANL) - 3 (BAT) Resistance Ignition SW OFF More than 1 MΩ (b) Steering Sensor Wire Harness View: S14 BAT ESS G24991 Specified value CANH CANL Check the harness side connector (S14) of the steering sensor. (1) Turn the ignition switch off. (2) Disconnect the connector (S14) from the steering sensor. (3) Measure the resistance according to the value(s) in the table below. G26210 Standard: Terminals Wiring Color Check item Condition Specified value S14-10 (CANH) - S14-9 (CANL) Y-W Resistance Ignition SW OFF 108 to 132 Ω S14-10 (CANH) - S14-2 (ESS) Y - W-B Resistance Ignition SW OFF More than 3 kΩ S14-9 (CANL) - S14-2 (ESS) W - W-B Resistance Ignition SW OFF More than 3 kΩ S14-10 (CANH) - S14-3 (BAT) Y-P Resistance Ignition SW OFF More than 1 MΩ S14-9 (CANL) - S14-3 (BAT) W - W-R Resistance Ignition SW OFF More than 1 MΩ 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2288 05-2099 DIAGNOSTICS Yaw Rate Sensor Connector Front View: 4. (a) Y1 CANH CANL GND - CAN COMMUNICATION SYSTEM YAW RATE SENSOR Check the yaw rate sensor harness side connector (Y1). (1) Turn the ignition switch off. (2) Disconnect the connector (Y1) from the yaw rate sensor. (3) Measure the resistance according to the value(s) in the table below. DLC3: D3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 BAT G26359 G26206 G26641 Standard: Terminals Wiring Color Check item Condition Specified value Y1-3 (CANH) - Y1-2 (CANL) B-W Resistance Ignition SW OFF 54 to 69 Ω Y1-3 (CANH) - Y1-1 (GND) B - W-B Resistance Ignition SW OFF More than 3 kΩ Y1-2 (CANL) - Y1-1 (GND) W - W-B Resistance Ignition SW OFF More than 3 kΩ Y1-3 (CANH) - D3-16 (BAT) B-W Resistance Ignition SW OFF More than 1 MΩ Y1-2 (CANL) - D3-16 (BAT) W-W Resistance Ignition SW OFF More than 1 MΩ 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2289 05-2100 DIAGNOSTICS 5. (a) Junction Connector (J16): CANH - CAN COMMUNICATION SYSTEM JUNCTION CONNECTOR (J16) Check the junction connector. (1) Turn the ignition switch off. (2) Disconnect the connector from the junction connector. (3) Check the junction connector between the terminals below on the junction connector. CANL G26430 G25476 Standard: Terminals Check item Condition Specified value 7, 8, 9, 10, 11 (CANH) ⇔ 18, 19, 20, 21, 22 (CANL) Resistance Ignition SW OFF More than 3 kΩ 7, 8, 9, 10, 11 (CANH) ⇔ Body ground Resistance Ignition SW OFF More than 3 kΩ 18, 19, 20, 21, 22 (CANL) ⇔ Body ground Resistance Ignition SW OFF More than 3 kΩ 7, 8, 9, 10, 11 (CANH) ⇔ +B Resistance Ignition SW OFF More than 3 kΩ 18, 19, 20, 21, 22 (CANL) ⇔ +B Resistance Ignition SW OFF More than 3 kΩ 7 (CANH) ⇔ 11 (CANH) Resistance Ignition SW OFF Less than 1 Ω 7 (CANH) ⇔ 10 (CANH) Resistance Ignition SW OFF Less than 1 Ω 7 (CANH) ⇔ 9 (CANH) Resistance Ignition SW OFF Less than 1 Ω 7 (CANH) ⇔ 8 (CANH) Resistance Ignition SW OFF Less than 1 Ω 18 (CANL) ⇔ 22 (CANL) Resistance Ignition SW OFF Less than 1 Ω 18 (CANL) ⇔ 21 (CANL) Resistance Ignition SW OFF Less than 1 Ω 18 (CANL) ⇔ 20 (CANL) Resistance Ignition SW OFF Less than 1 Ω 18 (CANL) ⇔ 19 (CANL) Resistance Ignition SW OFF Less than 1 Ω 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2290 05-840 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05CDG-11 ABS WARNING LIGHT CIRCUIT (REMAINS ON) CIRCUIT DESCRIPTION During DTC read by SST (CHECK WIRE), if the ABS warning light remains on, troubleshoot by following this inspection flow. WIRING DIAGRAM 6 IF2 W Skid Control ECU with Actuator 29 4 R-L IC4 S27 WA SB Combination Meter 13 C11 17 C11 9 IL1 SB ABS J6 J/C Passenger Side J/B 4 4M 4 4J 1 4E 2 P P E E 10 IC4 GR 4H I15 Ignition SW Instrument Panel J/B Y W F7 FL Block W B 1 ALT 2 10 1D ECU-IG 6 1G IGN 1 1A AM1 1 L-Y AM2 10 7 1C 1 1C 6 1C 46 S27 IG1 B-R G 4 IG1 AM1 2 GR 6 IG2 AM2 7 W 2 1 IC1 Y W-B 32 S27 GND1 A FL MAIN J4 J/C W-B Battery EA EB F46304 Author
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: 1030 05-841 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE 1 (a) CHECK DTC Is DTC output for ABS? Standard: DTC is not output A DTC is output B B REPAIR CIRCUIT INDICATED BY OUTPUT CODE A 2 INSPECT CHECK IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED NG CONNECT CONNECTOR TO ECU NG INSPECT CHARGING SYSTEM OK 3 (a) INSPECT BATTERY Check the battery voltage. Standard: Tester Connection Specified Condition Battery terminal ((+) - (-)) 11 to 14 V OK Author
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: 1031 05-842 DIAGNOSTICS 4 - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECT SKID CONTROL ECU TERMINAL VOLTAGE(IG1 TERMINAL) WHEN USING HAND-HELD TESTER: (a) Connect the hand-held tester to the DLC3. (b) Start the engine. (c) Select the DATA LIST mode on the hand-held tester. (d) Read the voltage condition output from the ECU displayed on the hand-held tester. Item IG VOLTAGE Measurement Item / Range (Display) ECU power supply voltage / TOO LOW / NORMAL Normal Condition NORMAL: 9.5 V or over TOO LOW: Below 9.5 V OK: ”Normal” is displayed. WHEN NOT USING HAND-HELD TESTER: (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch ON position. (c) Measure the voltage according to the value(s) in the table below. Standard: Skid Control ECU (harness side connector) S27 GND1 IG1 G24767 Tester Connection Specified Condition S27-46 (IG1) - S27-32 (GND1) 11 to 14 V NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK Author
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: 1032 05-843 DIAGNOSTICS 5 - ABS WITH EBD & BA & TRAC & VSC SYSTEM CHECK HARNESS AND CONNECTOR(SKID CONTROL ECU - COMBINATION METER) (a) Skid Control ECU Front View WA S27 (b) (c) Combination Meter (harness side view) C11 Disconnect the skid control ECU connector and combination meter connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition C11-17 - S27-29 (WA) Below 1 Ω Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-29 (WA) - Body ground 10 kΩ or higher NG F46286 REPAIR OR CONNECTOR REPLACE HARNESS OR OK 6 CHECK HARNESS AND CONNECTOR(SKID CONTROL ECU - BODY GROUND) (a) (b) Skid Control ECU (harness side connector) S27 Disconnect the skid control ECU connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-32 (GND1) - Body ground Below 1 Ω GND1 G24767 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
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: 1033 05-854 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05F1V-09 BRAKE WARNING LIGHT CIRCUIT CIRCUIT DESCRIPTION The BRAKE warning light comes on when the brake fluid is insufficient, the parking brake is applied or the EBD is defective. WIRING DIAGRAM Combination Meter 13 C11 11 B C12 10 C12 Brake SB 2 P 1 28 S27 PKB R-W P E R 1 IC4 R-B J6 J/C Skid Control ECU with Actuator 44 16 LG-B IC4 S27 BRL 15 IF3 V B4 Brake Warning SW 9 IL1 SB 6 IF3 W-B E Passenger Side J/B 4 4M 1 4E Y 1 1C GR 6 IG2 1 IC1 3 4J 9 4M 6 1G IGN LG Passenger Side J/B Instrument Panel J/B I15 Ignition SW 7 AM2 11 IC4 W F7 FL Block L-Y B 10 AM2 1 W FL MAIN Battery A J4 J/C EB P3 Parking Brake SW 1 F50610 Author
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: 1044 05-855 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE HINT: When releasing the parking brake, set the chocks to hold the vehicle for safety. 1 (a) (b) CHECK BRAKE FLUID Release the parking brake pedal. Check that the brake fluid level is proper. NG ADD BRAKE FLUID OK 2 (a) CHECK DTC FOR ABS Are the DTC recorded? (see page 05-765 ) NO Go to step 3 YES REPAIR CIRCUIT INDICATED BY OUTPUT CODE 3 INSPECT BRAKE WARNING LIGHT WHEN USING HAND-HELD TESTER: (a) Connect the hand-held tester to the DLC3. (b) Start the engine. (c) Select the item ”BRAKE WARN LIGHT” in the ACTIVE TEST and operate the BRAKE warning light on the hand-held tester. Item BRAKE WRN LIGHT Vehicle Condition / Test Details Turns BRAKE warning light ON / OFF Diagnostic Note Observe combination meter (d) Check that ”ON” and ”OFF” of the BRAKE warning light are indicated on the combination meter when using the hand-held tester. OK: Turn the BRAKE warning light on or off in accordance with the hand-held tester. WHEN NOT USING HAND-HELD TESTER: Skid Control ECU (a) Turn the ignition switch off and disconnect the connector (harness side connector) S27 from the skid control ECU. (b) Ground terminal BRL of the skid control ECU. (c) Turn the ignition switch to the ON position. (d) Check that the brake warning light. OK: Turn the light on or off in accordance with the connecBRL tion of terminal BRL and body ground. G24767 NG Go to step 4 OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
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: 1045 05-856 DIAGNOSTICS 4 - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECT PARKING BRAKE SWITCH ASSY Parking Brake Switch Release Push (a) (b) Remove the parking brake switch connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection P3 G26238 Switch Condition Specified Condition P3-1 - Ground part Released Below 1 Ω P3-1 - Ground part Pushed in 10 kΩ or higher NG REPLACE PARKING BRAKE SWITCH ASSY OK 5 CHECK HARNESS OR CONNECTOR(SKID CONTROL ECU - PARKING BRAKE SWITCH) Skid Control ECU (harness side connector) S27 (a) PKB Parking Brake Switch (harness side connector) (b) (c) P3 PKB G26243 G26242 Disconnect the skid control ECU connector and the parking brake switch connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-28 (PKB) - P3-1 (PKB) Below 1 Ω Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-28 (PKB) - Body ground 10 kΩ or higher NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK 6 INSPECT BRAKE FLUID LEVEL WARNING SWITCH (a) (b) Brake Fluid Level Warning Switch B4 (c) G26237 Remove the reservoir tank cap and strainer. Disconnect the brake fluid level warning switch connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Switch Condition Specified Condition (B4-1) - (B4-2) Float UP 10 kΩ or higher (B4-1) - (B4-2) Float DOWN Below 1 Ω NG REPLACE BRAKE FLUID LEVEL WARNING SWITCH OK Author
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: 1046 05-857 DIAGNOSTICS 7 - ABS WITH EBD & BA & TRAC & VSC SYSTEM CHECK HARNESS OR CONNECTOR(BRAKE FLUID LEVEL WARNING SWITCH COMBINATION METER) (a) Combination Meter (harness side view) (b) C12 (c) Brake Fluid Level Warning Switch (harness side connector) Disconnect the combination meter connector and the brake fluid level warning switch connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition (C12-10) - (B4-1) Below 1 Ω Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition (C12-10) - Body ground 10 kΩ or higher B4 NG I37939 REPAIR OR CONNECTOR REPLACE HARNESS OR OK Author
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: 1047 05-858 DIAGNOSTICS 8 S27 - ABS WITH EBD & BA & TRAC & VSC SYSTEM CHECK HARNESS OR CONNECTOR(SKID CONTROL ECU - COMBINATION METER) (a) Skid Control ECU (harness side connector) (b) (c) BRL Combination Meter (harness side view) C12 Disconnect the skid control ECU connector and combination meter connector. Measure the resistance according to the value(s) in the table below. Standard: Specified Condition Below 1 Ω Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-44 (BRL) - Body ground 10 kΩ or higher NG F46287 Tester Connection S27-44 (BRL) - (C12-3) REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPAIR OR REPLACE COMBINATION METER ASSY (SEE PAGE 32-37 ) Author
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: 1048 05-844 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05F1T-06 ABS WARNING LIGHT CIRCUIT (DOES NOT LIGHT UP) WIRING DIAGRAM 6 IF2 W Skid Control ECU with Actuator 29 4 R-L IC4 S27 WA SB Combination Meter 13 C11 17 C11 9 IL1 SB ABS J6 J/C Passenger Side J/B 4 4M 4 4J 1 4E 2 P P E E 10 IC4 GR 4H I15 Ignition SW Instrument Panel J/B Y W F7 FL Block W B 1 ALT 2 10 1D ECU-IG 6 1G IGN 1 1A AM1 1 L-Y AM2 10 7 1C 1 1C 6 1C 46 S27 IG1 B-R G 4 IG1 AM1 2 GR 6 IG2 AM2 7 W 2 1 IC1 Y W-B 32 S27 GND1 A FL MAIN J4 J/C W-B Battery EA EB F46304 Author
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: 1034 05-845 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE 1 INSPECT ABS WARNING LIGHT WHEN USING HAND-HELD TESTER: (a) Connect the hand-held tester to the DLC3 and start the engine. (b) Select the item ”ABS WARN LIGHT” in the ACTIVE TEST and operate the ABS warning light on the hand-held tester. Item ABS WARN LIGHT Vehicle Condition / Test Details Turns ABS warning light ON / OFF Diagnostic Note Observe combination meter (c) Check that ”ON” and ”OFF” of the ABS warning light can be shown on the combination meter by the hand-held tester. OK: Turn the ABS warning light ON or OFF in accordance with the hand-held tester. WHEN NOT USING HAND-HELD TESTER: Skid Control ECU (a) Turn the ignition switch off and disconnect the connector (harness side connector) S27 from the skid control ECU. (b) Ground terminal WA of the skid control ECU. (c) Turn the ignition switch to the ON position. (d) Check that the ABS warning light. OK: Turn the light ON or OFF in accordance with the conWA necting condition of terminal WA and body ground. G24767 NG CHECK AND REPAIR ABS WARNING LIGHT CIRCUIT OK Author
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: 1035 05-846 DIAGNOSTICS 2 - ABS WITH EBD & BA & TRAC & VSC SYSTEM CHECK HARNESS AND CONNECTOR(SKID CONTROL ECU - COMBINATION METER) (a) Skid Control ECU Front View S27 WA (b) (c) Combination Meter (harness side view) C11 Disconnect the skid control ECU connector and combination meter connector. Measure the resistance according to the value(s) in the table below. Standard: Specified Condition Below 1 Ω Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-29 (WA) - Body ground 10 kΩ or higher NG F46286 Tester Connection C11-17 - S27-29 (WA) REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
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: 1036 05-788 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05F1P-08 DTC C0200/31 RIGHT FRONT SPEED SENSOR DTC C0205/32 LEFT FRONT SPEED SENSOR DTC C1235/35 FOREIGN MATTER IS ATTACHED ON TIP OF RIGHT FRONT SENSOR DTC C1236/36 FOREIGN MATTER IS ATTACHED ON TIP OF LEFT FRONT SENSOR CIRCUIT DESCRIPTION Rotor The speed sensor detects wheel speed and sends the appropriate signals to the ECU. These signals are used to control the ABS control system. The front and rear rotors have 48 serrations each. When the rotors rotate, the magnetic field emitted by the permanent magnet in the speed sensor generates AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. Speed Sensor S Magnet N Coil To ECU Low Speed High Speed +V BR3583 BR3582 -V DTC No. F00010 DTC Detecting Condition Trouble Area C0200/31 C0205/32 (1) All the following conditions continues for at least 1 second.
Vehicle speed is more than 6 mph (10 km/h).
Open or short in vehicle speed sensor signal circuit of faulty wheel continues for 1 second or more. (2) Momentary interruption of the sensor signal of faulty wheel has occurred 7 times or more. (3) Sensor signal circuit is open for 0.5 seconds.
Right front and left front speed sensor
Each speed sensor circuit
Sensor rotor
Sensor installation C1235/35 C1236/36 All the following conditions for at least 5 seconds.
Vehicle speed is more than 12 mph (20 km/h).
Vehicle speed sensor signal receives.
Right front and left front speed sensor
Each speed sensor
Sensor installation HINT:

DTC C0200/31 and C1235/35 are for the right front speed sensor. DTC C0205/32 and C1236/36 are for the left front speed sensor. Author
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: 978 05-789 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM WIRING DIAGRAM Skid Control ECU with Actuator 2 A5 ABS Speed Sensor Front RH 1 R-Y 3 S27 FR+ LG 17 S27 FR- O 18 S27 FL+ P 4 S27 FL- 2 A4 ABS Speed Sensor Front LH 1 F40566 INSPECTION PROCEDURE HINT: Start the inspection from step 1 when using the hand-held tester and start from step 3 when not using the hand-held tester. 1 (a) (b) (c) (d) READ VALUE OF HAND-HELD TESTER(FRONT SPEED SENSOR) Connect the hand-held tester to the DLC3. Start the engine. Select the DATA LIST mode on the hand-held tester. Check that there is no difference between the speed value output from the speed sensor displayed on the hand-held tester and the speed value displayed on the speedometer when driving the vehicle. Item WHEEL SPD FR WHEEL SPD FL Measurement Item / Range (Display) Wheel speed sensor (FR) reading / min.: 0 km/h (0 MPH, max.: 326 km/h (202 MPH) Wheel speed sensor (FL) reading / min.: 0 km/h (0 MPH, max.: 326 km/h (202 MPH) Normal Condition Actual wheel speed Actual wheel speed OK: There is almost no difference from the displayed speed value. HINT: There is tolerance of ± 10 % in the speedometer indication. NG Go to step 3 OK Author
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: 979 05-790 DIAGNOSTICS 2 - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECT SPEED SENSOR AND SENSOR ROTOR SERRATIONS Normal Signal Waveform GND 2 m/s / Division 1 V / Division W04200 INSPECTION USING OSCILLOSCOPE (a) Connect the oscilloscope to terminal FR+ - FR- or FL+ - FL- of the skid control ECU. (b) Drive the vehicle at about 19 mph (30 km/h), and check the signal waveform. OK: A waveform as shown in a figure should be output. HINT:
As the vehicle speed (wheel revolution speed) increases, a cycle of the waveform narrows and the fluctuation in the output voltage becomes greater.
When noise is identified in the waveform on the oscilloscope, error signals are generated due to the speed sensor rotor’s scratches, looseness or foreign matter attached to it. NG Go to step 6 OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
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: 980 05-791 DIAGNOSTICS 3 - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECT FRONT SPEED SENSOR (a) 2 A4 (b) (c) 1 A5 Make sure that there is no looseness at the connectors’ locking part and connecting part of connector. Disconnect the speed sensor connector. Measure the resistance according to the value(s) in the table below. Standard: LH: Front Speed Sensor C93876 Tester Connection Specified Condition A4-1 (FL-) - A4-2 (FL+) 0.6 to 2.5 kΩ RH: (d) Tester Connection Specified Condition A5-1 (FR-) - A5-2 (FR+) 0.6 to 2.5 kΩ Measure the resistance according to the value(s) in the table below. Standard: LH: Tester Connection Specified Condition A4-1 (FL-) - Body ground 10 kΩ or higher A4-2 (FL+) - Body ground 10 kΩ or higher RH: Tester Connection Specified Condition A5-1 (FR-) - Body ground 10 kΩ or higher A5-2 (FR+) - Body ground 10 kΩ or higher NOTICE: Check the speed sensor signal after replacement (see page 05-765 ). NG REPLACE FRONT SPEED SENSOR (SEE PAGE 32-40 ) OK Author
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: 981 05-792 DIAGNOSTICS 4 - ABS WITH EBD & BA & TRAC & VSC SYSTEM CHECK HARNESS AND CONNECTOR(FRONT SPEED SENSOR - SKID CONTROL ECU) (a) Skid Control ECU (harness side connector) S27 FR+ FL- (b) FL+ FRFront Speed Sensor (harness side connector) A5 A4 FL- FL+ FR- Disconnect the skid control ECU connector and the front speed sensor connector. Measure the resistance according to the value(s) in the table below. Standard: LH: Tester Connection Specified Condition S27-18 (FL+) - A4-2 (FL+) Below 1 Ω S27-4 (FL-) - A4-1 (FL-) Below 1 Ω RH: FR+ G26177 (c) Tester Connection Specified Condition S27-3 (FR+) - A5-2 (FR+) Below 1 Ω S27-17 (FR-) - A5-1 (FR-) Below 1 Ω Measure the resistance according to the value(s) in the table below. Standard: LH: Tester Connection Specified Condition S27-18 (FL+) - Body ground 10 kΩ or higher S27-4 (FL-) - Body ground 10 kΩ or higher RH: Tester Connection Specified Condition S27-3 (FR+) - Body ground 10 kΩ or higher S27-17 (FR-) - Body ground 10 kΩ or higher NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK Author
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: 982 05-793 DIAGNOSTICS 5 - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECT SPEED SENSOR AND SENSOR ROTOR SERRATIONS Normal Signal Waveform GND 2 m/s / Division 1 V / Division W04200 INSPECTION USING OSCILLOSCOPE (a) Connect the oscilloscope to terminal FR+ - FR- or FL+ - FL- of the skid control ECU. (b) Drive the vehicle at about 19 mph (30 km/h), and check the signal waveform. OK: A waveform as shown in a figure should be output. HINT:
As the vehicle speed (wheel revolution speed) increases, a cycle of the waveform narrows and the fluctuation in the output voltage becomes greater.
When noise is identified in the waveform on the oscilloscope, error signals are generated due to the speed sensor rotor’s scratches, looseness or foreign matter attached to it. NG Go to step 6 OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) 6 INSPECT FRONT SPEED SENSOR INSTALLATION (a) Speed Sensor 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) No Clearance OK NG BR3795 Check the speed sensor installation. OK:
The installation bolt is tightened properly. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf)
There is no clearance between the sensor and the front steering knuckle. NOTICE: Check the speed sensor signal after the replacement (see page 05-765 ). NG REPLACE FRONT SPEED SENSOR (SEE PAGE 32-40 ) OK Author
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: 983 05-794 DIAGNOSTICS 7 - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECT SPEED SENSOR TIP (a) (b) Remove the front speed sensor (see page 32-40 ). Check the sensor tip. OK: No scratches or foreign matter on the sensor tip. NOTICE: Check the speed sensor signal after the replacement (see page 05-765 ). NG CLEAN OR REPAIR SPEED SENSOR OK 8 INSPECT SPEED SENSOR ROTOR (a) (b) Speed Sensor Rotor R00948 Remove the front speed sensor rotor. Check the sensor rotor serrations. OK: No scratches, missing teeth or foreign matter on the rotors. HINT: If there is foreign matter in the rotor, remove it and check the output waveform after reassembly. NOTICE: Check the speed sensor signal after the replacement (see page 05-765 ). NG CLEAN OR REPAIR SPEED SENSOR ROTOR OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
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: 984 05-795 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05H3B-03 DTC C0210/33 RIGHT REAR SPEED SENSOR DTC C0215/34 LEFT REAR SPEED SENSOR DTC C1238/38 FOREIGN MATTER IS ATTACHED ON TIP OF RIGHT REAR SENSOR DTC C1239/39 FOREIGN MATTER IS ATTACHED ON TIP OF LEFT REAR SENSOR CIRCUIT DESCRIPTION Refer to DTC C0200/31, C0205/32, C1235/35, C1236/36 on page 05-788 . DTC No. DTC Detecting Condition Trouble Area C0210/33 C0215/34 (1) All the following conditions continues for at least 1 second.
Vehicle speed is more than 6 mph (10 km/h).
Open or short in vehicle speed sensor signal circuit of faulty wheel continues for 1 second or more. (2) Momentary interruption of the sensor signal of faulty wheel has occurred 7 times or more. (3) Sensor signal circuit is open for 0.5 seconds.
Right rear and left rear speed sensor
Each speed sensor circuit
Sensor rotor
Sensor installation C1238/38 C1239/39 All the following conditions for at least 5 seconds.
Vehicle speed is more than 12 mph (20 km/h).
Vehicle speed sensor signal receives.
Right rear and left rear speed sensor
Each speed sensor
Sensor installation HINT:

DTC C0210/33 and C1238/38 are for the right rear speed sensor. DTC C0215/34 and C1239/39 are for the left rear speed sensor. WIRING DIAGRAM Skid Control ECU with Actuator V 12 IA1 O 16 IC2 G 6 S27 RL- R 2 IA1 Y 7 IC2 Y-G 20 S27 RL+ P 2 IO2 R 15 IC2 BR 19 S27 RR- GR 1 IO2 L 6 IC2 Y 5 S27 RR+ A24 ABS Speed Sensor Rear LH 2 1 A25 ABS Speed Sensor Rear RH 2 1 F46312 Author
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: 985 05-796 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1 when using the hand-held tester and start from step 3 when not using the hand-held tester. 1 (a) (b) (c) (d) READ VALUE OF HAND-HELD TESTER(REAR SPEED SENSOR) Connect the hand-held tester to the DLC3. Start the engine. Select the DATA LIST mode on the hand-held tester. Check that there is no difference between the speed value output from the speed sensor displayed by the hand-held tester and the speed value displayed on the speedometer when driving the vehicle. Item WHEEL SPD RL WHEEL SPD RR Measurement Item / Range (Display) Wheel speed sensor (RL) reading / min.: 0 km/h (0 MPH, max.: 326 km/h (202 MPH) Wheel speed sensor (RR) reading / min.: 0 km/h (0 MPH, max.: 326 km/h (202 MPH) Normal Condition Actual wheel speed Actual wheel speed OK: There is almost no difference in the displayed speed value. HINT: There is tolerance of ± 10 % in the speedometer indication. NG Go to step 3 OK 2 INSPECT SPEED SENSOR AND SENSOR ROTOR SERRATIONS Normal Signal Waveform GND 2 m/s / Division 1 V / Division W04200 INSPECTION USING OSCILLOSCOPE (a) Connect the oscilloscope to terminals RR+ - RR- or RL+ - RL- of the skid control ECU. (b) Drive the vehicle at approximately 19 mph (30 km/h), and check the signal waveform. OK: A waveform as shown in a figure should be output. HINT:
As the vehicle speed (wheel revolution speed) increases, a cycle of the waveform narrows and the fluctuation in the output voltage becomes greater.
When noise is identified in the waveform on the oscilloscope, error signals are generated due to the speed sensor rotor’s scratches, looseness or foreign matter attached to it. NG Go to step 6 OK REPLACE REAR SPEED SENSOR (SEE PAGE 32-37 ) Author
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: 986 05-797 DIAGNOSTICS 3 - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECT REAR SPEED SENSOR 2WD: (a) Disconnect the skid control sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard: Rear Speed Sensor 1 2 (c) F41836 Connector B 1 2 1 Connector A 2 F10180 Tester Connection Specified Condition 1-2 0.9 to 2.1 kΩ Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 1 - Body ground 10 kΩ or higher 2 - Body ground 10 kΩ or higher 2WD: Skid control sensor sub-wire harness: (a) Remove the seat cushion and seatback. (b) Make sure that there is no looseness at the connector’s locking part and connecting part of the connector. (c) Measure the resistance between terminal 1 of connector A and terminal 2 of connector B. (d) Measure the resistance between terminal 2 of connector A and terminal 1 of connector B. Standard: (e) Tester Connection Specified Condition A-1 - B-1 1 Ω or less A-2 - B-2 1 Ω or less Measure resistance between terminals 1 and 2 of speed sensor connector A and body ground. Standard: Tester Connection Specified Condition 1 - Body ground 10 kΩ or higher 2 - Body ground 10 kΩ or higher Author
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: 987 05-798 DIAGNOSTICS 1 2 - ABS WITH EBD & BA & TRAC & VSC SYSTEM 4WD: (a) Disconnect the rear speed sensor connector. (b) Measure the resistance according to the value(s) in the table below. Standard: (c) R14205 Tester Connection Specified Condition 1-2 0.9 to 1.3 kΩ at 25 C Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 1 - Body ground 10 kΩ or higher 2 - Body ground 10 kΩ or higher NOTICE: Check the speed sensor signal after replacement (see page 05-765 ). NG REPLACE REAR SPEED SENSOR (SEE PAGE 32-37 ) OK 4 CHECK HARNESS AND CONNECTOR(REAR SPEED SENSOR - SKID CONTROL ECU) (a) Skid Control ECU S27 (harness side connector) RR+ RL- (b) RL+ RRSkid Control Sensor (harness side connector) A24 RL- A25 RL+ RR- Disconnect the skid control ECU connector and the skid control sensor connector. Measure the resistance according to the value(s) in the table below. Standard: LH: Tester Connection Specified Condition S27-20 (RL+) - A24-1 (RL+) Below 1 Ω S27-6 (RL-) - A24-2 (RL-) Below 1 Ω RH: RR+ G26241 (c) Tester Connection Specified Condition S27-5 (RR+) - A25-1 (RR+) Below 1 Ω S27-19 (RR-) - A25-2 (RR-) Below 1 Ω Measure the resistance according to the value(s) in the table below. Standard: LH: Tester Connection Specified Condition S27-20 (RL+) - Body ground 10 kΩ or higher S27-6 (RL-) - Body ground 10 kΩ or higher RH: Tester Connection Specified Condition S27-5 (RR+) - Body ground 10 kΩ or higher S27-19 (RR-) - Body ground 10 kΩ or higher Author
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: 988 05-799 DIAGNOSTICS NG - ABS WITH EBD & BA & TRAC & VSC SYSTEM REPAIR OR CONNECTOR REPLACE HARNESS OR OK 5 INSPECT SPEED SENSOR AND SENSOR ROTOR SERRATIONS Normal Signal Waveform GND 2 m/s / Division 1 V / Division W04200 INSPECTION USING OSCILLOSCOPE (a) Connect the oscilloscope to terminals RR+ - RR- or RL+ - RL- of the skid control ECU. (b) Drive the vehicle at approximately 19 mph (30 km/h), and check the signal waveform. OK: A waveform as shown in a figure should be output. HINT:
As the vehicle speed (wheel revolution speed) increases, a cycle of the waveform narrows and the fluctuation in the output voltage becomes greater.
When noise is identified in the waveform on the oscilloscope, error signals are generated due to the speed sensor rotor’s scratches, looseness or foreign matter attached to it. NG Go to step 6 OK REPLACE REAR SPEED SENSOR (SEE PAGE 32-42 (FF) OR 32-44 (4WD)) Author
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: 989 05-800 DIAGNOSTICS 6 - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECT REAR SPEED SENSOR INSTALLATION 2WD: (a) Check the sensor installation. OK: There is no clearance between the sensor and rear axle carrier. Skid Control Sensor OK NG F10178 8.0 N⋅m (82 kgf⋅cm,71 in.⋅lbf) No Clearnace OK NG BR3795 4WD: (a) Check the speed sensor installation. OK: There is no clearance between the sensor and rear axle carrier. The installation bolt is tightened properly. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) NOTICE: Check the speed sensor signal after replacement (see page 05-765 ). NG REPLACE REAR SPEED SENSOR (SEE PAGE 32-42 (FF) OR 32-44 (4WD)) OK Author
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: 990 05-801 DIAGNOSTICS 7 - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECT SPEED SENSOR ROTOR AND SENSOR TIP 2WD: (a) Remove the skid control sensor (see page 32-42 ). (b) Check the sensor tip. OK: No scratches or foreign matter on the sensor tip. 4WD: (a) Remove the rear speed sensor (See page 32-44 ). (b) Check the sensor tip. OK: No scratches or foreign matter on the sensor tip. Sensor Rotor 2WD: (a) Check the sensor rotor serrations. OK: No scratches, missing teeth or foreign matter on the rotor. F08575 Sensor Rotor R00948 4WD: (a) Remove the rear drive shaft (See page 30-45 ). (b) Check the sensor rotor serrations. OK: No scratches, missing teeth or foreign matter. HINT: If foreign matter is attached, remove it and after reassembling, check the output waveform. NOTICE: Check the speed sensor signal after the replacement (see page 05-765 ). NG CLEAN OR REPLACE SPEED SENSOR AND SENSOR ROTOR SERRATIONS OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
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: 991 05-802 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM DTC C0226/21 SFR SOLENOID CIRCUIT DTC C0236/22 SFL SOLENOID CIRCUIT DTC C0246/23 SRR SOLENOID CIRCUIT DTC C0256/24 SRL SOLENOID CIRCUIT DTC C1225/25 SMC SOLENOID CIRCUIT 05CDP-15 CIRCUIT DESCRIPTION This solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel cylinders to control the braking force. DTC No. DTC Detecting Condition Trouble Area C0226/21 Open or short circuit in front right solenoid circuit (SFRR or SFRH) continues for 0.05 sec. or more.
ABS & TRAC actuator
Each solenoid circuit C0236/22 Open or short circuit in front left solenoid circuit (SFLR or SFLH) continues for 0.05 sec. or more.
ABS & TRAC actuator
Each solenoid circuit C0246/23 Open or short circuit in rear right solenoid circuit (SRRR or SRRH) continues for 0.05 sec. or more.
ABS & TRAC actuator
Each solenoid circuit C0256/24 Open or short circuit in rear left solenoid circuit (SRLR or SRLH) continues for 0.05 sec. or more.
ABS & TRAC actuator
Each solenoid circuit C1225/25 When any of the following (1 to 5) is detected: (1) All the following conditions continues for at least 0.05 seconds.
When switching solenoid (SM1 or SM2) outputs ON signal.
Over current. (2) All the following conditions continues for at least 0.05 seconds.
When switching solenoid (SM1 or SM2) outputs OFF signal.
Open circuit. (3) All the following conditions continues for at least 0.05 seconds.
When switching solenoid (SM1 or SM2) outputs OFF signal.
Output current monitor is more than 0.15 A. (4) All the following conditions continues for at least 0.05 seconds.
When switching solenoid (SM1 or SM2) outputs ON signal.
Output current is more than 0.348 A.
Difference between current monitor and target value exceeds 2, continues for between 0.1 sec. and 0.15 sec. (5) All the following conditions continues for at least 0.2 seconds.
When switching solenoid (SM1 or SM2) outputs ON signal.
Output current is more than 0.348 A. 1. More than 2.08 2. Less than 0.48
ABS & TRAC actuator
Each solenoid circuit Author
: Date
: 992 05-803 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM WIRING DIAGRAM F7 FL Block Skid Control ECU with Actuator W 31 S27 +BS B 1 ABS1 8 W-B 32 S27 GND1 A J4 J/C FL MAIN W-B Battery EA EB F46309 INSPECTION PROCEDURE 1 RECONFIRM DTC HINT: This code is detected when a problem is determined in the brake actuator assy. The solenoid circuit is in the brake actuator assy. Therefore, solenoid circuit inspection and solenoid unit inspection cannot be performed. Be sure to check if the DTC code is output before replacing the brake actuator assy. (a) Clear the DTCs(see page 05-765 ). (b) Turn the ignition switch to the ON position. (c) Are the same DTCs recorded? NO PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-786 ). YES REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
: Date
: 993 05-804 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05F1Q-09 DTC C0273/13 OPEN CIRCUIT IN ABS MOTOR RELAY CIRCUIT DTC C0274/14 SHORT CIRCUIT IN ABS MOTOR RELAY CIRCUIT DTC C1361/91 SHORT CIRCUIT IN ABS MOTOR FAIL SAFE RELAY CIRCUIT CIRCUIT DESCRIPTION



The VSC motor relays consist of 2 relays are included in the ABS R/B. The VSC cut relay is turned on after turning the ignition switch to the ON position. If the DTCs in the ABS pump motor circuit are memorized, the VSC cut relay cuts off the power supply to the VSC motor relay and performs the fail safe. While any of the ABS, BA, TRAC and VSC is operating, the skid control ECU (included in the actuator) turns the VSC motor relay on to operate the actuator pump motor. If the voltage applied to the VSC motor relays (+BM) drops below the condition that detects the DTCs due to the shortage of the battery or alternator output, the DTCs may be memorized. DTC No. C0273/13 C0274/14 C1361/91 DTC Detecting Condition Trouble Area When any of the following (1 to 2) is detected: (1) All the following conditions continues for at least 0.2 seconds.
IG1 voltage is between 9.5 and 17.2 V.
During initial check.
ABS, BA, TRAC, and VSC are in operation.
Relay contact is open when the relay is ON. (2) All the following conditions continues for at least 0.2 seconds.
IG1 voltage is less than 9.5 V.
Relay contact remains open when the relay is ON.
ABS No.2 fuse
ABS MTR relay
ABS MTR relay circuit
ABS R/B
ABS cut relay
ABS cut relay circuit The following condition continue for at least 4 seconds.
Relay contact is closed when the relay is OFF.
ABS No.2 fuse
ABS MTR relay
ABS MTR relay circuit
ABS R/B
ABS cut relay
ABS cut relay circuit All the following conditions continues for at least 4 seconds.
Immediately after turning IG switch to the ON position.
Relay contact is closed when fail-safe relay is OFF.
ABS No.2 fuse
ABS MTR relay
ABS MTR relay circuit
ABS R/B
ABS cut relay
ABS cut relay circuit Author
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: 994 05-805 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM WIRING DIAGRAM B-O Skid Control ECU with Actuator 45 S27 R+ ABS R/B ABS MTR Relay B-O B 5 5 1 2 5 3 LG 5 W-L 5 15 S27 MR 2 S27 BM ABS CUT Relay 5 5 FL MAIN 5 3 1 B-R 5 G-R 5 2 14 S27 MRF F7 FL Block W 1 ABS2 9 Battery F46308 Author
: Date
: 995 05-806 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1 when using the hand-held tester and start from step 2 when not using the hand-held tester. 1 (a) (b) (c) (d) PERFORM ACTIVE TEST BY HAND-HELD TESTER(ABS MOTOR RELAY OPERATION) Connect the hand-held tester to the DLC3. Start the engine. Select the ACTIVE TEST mode on the hand-held tester. Check the operation sound of the ABS motor individually when operating it with the hand-held tester. Item Vehicle Condition / Test Details ABS MOT RELAY Vehicle Condition / Test Details ABS motor relay / ON or OFF ON : Motor relay ON OK: The operation sound of the ABS motor should be heard. NG Go to step 2 OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) 2 INSPECT FUSE(ABS2 FUSE) (a) (b) FL BLOCK Remove ABS2 fuse from the FL BLOCK. Check continuity of ABS2 fuse. Standard: ABS No.1 fuse NG ABS2 F40458 Below 1Ω (Continuity) CHECK FOR SHORT IN ALL HARNESS AND CONNECTOR CONNECTED TO FUSE AND REPLACE FUSE OK Author
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: 996 05-807 DIAGNOSTICS 3 - ABS WITH EBD & BA & TRAC & VSC SYSTEM CHECK TERMINAL VOLTAGE(VSC MOTOR RELAY 5 TERMINAL OF ABS R/B) (a) (b) (c) ABS R/B: 5 Remove the VSC MTR relay from the ABS R/B. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester Connection Specified Condition Terminals 5 - Body ground 10 to 14 V NG I37487 REPAIR OR CONNECTOR REPLACE HARNESS OR OK 4 INSPECT VSC MOTOR RELAY (a) Measure the resistance according to the value(s) in the table below. Standard: Tester Connection 3-5 3-5 B57491 NG Connection Specified resistance Always 10 kΩ or higher (No continuity) Apply B+ between terminal 1 and 2 Below 1 Ω REPLACE VSC MOTOR RELAY OK 5 INSPECT VSC CUT RELAY (a) Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Connection Specified resistance 3-5 Always 10 kΩ or higher (No continuity) 3-5 B16200 NO Apply B+ between terminal 1 and 2 Below 1 Ω REPLACE VSC CUT RELAY OK Author
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: 997 05-808 DIAGNOSTICS 6 - ABS WITH EBD & BA & TRAC & VSC SYSTEM CHECK HARNESS AND CONNECTOR(VSC MOTOR RELAY - SKID CONTROL ECU) Skid Control ECU (harness side connector) BM (a) (b) S27 (c) Disconnect the skid control ECU connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-2 (BM) - 3 (ABS R/B) Below 1 Ω Measure the resistance according to the value(s) in the table below. Standard: ABS R/B: NG 3 I37488 Tester Connection Specified Condition S27-2 BM - Body ground 10 kΩ or higher REPAIR OR CONNECTOR REPLACE HARNESS OR OK 7 CHECK HARNESS AND CONNECTOR(VSC MOTOR RELAY - SKID CONTROL RELAY) (a) ABS R/B: 5 (b) Remove the ABS motor relay and skid control relay from ABS R/B. Measure the resistance according to the value(s) in the table below. Standard: 3 I37487 NG Tester Connection Specified Condition 5 (ABS MOTOR Relay) 3 (Skid Control Relay) Below 1 Ω REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
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: 998 05-809 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05CD5-19 DTC C0278/11 OPEN CIRCUIT IN ABS SOLENOID RELAY CIRCUIT DTC C0279/12 SHORT CIRCUIT IN ABS SOLENOID RELAY CIRCUIT CIRCUIT DESCRIPTION The ABS solenoid relay is built in the ABS & TRACTION Actuator assy. This relay supplies power to each ABS solenoid. If the initial check is OK, after the ignition switch is turned to the ON position, the relay goes on. DTC No. DTC Detecting Condition Trouble Area C0278/11 When any of the following (1 to 2) is detected: (1) All the following conditions continues for at least 0.2 seconds.
IG voltage is between 9.5 and 17.2 V.
Relay contact is open when the relay is ON. (2) All the following conditions continues for at least 0.2 seconds.
IG voltage is 9.5 V or less when the relay is ON.
Relay contact remains open.
ABS No.1 fuse
ABS SOL relay
ABS SOL relay circuit
ABS & TRAC actuator C0279/12 The following condition continue for at least 0.2 seconds.
Relay contact is closed immediately after turning IG switch to the ON position when the relay is OFF.
ABS No.1 fuse
ABS SOL relay
ABS SOL relay circuit
ABS & TRAC actuator WIRING DIAGRAM F7 FL Block Skid Control ECU with Actuator W 31 S27 +BS B 1 ABS1 8 W-B 32 S27 GND1 A J4 J/C FL MAIN W-B Battery EA EB F46309 Author
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: 999 05-810 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE 1 INSPECT FUSE(ABS1 FUSE) (a) (b) FL BLOCK Remove ABS1 fuse from the FL BLOCK. Check continuity of ABS1 fuse. Standard: ABS No.2 fuse NG ABS1 F40458 Below 1 Ω (Continuity) CHECK FOR SHORT IN ALL HARNESS AND CONNECTOR CONNECTED TO FUSE AND REPLACE FUSE OK 2 INSPECT SKID CONTROL ECU CONNECTOR(+BS TERMINAL VOLTAGE) (a) (b) (c) Skid Control ECU S27 (harness side connector) GND1 +BS Disconnect the skid control ECU connector. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-31 (+BS) - S27-32 (GND1) 10 to 14 V NG Go to step 4 G24767 OK 3 RECONFIRM DTC (a) Clear the DTCs (see page 05-765 ). (b) Turn the ignition switch to the ON position. (c) Are the same DTCs recorded? NOTICE: When replacing ABS & TRACTION ACTUATOR ASSY, perform zero point calibration (see page 05-765 ). NO PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-786 ) YES REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
: Date
: 1000 05-81 1 DIAGNOSTICS 4 - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECT SKID CONTROL ECU CONNECTOR(GND TERMINAL CONTINUITY) (a) (b) Skid Control ECU S27 (harness side connector) GND1 G24767 Disconnect the skid control ECU connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-32 (GND1) - Body ground Below 1 Ω NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK 5 RECONFIRM DTC (a) Clear the DTCs (see page 05-765 ). (b) Turn the ignition switch to the ON position. (c) Are the same DTCs recorded? (see page 05-765 ). HINT: It is suspect that the DTCs output was caused by the poor connection of the connector terminal. NO PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-786 ) YES REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
: Date
: 1001 05-812 DIAGNOSTICS DTC - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05CD6-06 C1201/51 ENGINE CONTROL SYSTEM MALFUNCTION CIRCUIT DESCRIPTION If trouble occurs in the engine control system, the skid control ECU prohibits TRAC and VSC control. DTC No. C1201/51 DTC Detecting Condition Trouble Area At the engine speed of 500 rpm, a trouble signal in the engine control system continues for 5 secs. or more. Engine control system INSPECTION PROCEDURE 1 (a) CHECK DTC FOR ENGINE Check if the normal code is recorded for SFI system. A Normal System Code B Trouble Code B REPAIR ENGINE CONTROL ACCORDING TO DTC OUTPUT SYSTEM A REPLACE ECM Author
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: 1002 05-813 DIAGNOSTICS DTC - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05CDQ-14 C1203/53 ECM COMMUNICATION CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION The circuit is used to send TRAC & VSC control information from the skid control ECU to the ECM (TRC+, TRC-), and engine control information from the ECM to the skid control ECU (ENG+, ENG-). DTC No. DTC Detecting Condition Trouble Area C1203/53 When any of the following (1 to 3) is detected: (1) All the following conditions continues for at least 5 seconds.
IG1 terminal voltage is 9.5 V or more.
Cannot send data to ECM. (2) All the following conditions continues for at least 5 seconds.
IG1 terminal voltage is more than 9.5 V.
Engine speed is 500 rpm or more.
Cannot receive data from ECM. (2) All the following conditions repeats 10 times in a series.
Cannot send data to ECM.
Cannot receive data from ECM.
Both of the above occur at least once within 5 sec.
TRC+ or TRC- circuit
ENG+ or ENG- circuit
ECM WIRING DIAGRAM Skid Control ECU with Actuator ECM 24 ENG+ E5 V 5 IC4 W-L 9 S27 ENG+ 30 E5 R 18 IC4 W-G 23 S27 ENG- 25 TRC+ E5 Y 7 IC4 G-B 8 S27 TRC+ 31 E5 G 19 IC4 Y-B 22 S27 TRC- ENG- TRC- F46313 Author
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: 1003 05-814 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(ECM - SKID CONTROL ECU) S27 Skid Control ECU (harness side connector) (a) ENG+ (b) TRC+ TRC- ENG- ECM (c) E5 ENG+ TRC+ TRC- F44428 F45165 ENGF45351 Disconnect the skid control ECU connector and ECM connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-8 (TRC+) - E5-25 (TRC+) Below 1 Ω S27-22 (TRC-) - E5-31 (TRC-) Below 1 Ω S27-9 (ENG+) - E5-24 (ENG+) Below 1 Ω S27-23 (ENG-) - E5-30 (ENG-) Below 1 Ω Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-8 (TRC+) - Body ground 10 kΩ or higher S27-22 (TRC-) - Body ground 10 kΩ or higher S27-9 (ENG+) - Body ground 10 kΩ or higher S27-23 (ENG-) - Body ground 10 kΩ or higher NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK 2 ECM CHECK HARNESS AND CONNECTOR(E1 OF ECM - BODY GROUND) (a) (b) E7 Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard: E1 G26183 NG Tester Connection Specified Condition E7-1 (E1) - Body ground Below 1 Ω REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
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: 1004 05-815 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05F1R-07 DTC C1210/36 ZERO POINT CALIBRATION OF YAW RATE SENSOR UNDONE DTC C1336/39 ZERO POINT CALIBRATION OF DECELERATION SENSOR UNDONE CIRCUIT DESCRIPTION Brake actuator receives signals from the yaw rate sensor (deceleration sensor) via CAN communication system. Yaw rate sensor has the built-in G sensor. If there is trouble in the bus lines between the yaw rate sensor (deceleration sensor) and CAN communication system, the DTC U0123/62 (yaw rate sensor communication trouble) and U0124/95 (G sensor communication trouble) are output. DTC No. DTC Detecting Condition Trouble Area C1210/36 Zero point calibration of yaw rate sensor undone
Yaw rate sensor (Deceleration sensor)
Zero point calibration undone (Perform zero point calibration and DTC. If DTC is not output again, the sensor is normal) C1336/39 When all the following (1 to 2) is detected: (1) Drives in normal mode before completing zero point calibration. (2) Zero point voltage is not within 2.38 V and 2.62 V at zero point calibration.
Yaw rate sensor (Deceleration sensor)
Zero point calibration undone (If DTC is not output again, the sensor is normal) Author
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: 1005 05-816 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE HINT: When U0121/94, U0123/62, U0124/95 or U0126/63 are output accompanied with C1210/36 or C1336/39, inspect and repair the trouble areas indicated by U0121/94, U0123/62, U0124/95 or U0126/63 first. 1 (a) PERFORM ZERO POINT CALIBRATION OF YAW RATE SENSOR AND DECELERATION SENSOR Perform the zero point calibration of the yaw rate sensor and deceleration sensor (see page 05-765 ). NEXT 2 (a) (b) (c) RECONFIRM DTC Clear the DTCs (see page 05-765 ). Turn the ignition switch to the ON position. Are the same DTCs recorded? (see page 05-765 ). NO PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-786 ) YES 3 (a) CHECK SENSOR INSTALLATION Check that the yaw rate sensor has been installed properly (see page 32-46 ). NG INSTALL YAW RATE SENSOR CORRECTLY OK REPLACE YAWRATE SENSOR(SEE PAGE 32-46 ) Author
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: 1006 05-817 DIAGNOSTICS DTC - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05CD8-07 C1223/43 ABS CONTROL SYSTEM MALFUNCTION CIRCUIT DESCRIPTION HINT:

This DTC is output when the VSC system detects a malfunction in the ABS system. When DTC C1223/43 is memorized, there is no malfunction in the skid control ECU. DTC No. C1223/43 DTC Detecting Condition Trouble Area Malfunction in ABS control system ABS control system INSPECTION PROCEDURE 1 (a) (b) (c) CHECK DTC(FOR ABS SYSTEM) Clear the DTCs (see page 05-765 ). Turn the ignition switch to the ON position. Are the same DTCs recorded? (see page 05-765 ) NO PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-786 ) YES REPAIR CIRCUIT INDICATED BY OUTPUT DTC Author
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: 1007 05-818 DIAGNOSTICS DTC - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05CD9-17 C1224/44 NE SIGNAL CIRCUIT CIRCUIT DESCRIPTION The skid control ECU receives engine revolution speed signals (NE signals) from the ECM. DTC No. C1224/44 DTC Detecting Condition Trouble Area When any of the following (1 to 2) is detected: (1) Any of the following conditions continues for at least 10 seconds.
Data can be received properly from ECM at a speed of more than 19 mph (30 km/h).
Open or short in engine rpm signal circuit. (2) Any of the following conditions continues for at least 0.24 seconds.
TRAC is in operation.
Open or short in engine rpm signal circuit.
NEO circuit
ECM
Skid control ECU WIRING DIAGRAM Skid Control ECU with Actuator ECM 17 NEO E5 B 3 IC4 V 10 S27 NEO F46314 Author
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: 1008 05-819 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(SKID CONTROL ECU - ECM) (a) Skid Control ECU S27 (harness side connector) NEO (b) (c) ECM Disconnect the skid control ECU connector and the ECM connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-10 (NEO) - E5-17 (NEO) Below 1 Ω Measure the resistance according to the value(s) in the table below. Standard: E5 Tester Connection Specified Condition S27-10 (NEO) - Body ground 10 kΩ or higher NEO G26436 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK Author
: Date
: 1009 05-820 DIAGNOSTICS 2 - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECT ECM TERMINAL VOLTAGE(NEO TERMINAL) (a) ECM Reconnect the ECM connector and the skid control ECU connector. Check the signal waveform between terminal NEO (E5-17) of the ECM and body ground for the engine conditions below. OK: E5 (b) NEO G26185 Tester Connection Engine Condition Specified condition E5-17 (NEO) - Body ground OFF (Ignition switch ON) 4.5 to 14 V or below 1 V E5-17 (NEO) - Body ground ON (Idling) Pulse generation (4.5 to 14 V ↔ below 1 V) Pulse Generation 20 V/DIV, 1 ms/DIV 4.5 to 14 V Below 1 V A20293 NG REPLACE ECM OK 3 CHECK IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED NG CONNECT CONNECTOR TO ECU OK 4 (a) (b) (c) RECONFIRM DTC Clear the DTCs (see page 05-765 ). Turn the ignition switch to the ON position. Are the same DTCs recorded? NO PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-786 ) YES REPLACE ABS & TRACTION ACTUATOR ASSY(SEE PAGE 32-37 ) Author
: Date
: 1010 05-821 DIAGNOSTICS DTC - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05CDA-18 C1231/31 MALFUNCTION IN STEERING ANGLE SENSOR CIRCUIT CIRCUIT DESCRIPTION The steering angle sensor signal is sent to the skid control ECU through the CAN communication system. When there is a malfunction in the communication, it will be detected by the diagnosis function. DTC No. DTC Detecting Condition C1231/31 When ECU IG1 terminal voltage is 9.5 V or more, the steering angle sensor malfunction signal is received. Trouble Area
Steering angle sensor
Steering angle sensor circuit
+B circuit
CAN communication system Author
: Date
: 1011 05-822 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM WIRING DIAGRAM S14 Steering Sensor CANL CANH J16 J/C W 13 IC4 12 IC4 W 9 21 19 10 8 L Y 10 W B Skid Control ECU with Actuator 25 S27 CANL 11 S27 CANH Passenger Side J/B ESS 3 4C W-B 2 J17 J/C BAT IG1 9 1D P E E 10 1G Passenger Side J/B 11 4 4C 4J L 1 I15 Ignition SW W-B BR 5 IC3 Y Instrument Panel J/B G 7 1C ECU-IG 10 1D W 6 1C AM1 1 1A IG1 4 2 AM1 W-B Instrument Panel J/B P 3 1 4N 7 4L 2 F7 FL Block 1 B W 1 ALT 2 Engine Room J/B FL MAIN W 3 1 2I D.C.C ECU-B 4 2A W-L IC Battery F46318 Author
: Date
: 1012 05-823 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE HINT:
When U0121/94, U0123/62, U0124/95 or U0126/63 are output together with C1231/31, inspect and repair the trouble areas indicated by U0121/94, U0123/62, U0124/95 or U0126/63 first. When the speed sensor or the yaw rate sensor has trouble, DTCs for the steering angle sensor may be output even when the steering angle sensor is normal. When DTCs for the speed sensor or yaw rate sensor are output together with other DTCs for the steering angle sensor, inspect and repair the speed sensor and yaw rate sensor first, and then inspect and repair the steering angle sensor. Start the inspection from step 1 when using the hand-held tester and start from step 2 when not using the hand-held tester.

1 (a) (b) (c) (d) READ VALUE OF HAND-HELD TESTER(STEERING ANGLE SENSOR) Connect the hand-held tester to the DLC3. Start the engine. Select the DATA LIST mode on the hand-held tester. Check that the steering angle value of the steering angle sensor indicated on the hand-held tester, changes when the steering wheel is turned. Measurement Item / Range (Display) Steering sensor/ Min.: -1152 deg, Max.: 1150.875 deg Item STEERING ANG Normal Condition Min.: -128 deg/s Max.: 128 deg/s OK: Steering angle value should change. OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) NG 2 CHECK TERMINAL VOLTAGE(STEERING ANGLE SENSOR CONNECTOR) (a) (b) (c) (d) Steering Angle Sensor (harness side connector) (+) (-) BAT S14 Remove the steering wheel and the column lower cover. Disconnect the steering angle sensor connector S14. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester Connection Specified Condition S14-1 (IG1) - S14-2 (ESS) 10 to 14 V S14-3 (BAT) - S14-2 (ESS) 10 to 14 V IG1 (+) (-) ESS G26292 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE STEERING ANGLE SENSOR Author
: Date
: 1013 05-824 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05CDB-18 DTC C1232/32 MALFUNCTION IN DECELERATION SENSOR DTC C1234/34 MALFUNCTION IN YAW RATE SENSOR DTC C1243/43 MALFUNCTION IN DECELERATION SENSOR DTC C1244/44 OPEN OR SHORT IN DECELERATION SENSOR CIRCUIT DTC C1245/45 MALFUNCTION IN DECELERATION SENSOR DTC C1381/97 MALFUNCTION IN POWER SUPPLY VOLTAGE YAW/DECELERATION SENSOR CIRCUIT DESCRIPTION The yaw rate sensor and deceleration sensor signals are sent to the skid control ECU through the CAN communication system. When there is a malfunction in the communication, it will be detected by the diagnosis function. DTC No. DTC Detecting Condition Trouble Area C1232/32 While the vehicle is at a speed of 6mph (10 km/h) or more, the condition that the fluctuation range of the signal from either GL1 or GL2 is under 80 mV and the other is above 1.9 V continues for 30 seconds or more.
Yaw rate/deceleration sensor
Yaw rate/deceleration sensor circuit C1234/34 S Sensor malfunction lf ti signal i l iis reccives i ffrom yaw rate t sensor.
Yaw rate/deceleration sensor
Yaw rate/deceleration sensor circuit C1243/43 The following condition repeats 16 times.
GL1 and GL2 do not change by more than 2LSB when the vehicle decelerates from 19 mph (30 km/h) to 0 mph (0 km/h).
Yaw rate/deceleration sensor
Yaw rate/deceleration sensor circuit C1244/44 When any of the following (1 to 2) is detected: (1) All the following conditions continues for at least 60 seconds.
Vehicle is stopped.
Difference between IGL1I and IGL2I does not drop below 0.4 G once it reaches 0.6 G or more. (2) Data malfunction signal is received from G sensor.
Yaw rate/deceleration sensor
Yaw rate/deceleration sensor circuit C1245/45 The following condition continue for at least 60 seconds.
Difference between the values calculated from G sensor value and vehicle speed exceeds 0.35 G.
Yaw rate/deceleration sensor
Yaw rate/deceleration sensor circuit C1381/97
G sensor power source malfunction signal is received for at least 10 sec. at a speed of more than 2 mph (3 km/h).
Yaw rate/deceleration sensor
Yaw rate/deceleration sensor circuit Author
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: 1014 05-825 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM WIRING DIAGRAM Y1 Yaw Rate Sensor CANL CANH GND IG W 2 B 3 J16 J/C 13 IO2 W 12 IO2 G 20 W 13 IC4 W L 12 IC4 B 19 9 8 Skid Control ECU with Actuator 25 S27 CANL 11 S27 CANH W-B 1 Passenger Side J/B 3 IO2 O 5 V I15 Ignition SW 2 AM1 FL MAIN 4 4J 2 4C Instrument Panel J/B G 7 1C ECU-IG 10 1D W 6 1C AM1 1 1A IG1 4 F7 FL Block 2 1 W 1 Y ALT B A J19 J/C W-B A BF 2 Battery F46306 INSPECTION PROCEDURE HINT: When U0121/94, U0123/62, U0124/95 or U0126/63 are output together with C1232/32 or C1334/34, inspect and repair the trouble areas indicated by U0121/94, U0123/62, U0124/95 or U0126/63 first. 1 (a) CHECK SENSOR INSTALLATION(YAW RATE SENSOR) Check that the yaw rate and deceleration sensor has been installed properly (see page 32-46 ). NG INSTALL YAW RATE SENSOR CORRECTLY (SEE PAGE 32-46 ) OK Author
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: 1015 05-826 DIAGNOSTICS 2 - ABS WITH EBD & BA & TRAC & VSC SYSTEM CHECK HARNESS AND CONNECTOR(IG TERMINAL) (a) (b) (c) Yaw Rate Sensor (harness side connector) Y1 IG Disconnect the yaw rate sensor connector. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: NG F45082 Tester Connection Specified Condition Y1-5 (IG) - Body ground 10 to 14 V REPAIR OR CONNECTOR REPLACE HARNESS OR OK 3 CHECK HARNESS AND CONNECTOR(GND TERMINAL) (a) (b) Yaw Rate Sensor (harness side connector) Y1 Disconnect the yaw rate sensor connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition Y1-1 (GND) - Body ground Below 1 Ω GND F45082 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
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: 1016 05-827 DIAGNOSTICS DTC - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05CDC-20 C1241/41 LOW BATTERY POSITIVE VOLTAGE CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition C1241/41 When any of the following (1 to 2) is detected: (1) Any of the following conditions continues for at least 10 seconds.
Vehicle speed is more than 2 mph (3 km/h).
IG1 terminal voltage is less than 9.5 V. (2) Any of the following conditions continues for at least 0.2 seconds.
Solenoid relay remains ON.
IG1 terminal voltage is less than 9.5 V.
Relay contact is open. Trouble Area
Battery
Charging system
Power source circuit WIRING DIAGRAM I15 Ignition SW Instrument Panel J/B G 2 AM1 IG1 4 W 7 1C ECU-IG 10 1D 6 1C AM1 1 1A 2 Passenger Side J/B Y 4 4J 2 4H GR Skid Control ECU with Actuator 46 10 B-R IC4 S27 IG1 1 B W 1 ALT 2 F7 FL Block FL MAIN Battery W-B 32 S27 GND1 A J4 J/C W-B EB EA F46315 Author
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: 1017 05-828 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE 1 INSPECT FUSE(ECU-IG FUSE) (a) (b) Instrument Panel J/B ECU-IG Remove ECU-IG fuse from the instrument panel J/B. Check continuity of ECU-IG fuse. Standard: ECU-IG Fuse Below 1 Ω (Continuity) NG INSPECT FOR SHORT CIRCUIT IN ALL HARNESS AND COMPONENTS CONNECTED TO ECU-IG FUSE NG INSPECT CHARGING SYSTEM (SEE PAGE 19-12 (2AZ-FE) OR 19-36 (3MZ-FE)) F40457 OK 2 (a) INSPECT BATTERY Check the battery voltage. Standard: Tester Connection Specified Condition Battery terminal ((+) - (-)) 11 to 14 V OK Author
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: 1018 05-829 DIAGNOSTICS 3 - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECT SKID CONTROL ECU TERMINAL VOLTAGE(IG1 TERMINAL) WHEN USING HAND-HELD TESTER: (a) Connect the hand-held tester to the DLC3. (b) Start the engine. (c) Select the DATA LIST mode on the hand-held tester. (d) Read the voltage condition output from the ECU displayed on the hand-held tester. Item IG VOLTAGE Measurement Item / Range (Display) ECU power supply voltage / TOO LOW / NORMAL Normal Condition NORMAL: 9.5 V or over TOO LOW: Below 9.5 V OK: ”Normal” is displayed. WHEN NOT USING HAND-HELD TESTER: (a) Disconnect the skid control ECU connector S27. (b) Turn the ignition switch to the ON position. (c) Measure the voltage according to the value(s) in the table below. Standard: Skid Control ECU (harness side connector) S27 GND1 IG1 G24767 Tester Connection Specified Condition S27-46 (IG1) - S27-32 (GND1) 10 to 14 V NG Go to step 4 OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) 4 INSPECT SKID CONTROL ECU CONNECTOR(GND TERMINAL CONTINUITY) (a) (b) Skid Control ECU (harness side connector) S27 Disconnect the skid control ECU connector S27. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-32 (GND1) - Body ground Below 1 Ω NG GND1 G24767 REPAIR OR REPLACE HARNESS OR CONNECTOR (GND TERMINAL - BODY GROUND) OK CHECK AND REPAIR HARNESS AND CONNECTOR (IG1 TERMINAL - BATTERY) Author
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: 1019 05-830 DIAGNOSTICS DTC - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05H3Q-02 C1246/46 MALFUNCTION IN MASTER CYLINDER PRESSURE SENSOR CIRCUIT DESCRIPTION Master cylinder pressure sensor is connected to the skid control ECU in the actuator. DTC No. DTC Detecting Condition Trouble Area C1246/46 When any of the following (1 to 5) is detected: (1) All the following conditions continues for at least 30 seconds.
Vehicle speed is more than 4 mph (7 km/h).
PMC terminal voltage does not change by more than 0.005 V once it exceeds 0.86 V. (2) PMC terminal receives interference at least 7 times within 5 sec. (3) All the following conditions continues for at least 1.2 seconds.
Stop switch is OFF.
PMC terminal voltage is more than 0.86 V or less than 0.3 V. (4) All the following conditions continues for at least 1.2 seconds.
IG1 terminal voltage is between 9.5 and 17.2 V.
VCM terminal voltage is not within 4.4 and 5.6 V. (5) All the following conditions continues for at least 1.2 seconds.
VCM terminal voltage is between 4.4 and 5.6 V.
PMC terminal voltage is not within 0.14 and 4.85 V.
Master cylinder pressure sensor
Master cylinder pressure sensor circuit INSPECTION PROCEDURE HINT: Start the inspection from step 1 when using the hand-held tester and start from step 2 when not using the hand-held tester. 1 (a) (b) (c) READ VALUE OF HAND-HELD TESTER(MASTER CYLINDER PRESSURE SENSOR) Connect the hand-held tester to the DLC3. Start the engine. Select the DATA LIST mode on the hand-held tester. Item MAS CYL PRS 1 (d) Measurement Item / Range (Display) Master cylinder pressure sensor 1 reading / min.: 0 V, max.: 5 V Normal Condition When brake pedal is released : 0.3 to 0.9 V Check that the brake fluid pressure value of the master cylinder pressure sensor indicated on the hand-held tester, changes when the brake pedal is depressed. Standard: Brake fluid pressure value should change. NG Go to step 2 OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
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: 1020 05-831 DIAGNOSTICS 2 - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECT SKID CONTROL ECU TERMINAL VOLTAGE(STP TERMINAL) (a) (b) Skid Control ECU (harness side connector) S27 STP Disconnect the skid control ECU connector. Measure the voltage according to the value(s) in the table below. Standard: Tester Connection Switch condition Specified Condition S27-27 (STP) Body ground Brake pedal depressed 8 to 14 V S27-27 (STP) Body ground Brake pedal released Below 1 V G24767 NG CHECK AND REPLACE STOP LIGHT SWITCH CIRCUIT OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
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: 1021 05-832 DIAGNOSTICS DTC - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05CDD-20 C1249/49 OPEN CIRCUIT IN STOP LIGHT SWITCH CIRCUIT CIRCUIT DESCRIPTION This circuit recognizes brake operation by sending a stop lamp signal to the skid control ECU. DTC No. DTC Detecting Condition Trouble Area C1249/49 All the following conditions continues for at least 0.3 seconds.
IG1 terminal voltage is between 9.5 and 17.2 V.
Open in stop switch circuit.
When the brake pedal load sensing switch is on, the master cylinder pressure is 2MPa or more and the deceleration calculated from the vehicle speed is 0.2 G or more, the stop lamp switch is off for 2 seconds or more.
Stop lamp bulb
Stop lamp switch
Stop lamp switch circuit WIRING DIAGRAM Passenger Side J/B S15 Stop Light SW Y 3 4L B 1 2 6 IA2 L 11 4A 1 4L G Skid Control ECU with Actuator 27 22 G-Y IC4 S27 STP B R7 Stop Light LH (Rear Comb. Light LH) B L B B B J10 J/C W-B 5 R8 Stop Light RH (Rear Comb. Light RH) L 6 J12 J/C W-B 5 B B 6 H11 High Mounted Stop Light 5 BG2 L B W-B 1 Instrument Panel J/B 1 1E STOP FL MAIN 1 1A B 2 F7 FL Block B 2 ALT 1 W-B W A J14 J/C BE Battery BC F46299 Author
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: 1022 05-833 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE 1 (a) CHECK STOP LAMP SWITCH OPERATION Check that the stop light comes on when the brake pedal is depressed and goes off when the brake pedal is released. HINT: Check the stop lamp bulb as it may have burnt out. Standard: Stop lamp switch function is normal. NG Go to step 4 OK 2 INSPECT SKID CONTROL ECU TERMINAL VOLTAGE(STP TERMINAL) (a) (b) Skid Control ECU (harness side connector) S27 STP Disconnect the skid control ECU connector. Measure the voltage according to the value(s) in the table below. Standard: Tester Connection Switch condition Specified Condition S27-27 (STP) Body ground Brake pedal depressed 8 to 14 V S27-27 (STP) Body ground Brake pedal released Below 1 V G24767 NG Go to step 5 OK 3 (a) (b) (c) RECONFIRM DTC Clear the DTCs(see page 05-765 ). Turn the ignition switch to the ON position. Are the same DTCs detected? (see page 05-765 ). NO PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-786 ) YES REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
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: 1023 05-834 DIAGNOSTICS 4 ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECT STOP LAMP SWITCH ASSY Stop Lamp Switch Assy 2 1 (a) (b) ⇔ Free - Disconnect the stop lamp switch assy connector. Measure the resistance according to the value(s) in the table below. Standard: Switch condition Tester connection Specified condition Switch pin free 1-2 Below 1 Ω Switch pin pushed in 1-2 10 kΩ or higher Pushed In NG REPLACE STOP LAMP SWITCH ASSY F47536 OK 5 CHECK HARNESS AND CONNECTOR(STOP LAMP SWITCH - SKID CONTROL ECU) (a) Skid Control ECU (harness side connector) S27 (b) Disconnect the stop lamp switch connector and skid control ECU connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-27 (STP) - S15-1 (STP) Below 1 Ω STP Stop Lamp Switch (harness side connector) S15 STP G25017 C82562 G26188 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE ABS & TRACTION ACTUATOR ASSY(SEE PAGE 32-37 ) Author
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: 1024 05-835 DIAGNOSTICS DTC - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05F1S-09 C1251/51 PUMP MOTOR IS LOCKED/OPEN CIRCUIT IN PUMP MOTOR GROUND CIRCUIT DESCRIPTION The ABS pump motor is located inside the brake actuator. The motor is used for BA, TRAC and VSC operation. DTC No. DTC Detecting Condition Trouble Area C1251/51
Actuator pump motor does not operate properly.
Open in actuator pump motor circuit continues for at least 2 sec.
ABS & TRAC actuator
ABS & TRAC actuator circuit WIRING DIAGRAM B-O Skid Control ECU with Actuator 45 S27 R+ ABS R/B ABS MTR Relay B-O B 5 5 1 2 5 3 LG 5 W-L 5 15 S27 MR 2 S27 BM ABS CUT Relay 5 5 FL MAIN 5 3 1 B-R 5 G-R 5 2 14 S27 MRF F7 FL Block W 1 ABS2 9 Battery F46308 Author
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: 1025 05-836 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1 in case of using the hand-held tester and start from step 2 in case of not using the hand-held tester. 1 (a) (b) (c) (d) PERFORM ACTIVE TEST BY HAND-HELD TESTER(ABS MOTOR RELAY OPERATION) Connect the hand-held tester to the DLC3. Start the engine. Select the ACTIVE TEST mode on the hand-held tester. Check the operation sound of the ABS motor individually when operating it with the hand-held tester. Item ABS MOT RELAY Vehicle Condition / Test Details ABS motor relay / ON or OFF Vehicle Condition / Test Details ON: Motor relay ON OK: The operation sound of the ABS motor should be heard. NG Go to step 2 OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) 2 INSPECT HARNESS AND CONNECTOR(GND2 OF SKID CONTROL ECU AND BODY GROUND) (a) (b) Skid Control ECU (harness side connector) S27 Disconnect the skid control ECU connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-1 (GND2) - Body ground Below 1 Ω NG GND2 G24767 REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
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: 1026 05-837 DIAGNOSTICS DTC - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05H3S-03 C1267/67 Brake Pedal Load Sensing Switch CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition C1267/67
Open or short circuit in brake pedal load sensing switch continues for 0.3 secs. or more.
Immediately after IG1 is turned to the ON position, the condition that brake pedal load sensing switch is ON and stop lamp switch is off continues for 10 secs. or more.
While vehicle speed changes from 0 mph (0 km/h0 mph) to 19 mph (30 km/h19 mph), the condition that the brake pedal load sensing switch is on repeatedly occurs 5 times. Trouble Area
Brake pedal load sensing switch
Brake pedal load sensing switch circuit WIRING DIAGRAM B13 Brake Pedal Load Sensing SW Passenger Side J/B W-B 1 4N 7 4J Skid Control ECU with Actuator W-B P 1 2 6 IC4 G-W 7 S27 FSW+ IC F46316 INSPECTION PROCEDURE 1 (a) (b) (c) (d) READ VALUE OF HAND-HELD TESTER Connect the hand-held tester to the DLC3. Start the engine. Select the DATA LIST mode on the hand-held tester. Read the value of the brake pedal load sensing switch displayed on the hand-held tester when depressing and releasing the brake pedal. Item BRAKE WRN LIGHT Vehicle Condition / Test Details Brake load sensing switch / ON or OFF Diagnostic Note ON : Depressed brake pedal OFF : Released brake pedal OK: Condition Display Depress the brake pedal ON Release the brake pedal OFF OK Go to step 4 NG Author
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: 1027 05-838 DIAGNOSTICS 2 - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECT BRAKE PEDAL LOAD SENSING SWITCH NOTICE: Do not disassemble the brake pedal sub-assy. HINT: Replace the brake pedal sub-assy when there is a malfunction in the brake pedal load sensing switch. (a) Disconnect the brake pedal load sensing switch connecB13 FSW+ tor B13. (b) Measure the resistance according to the value(s) in the GND 2 1 Brake Pedal Load table below. Sensing Switch Standard: Release Brake Pedal (ON) 1000 Ω 2 270 Ω Tester Connection Condition Specified Condition B13-2 B13 2 (FSW+) B13-1 (GND) Depress brake pedal Approx. 1000 Ω Release brake pedal Approx. 213 Ω 1 Depress Brake Pedal (OFF) Brake pedal sub-assy NG G26239 REPLACE BRAKE PEDAL SUB-ASSY (SEE PAGE 32-1 1) OK 3 CHECK HARNESS AND CONNECTOR(BRAKE PEDAL LOAD SENSING SWITCH SKID CONTROL ECU) (a) Skid Control ECU (harness side connector) S27 FSW+ (b) Brake Pedal Load Sensing Switch (harness side connector) (c) B13 FSW G26242 Disconnect the skid control ECU connector S27 and the brake pedal load sensing switch connector B13. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-7 (FSW+) - B13-2 (FSW) Below 1 Ω Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-7 (FSW+) - Body ground 10 kΩ or higher NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK Author
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: 1028 05-839 DIAGNOSTICS 4 - ABS WITH EBD & BA & TRAC & VSC SYSTEM CHECK SKID CONTROL ECU TERMINAL VOLTAGE(STP TERMINAL) (a) (b) Skid Control ECU (harness side connector) S27 STP Disconnect the skid control ECU connector. Measure the voltage according to the value(s) in the table below. Standard: Tester Connection Switch condition Specified Condition S27-27 (STP) Body ground Brake pedal depressed 8 to 14 V S27-27 (STP) Body ground Brake pedal released Below 1 V G24767 NG INSPECT STOP LAMP SWITCH CIRCUIT OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
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: 1029 05-763 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05CCX-06 CUSTOMER PROBLEM ANALYSIS CHECK ABS & EBD & BA Check Sheet Inspector’s : Name VIN Production Date Customer’s Name / / Licence Plate No. Date Vehicle Brought In / Date Problem First Occurred Frequency Problem Occurs km miles Odometer Reading / / Continuously / Intermittently ( times a day) ABS does not operate. ABS does not operate efficiently. BA does not operate. Symptoms EBD does not operate. ABS Warning Light Abnormal Brake Warning Light Abnormal (PKB released) Remains ON Does not Come On Remains ON Does not Come On 1st Time Normal System Code Trouble Code (Code ) 2nd Time Normal System Code Trouble Code (Code ) DTC Check STOP LIGHT SW OFF ON NO SYS Freeze Frame Data ABS SYSTEM BA FAIL SF #IG ON km/h MPH VEHICLE SPD Author
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: 953 05-764 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM TRAC & VSC Check Sheet Inspector’s : Name VIN / Production Date Customer’s Name / Licence No. Date Vehicle Brought In / / km miles Odometer Reading / Date Problem First Occurred Frequency Problem Occurs / Continuous Intermittent ( times a day) TRAC does not operate. (Wheels spin when starting rapidly.) VSC does not operate. (Wheels sideslip at the time of sharp turning.) TRAC OFF Indicator Light Abnormal Symptoms Check Item Remains ON Does not Come On VSC Warning Indicator Abnormal Displays Does not Display SLIP Indicator Light Abnormal Remains ON Does not Come On Skid Control Buzzer Abnormal Sounds Does not Sound ABS Warning Light Normal Trouble Code (Code ) Malfunction Indicator Light Normal Trouble Code (Code ) 1st Time Normal System Code Trouble Code (Code ) 2nd Time Normal System Code Trouble Code (Code ) DTC Check VSC/TRC OFF SW Freeze Frame Data SYSTEM SHIFT POSITION OFF ON VSC/TRAC P,N 2 R 3 D 4 L FAIL STEERING ANG deg YAW RAT deg/s MAS CYL PRESS V THROTTLE deg MPa/s MAS PRESS GRADE G (RIGHT&LEFT) G G (BACK&FORTH) G Author
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: 954 05-779 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05CCZ-12 DIAGNOSTIC TROUBLE CODE CHART HINT:
If a malfunction code is displayed during the DTC check, check the circuit indicated by the DTC. For details of each code, turn to the page for the respective ”DTC No.” in the DTC chart.
When U0121/94, U0123/62, U0124/95 or U0126/63 are output, inspect and repair the trouble areas indicated by U0121/94, U0123/62, U0124/95 or U0126/63 first. DTC chart of ABS: DTC No. (See Page) Detection Item Trouble Area Right front wheel speed sensor signal malfunction
Right front and left front speed sensor
Each speed sensor circuit
Sensor rotor
Sensor installation Left front wheel speed sensor signal malfunction
Right front and left front speed sensor
Each speed sensor circuit
Sensor rotor
Sensor installation Right rear wheel speed sensor signal malfunction
Right rear and left rear speed sensor
Each speed sensor circuit
Sensor rotor
Sensor installation Left rear wheel speed sensor signal malfunction
Right rear and left rear speed sensor
Each speed sensor circuit
Sensor rotor
Sensor installation C0226/21 (05-802 ) Open or short circuit in brake actuator solenoid circuit (SFR circuit)
ABS & TRAC actuator
SFRH or SFRR circuit C0236/22 (05-802 ) Open or short circuit in brake actuator solenoid circuit (SFL circuit)
ABS & TRAC actuator
SFLH or SFLR circuit C0246/23 (05-802 ) Open or short circuit in brake actuator solenoid circuit (SRR circuit)
ABS & TRAC actuator
SRRH or SRRR circuit C0256/24 (05-802 ) Open or short circuit in brake actuator solenoid circuit (SRL circuit)
ABS & TRAC actuator
SRLH or SRLR circuit Open circuit in ABS MTR relay circuit
ABS No.2 fuse
ABS MTR relay
ABS MTR relay circuit
J/B No.2 Short circuit in ABS MTR relay circuit
ABS No.2 fuse
ABS MTR relay
ABS MTR relay circuit
J/B No.2 Open circuit in ABS SOL relay circuit
ABS No.1 fuse
ABS SOL relay
ABS SOL relay circuit
ABS & TRAC actuator C0279/12 (05-809 ) Short circuit in ABS SOL relay circuit
ABS No.1 fuse
ABS SOL relay
ABS SOL relay circuit
ABS & TRAC actuator C1225/25 (05-802 ) Open or short circuit in brake actuator solenoid circuit (SMC circuit)
SMF or SMR circuit
ABS & TRAC actuator C1235/35 (05-788 ) Foreign matter is attached on the tip of the right front sensor
Right front and left front speed sensor
Each speed sensor
Sensor installation C0200/31*1 (05-788 ) C0205/32*1 (05-788 ) C0210/33*1 (05-795 ) C0215/34*1 (05-795 ) C0273/13*1 (05-804 ) C0274/14 (05-804 ) C0278/11 (05-809 ) Author
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: 969 05-780 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM C1236/36 (05-788 ) Foreign matter is attached on the tip of the left front sensor
Right front and left front speed sensor
Each speed sensor
Sensor installation C1238/38 (05-795 ) Foreign matter is attached on the tip of the right rear sensor
Right rear and left rear speed sensor
Each speed sensor
Sensor installation C1239/39 (05-795 ) Foreign matter is attached on the tip of the left rear sensor
Right rear and left rear speed sensor
Each speed sensor
Sensor installation C1241/41 (05-827 ) Low battery positive voltage
Battery
Charging system
Power source circuit Malfunction in deceleration sensor (constant output)
Yaw rate sensor (Deceleration sensor)
Yaw rate sensor circuit (Deceleration sensor circuit) C1244/44 (05-824 ) Malfunction in deceleration sensor
Yaw rate sensor (Deceleration sensor)
Yaw rate sensor circuit (Deceleration sensor circuit) C1245/45*1 (05-824 ) Malfunction in deceleration sensor
Yaw rate sensor (Deceleration sensor)
Yaw rate sensor circuit (Deceleration sensor circuit) C1246/46*2 (05-830 ) Malfunction in master cylinder pressure sensor
Master cylinder pressure sensor
Master cylinder pressure sensor circuit Open circuit in stop light switch circuit
Stop lamp bulb
Stop lamp switch
Stop lamp switch circuit ABS pump motor is locked Open circuit in pump motor circuit
ABS & TRAC actuator
ABS & TRAC actuator circuit Open or short circuit of brake pedal load sensing switch circuit
Brake pedal load sensing switch
Brake pedal load sensing switch circuit C1361/91 (05-804 ) Short circuit in ABS motor fail safe relay circuit
ABS No.2 fuse
ABS MTR relay
ABS MTR relay circuit
J/B No.2 C1381/97 (05-824 ) Malfunction in power supply voltage yaw/deceleration sensor
Yaw rate sensor
Yaw rate sensor power source circuit U0121/94 (05-2090 ) Malfunction in CAN communication
Wire harness
Skid control ECU U0124/95 (05-2090 ) Malfunction in CAN communication with deceleration sensor
Wire harness
Yaw rate sensor (Deceleration sensor) C1243/43*1 (05-824 ) C1249/49 (05-832 ) C1251/51*1 (05-835 ) C1267/67 (05-837 ) *1, *2: Even after the trouble areas are repaired, the ABS warning light will not go off unless the following operations are performed.
*1: (1) Drive the vehicle at 12 mph (20 km/h) for 30 seconds or more and check that the ABS warning light goes off. (2) Clear the DTC (see page 05-765 ).
*2: (1) Keep the vehicle in a stationary condition for 5 seconds or more and depress the brake pedal lightly 2 or 3 times. (2) Drive the vehicle at a vehicle speed of 31 mph (50 km/h). Then depress the brake pedal strongly for about 3 seconds. (3) Repeat the above operation 3 times or more and check that the ABS warning light goes off. (4) Clear the DTC (see page 05-765 ). Author
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: 970 05-781 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM HINT:
In some cases, the hand-held tester cannot be used when ABS warning light remains on. DTC chart of VSC: DTC No. (See Page) Detection Item Trouble Area C1201/51 (05-812 ) Malfunction in ECM Engine control system C1203/53 (05-813 ) Malfunction in ECM communication circuit
TRC+ or TRC- circuit
ENG+ or ENG- circuit
ECM C1210/36 (05-815 ) Zero point calibration of yaw rate sensor undone
Yaw rate sensor (Deceleration sensor)
Zero point calibration undone C1223/43 (05-817 ) Malfunction in ABS control system ABS control system C1224/44 (05-818 ) Open or short circuit in NEO signal circuit
NEO circuit
ECM
Skid control ECU C1231/31 (05-821 ) Malfunction in steering angle sensor
Steering angle sensor
Steering angle sensor circuit
+B circuit
Can communication system C1232/32 (05-824 ) Malfunction in deceleration sensor
Yaw rate / deceleration
Yaw rate / deceleration sensor circuit C1234/34 (05-824 ) Malfunction in yaw rate sensor
Yaw rate / deceleration
Yaw rate / deceleration sensor circuit C1336/39 (05-815 ) Zero point calibration of deceleration sensor undone
Yaw rate sensor (Deceleration sensor)
Zero point calibration not done U0123/62 (05-2090 ) Malfunction in CAN communication with yaw rate sensor
Wire harness
Yaw rate sensor (Deceleration sensor) U0126/63 (05-2090 ) Malfunction in CAN communication with angle position sensor
Wire harness
Steering angle sensor HINT: In some cases, the hand-held tester cannot be used when the VSC warning light remains on. DTC of sensor check function: Code No. Diagnosis Trouble Area C1271/71 Low output voltage of right front speed sensor
Right front speed sensor
Sensor installation
Sensor rotor C1272/72 Low output voltage of left front speed sensor
Left front speed sensor
Sensor installation
Sensor rotor C1273/73 Low output voltage of right rear speed sensor
Right rear speed sensor
Sensor installation
Sensor rotor C1274/74 Low output voltage of left rear speed sensor
Left rear speed sensor
Sensor installation
Sensor rotor C1275/75 Abnormal change in output voltage of right front speed sensor Right front sensor rotor C1276/76 Abnormal change in output voltage of left front speed sensor Left front speed sensor rotor C1277/77 Abnormal change in output voltage of right rear speed sensor Right rear sensor rotor C1278/78 Abnormal change in output voltage of left rear speed sensor Left rear speed sensor rotor Author
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: 971 05-782 DIAGNOSTICS Code No. - ABS WITH EBD & BA & TRAC & VSC SYSTEM Diagnosis Trouble Area C1279/79 Deceleration sensor is faulty
Yaw rate sensor (Deceleration sensor)
Sensor installation C1281/81 Master cylinder pressure sensor output signal is faulty Master cylinder pressure sensor C0371/71 Yaw rate sensor output signal is faulty Yaw rate sensor (Deceleration sensor) Author
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: 972 05-761 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM ABS WITH EBD & BA & TRAC & VSC SYSTEM 05CCW-06 HOW TO PROCEED WITH TROUBLESHOOTING The hand-held tester can be used at step 3, 6, 9, 12. 1 Vehicle Brought to Workshop 2 Customer Problem Analysis (SEE PAGE 05-763 ) 3 Check and Clear DTCs and Freeze Frame Data (SEE PAGE 05-765 ) 4 Problem Symptom Confirmation Symptom does not occurs: Go to step 5 Symptom occurs: Go to step 6 5 Symptom Simulation (SEE PAGE 01-36 ) 6 DTC Check (SEE PAGE 05-765 ) There is no output: Go to step 7 There is output: Go to step 8 7 Problem Symptoms Table (SEE PAGE 05-786 ) Check for fluid leakage and Go to step 10 8 DTC Chart (SEE PAGE 05-779 ) 9 Circuit Inspection (SEE PAGE 05-788 to 05-873 ) 10 Identification of Problem Author
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: 951 05-762 DIAGNOSTICS 11 Repair 12 Confirmation Test - ABS WITH EBD & BA & TRAC & VSC SYSTEM End Author
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: 952 05-783 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05CD0-06 LOCATION VSC R/B
ABS MTR Relay
ABS CNT Relay Parking Brake Switch Rear Speed Sensor Rotor ABS & TRACTION Actuator (with Skid Control ECU) Rear Speed Sensor 2WD: Stop Lamp Switch Engine Room J/B
ABS NO.1 Fuse
ABS NO.2 Fuse Front Speed Sensor Front Speed Sensor Rotor Rear Speed Sensor and Rotor Steering Angle Sensor Combination Meter Assy
ABS Warning Lamp
Brake Warning Lamp
VSC Warning Lamp
TRAC OFF Indicator
Slip Indicator ECM Skid Control Buzzer DLC 3 Driver Side J/B
ECU-IG Fuse 2WD: TRAC OFF Switch Yaw Rate Sensor (Deceleration Sensor) F46284 Author
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: 973 05-765 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05H3Y-02 ABS Warning Light BRAKE Warning Light USA: USA: Canada: Canada: VSC Warning Light SLIP Indicator Light TRAC OFF Indicator Light F45096 PRE-CHECK 1. (a) DIAGNOSIS SYSTEM Check the warning lights. (1) Release parking brake lever. NOTICE: When releasing the parking brake, set the chocks to hold the vehicle for safety. HINT: When the parking brake is applied or the level of the brake fluid is low, the BRAKE warning light comes on. (2) When the ignition switch is turned to the ON position, check that the ABS warning light, BRAKE warning light, VSC warning light, TRAC OFF indicator light and SLIP indicator light remain on for approx. 3 seconds. HINT:
If the ECU has any stored DTCs, the ABS warning light, VSC warning light and TRAC OFF indicator light come on.
If the indicator does not come on, inspect if the bulb is blown out, and also the wire harness between the skid control ECU and the combination meter.
If the indicator remains on, proceed to troubleshooting for the light circuit below. Trouble Area See page ABS warning light circuit 05-840 or 05-844 VSC warning light circuit 05-847 or 05-851 BRAKE warning light circuit 05-854 TRAC OFF indicator light circuit 05-859 SLIP indicator light circuit 05-863 Author
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: 955 05-766 DIAGNOSTICS DLC3 2. (a) Tc CG C52361 - ABS WITH EBD & BA & TRAC & VSC SYSTEM DTC CHECK/CLEAR (USING SST CHECK WIRE) Check DTCs. (1) Using SST, connect terminals Tc and CG of the DLC3. SST 09843-18040 (2) Turn the ignition switch to the ON position. (3) Read the DTC from the ABS warning light or VSC warning light on the combination meter. HINT:

If 2 or more malfunctions are detected at the same time, the lowest numbered code will be displayed first. If no code appears, inspect the diagnostic circuit, ABS warning light circuit or VSC warning light circuit. Trouble Area See page Tc and CG terminal circuit 2 sec. ABS warning light circuit VSC warning light circuit 05-847 or 05-851
Normal Blinking 0.25 sec. 0.25 sec. ON 05-868 05-840 or 05-844 As an example, the blinking patterns for a normal system code and codes 11 and 21 are shown on the left. (4) Codes are explained in the code table on page 05-779 . (5) After completing the check, disconnect terminals Tc and CG of the DLC3, and turn off the display. OFF Code 11 and 21 0.5 sec. 0.5 sec. 1.5 sec. 4 sec. 2.5 sec. ON OFF Code 11 Code 21 R01346 Author
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: 956 05-767 DIAGNOSTICS (b) BR3890 - ABS WITH EBD & BA & TRAC & VSC SYSTEM Clear DTCs. (1) Using SST, connect terminals Tc and CG of the DLC3. SST 09843-18040 (2) Turn the ignition switch to the ON position. (3) Clear the DTCs stored in the ECU by depressing the brake pedal 8 or more times within 5 sec. (4) Check that the ABS warning light and VSC warning light shows normal blinking patterns. (5) Remove the SST from the DLC3. SST 09843-18040 HINT: Cancellation cannot be preformed by removing the battery cable or the ECU-IG fuse. 3. DTC CHECK/CLEAR (USING HAND-HELD TESTER) (a) Check DTCs. (1) Connect the hand-held tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) Read the DTCs following the prompts on the tester screen. HINT: Refer to the hand-held tester operator’s manual for further details. (b) Clear the DTCs. (1) Connect the hand-held tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) Operate the hand-held tester to erase the codes. HINT: Refer to the hand-held tester operator’s manual for further details. 4. DATA LIST HINT: According to the DATA LIST displayed on the Hand-held tester, you can read the value and status of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as a first step of troubleshooting is one of the methods to shorten the labor time. (a) Connect the Hand-held tester to the DLC3. (b) Turn the ignition switch ON. (c) From the display on the tester, read the ”DATA LIST”. *: 2WD only Item ABS MOT RELAY SOL RELAY VSC / TRC OFF SW* IDLE SW Measurement Item / Range (Display) ABS motor relay / ON or OFF Solenoid relay / ON or OFF TRAC control switch / ON or OFF Main idle switch / ON or OFF Normal Condition Diagnostic Note ON : Motor relay ON - ON : Solenoid relay ON - ON : TRAC control switch ON - ON : Accelerator pedal released OFF : Accelerator pedal depressed - Author
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: 957 05-768 DIAGNOSTICS Item Measurement Item / Range (Display) STOP LIGHT SW Stop lamp switch / ON or OFF PKB SW Parking brake switch / ON or OFF STEP FORCE SW Brake load sensing switch / ON or OFF ABS OPERT FR ABS operation (FR) / BEFORE or OPERATE ABS OPERT FL ABS operation (FL) / BEFORE or OPERATE ABS OPERT RR ABS operation (RR) / BEFORE or OPERATE ABS OPERT RL ABS operation (RL) / BEFORE or OPERATE WHEEL SPD FR WHEEL SPD FL WHEEL SPD RR WHEEL SPD RL DECELERAT SENS DECELERAT SENS2 IG VOLTAGE SFRR SFRH SFLR Wheel speed sensor (FR) reading / min.: 0 km/h (0 MPH, max.: 326 km/h (202 MPH) Wheel speed sensor (FL) reading / min.: 0 km/h (0 MPH, max.: 326 km/h (202 MPH) Wheel speed sensor (RR) reading / min.: 0 km/h (0 MPH, max.: 326 km/h (202 MPH) Wheel speed sensor (RL) reading / min.: 0 km/h (0 MPH, max.: 326 km/h (202 MPH) Deceleration sensor 1 reading / min.: -1.869 G, max.: 1.869 G Deceleration sensor 2 reading / min.: -1.869 G, max.: 1.869 G ECU power supply voltage / TOO LOW / NORMAL ABS solenoid (SFRR) / ON or OFF ABS solenoid (SFRH) / ON or OFF ABS solenoid (SFLR) / ON or OFF - ABS WITH EBD & BA & TRAC & VSC SYSTEM Normal Condition Diagnostic Note ON : Brake pedal depressed OFF : Brake pedal released ON : Parking brake applied OFF : Parking brake released ON : Depressed brake pedal OFF : Released brake pedal BEFORE : No ABS operation (FR) OPERATE : During ABS operation (FR) BEFORE : No ABS operation (FL) OPERATE : During ABS operation (FL) BEFORE : No ABS operation (RR) OPERATE : During ABS operation (RR) BEFORE : No ABS operation (RL) OPERATE : During ABS operation (RL) - - - - - - - Actual wheel speed Similar speed as indicated on speedometer Actual wheel speed Similar speed as indicated on speedometer Actual wheel speed Similar speed as indicated on speedometer Actual wheel speed Similar speed as indicated on speedometer Approximately 0 ± 0.13G at still condition Reading changes when vehicle is bounced Approximately 0 ± 0.13G at still condition Reading changes when vehicle is bounced NORMAL: 9.5 V or over TOO LOW: Below 9.5 V - ON : Operate - ON : Operate - ON : Operate - Author
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: 958 05-769 DIAGNOSTICS Item SFLH SRRR (SRR) SRRH (SRH) SRLR SRLH SMF (BA-SOL) SMR THROTTLE ENGINE SPD VEHICLE SPD YAW RATE YAW ZERO VALUE STEERING ANG MAS CYL PRS 1 TEST MODE #CODES Measurement Item / Range (Display) ABS solenoid (SFLH) / ON or OFF ABS solenoid (SRRR (SRR)) / ON or OFF ABS solenoid (SRRH (SRH)) / ON or OFF ABS solenoid (SRLR) / ON or OFF ABS solenoid (SRLH) / ON or OFF TRAC solenoid (SMF) / ON or OFF TRAC solenoid (SMR) / ON or OFF Throttle position sensor/ Min.: 0 deg, Max.: 125 deg Engine Speed/ Min.: 0 rpm, Max.: 6,000 rpm Maximum wheel speed sensor reading / min.: 0 km/h (0 MPH), max.: 326 km/h (202 MPH) Yaw rate sensor/ Min.: -128 deg/s, Max.: 128 deg/s Memorized zero value/ Min.: -128 deg/s, Max.: 128 deg/s Steering sensor/ Min.: -1152 deg, Max.: 1150.875 deg Master cylinder pressure sensor 1 reading / min.: 0 V, max.: 5 V Test mode / NORMAL or TEST Number of DTC recorded / min.: 0, max.: 255 - ABS WITH EBD & BA & TRAC & VSC SYSTEM Normal Condition Diagnostic Note ON : Operate - ON : Operate - ON : Operate - ON : Operate - ON : Operate - ON : Operate - ON : Operate - Release accelerator pedal: Approx. 0 deg. Depress accelerator pedal: Approx. 90 deg. - Actual engine speed - Actual vehicle speed Similar speed as indicated on speedometer Min.: -128 deg/s Max.: 128 deg/s - Min.: -128 deg/s Max.: 128 deg/s - Left turn: Increase Right turn: Decrease - When brake pedal is released : 0.3 to 0.9 V Reading increases when brake pedal is depressed NORMAL : Normal mode TEST : During test mode - Min.: 0, max.: 39 - Author
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: 959 05-770 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 5. ACTIVE TEST HINT: Performing the ACTIVE TEST using the hand-held tester allows the relay and actuator, etc. to operate without removing any parts. Performing the ACTIVE TEST as the first step of troubleshooting is one of the methods to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) According to the display on the tester, perform the ”ACTIVE TEST”. HINT: Ignition switch must be turned to the ON position to proceed to the ACTIVE TEST using the hand-held tester. Item Vehicle Condition / Test Details SFRR Turns ABS solenoid (SFRR) ON / OFF SFRH Turns ABS solenoid (SFRH) ON / OFF SFLR Turns ABS solenoid (SFLR) ON / OFF SFLH Turns ABS solenoid (SFLH) ON / OFF SRRR Turns ABS solenoid (SRRR) ON / OFF SRRH Turns ABS solenoid (SRRH) ON / OFF SRLR Turns ABS solenoid (SRLR) ON / OFF SRLH Turns ABS solenoid (SRLH) ON / OFF SMF (BA-SOL) Turns TRAC solenoid SMF (BA-SOL) ON / OFF SMR Turns TRAC solenoid SMR ON / OFF SOL RELAY Turns ABS solenoid relay ON / OFF ABS MOT RELAY Turns ABS motor relay ON / OFF ABS WARN LIGHT Turns ABS warning light ON / OFF VSC WARN LIGHT Turns VSC warning light ON / OFF VSC / TRAC OFF IND* Turns VSC / TRAC OFF indicator ON / OFF SLIP INDI LIGHT Turns SLIP indicator light ON / OFF Author
: Diagnostic Note Operation of solenoid (clicking sound) can be heard Operation of solenoid (clicking sound) can be heard Operation of solenoid (clicking sound) can be heard Operation of solenoid (clicking sound) can be heard Operation of solenoid (clicking sound) can be heard Operation of solenoid (clicking sound) can be heard Operation of solenoid (clicking sound) can be heard Operation of solenoid (clicking sound) can be heard Operation of solenoid (clicking sound) can be heard Operation of solenoid (clicking sound) can be heard Operation of solenoid (clicking sound) can be heard Operation sound of motor can be heard Observe combination meter Observe combination meter Observe combination meter Observe combination meter Date
: 960 05-771 DIAGNOSTICS Item - ABS WITH EBD & BA & TRAC & VSC SYSTEM Vehicle Condition / Test Details BRAKE WRN LIGHT Turns BRAKE warning light ON / OFF VSC / BR WARN BUZ Turns VSC / BRAKE warning buzzer ON / OFF Diagnostic Note Observe combination meter Buzzer can be heard *: 2WD only 6. FREEZE FRAME DATA HINT:
Whenever a DTC is detected or the ABS operates, the skid control ECU stores the current vehicle (sensor) state as freeze frame data.
The skid control ECU stores the number of times (maximum: 31) the ignition switch has been turned from off to the On position since the last time ABS was activated. However, if the vehicle was stopped or at low speed (4.3 mph (7 km/h) or less), or if a DTC is detected, the skid control ECU will not count the number since then.
Freeze frame data at the time the ABS operates: The skid control ECU stores and updates data whenever the ABS system operates. When the ECU stores data at the time a DTC is detected, the data stored when the ABS operated is erased.
Freeze frame data at the time a DTC is detected: When the skid control ECU stores data at the time a DTC is detected, no updates will be performed until the data is cleared. (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 ”FREEZE FRAME DATA”. Hand-held tester display VEHICLE SPD Measurement Item Reference Value Wheel speed sensor reading Speed indicated on speedometer Stop lamp switch signal Stop lamp switch ON: ON, OFF: OFF Number of operations of ignition switch ON after memorizing freeze frame data 0 to 31 MAS CYL PRESS Master cylinder pressure sensor reading Brake pedal release : 0.3 to 0.9 V Brake pedal depress: 0.8 to 4.5 V MASS PRESS GRADE Master cylinder pressure sensor change -30 to 200 MPa/s System status ABS activated: ABS VSC/TRC activated: VSC/TRC BA activated: BA Fail safe mode activated: FAIL SF No system activated: NO SYS Yaw rate angle sensor reading -100 to 100 Steering sensor reading Left turn: Increase Right turn: Decrease STOP LIGHT SW # IG ON SYSTEM YAW RATE STEERING ANG G (RIGHT & LEFT) Right and left G -1.869 to 1.869 G (BACK & FORTH) Back and forth G -1.869 to 1.869 VSC (TRC) OFF SW* TRAC control switch signal TRC control switch ON: ON OFF: OFF Shift lever position FAIL P,N R D 4 3 2 L Throttle sensor reading 0 to 125 deg. SHIFT POSITION THROTTLE *: 2WD only Author
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: 961 05-772 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 7. DLC3 Ts CG C52361 SENSOR SIGNAL CHECK (TEST MODE) (USING SST CHECK WIRE) NOTICE: After replacing the yaw rate sensor (deceleration sensor) and/or brake actuator assembly (skid control ECU), perform zero point calibration of the yaw rate sensor and deceleration sensor. (See step 9.) HINT:
If the ignition switch is turned from ON to the ACC or LOCK position during test mode, DTC of sensor check function will be erased.
During test mode, ECU records all DTCs of sensor check functions. By preforming sensor signal check, the codes are erased if normality is confirmed. The codes left over are the codes where an abnormality was found. (a) Procedures for test mode: (1) Turn the ignition switch off. (2) Check that the steering wheel is in the straightahead position and shift the shift lever to the P position. (3) Using SST, connect terminals Ts and CG of the DLC3. SST 09843-18040 (4) Turn the ignition switch to the ON position. (5) 0.13 sec. 0.13 sec. Check that the ABS warning light and VSC warning light blink. HINT: If the ABS warning light and VSC warning light do not blink, inspect the ABS warning light circuit, VSC warning light and Ts terminal circuit. ON Trouble area OFF See Page Ts and CG terminal circuit BR3904 05-873 ABS warning light circuit 05-840 or 05-844 VSC warning light circuit 05-847 or 05-851 (b) Check the master cylinder pressure sensor: (1) Leave the vehicle in a stationary condition and the brake pedal in a free condition for 1 second or more, and quickly depress the brake pedal with a force of 98 N (10 kgf, 22 lbf) or more for 1 second or more. HINT:


At this time, the ABS warning light remains on for 3 seconds. While the ABS warning light remains on, continue to depress the brake pedal with a force of 98 N (10 kgf) or more. The ABS warning light comes on for 3 seconds every time the brake pedal operation above is performed. Author
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: 962 05-773 DIAGNOSTICS


ABS WITH EBD & BA & TRAC & VSC SYSTEM If master cylinder pressure sensor check can not be completed, 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) Start Position Within ± 5° End Position - F02135 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 vehicle. (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. Author
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: 963 05-774 DIAGNOSTICS


- ABS WITH EBD & BA & TRAC & VSC SYSTEM Speed sensor check may not be completed if speed sensor check is started while turning the steering wheel or spinning the wheels. After the ABS warning light goes off, if the vehicle speed exceeds 50 mph (80 km/h), sensor check code is stored again. Decelerate or stop the vehicle before the speed reaches 50 mph (80 km/h). If sensor check has not been completed, the ABS warning light blinks while driving and ABS system does not operate. HINT: When sensor check has been completed, the ABS warning light goes off while driving and blinks in the test mode pattern while standing. DLC3 (3) Using SST, connect terminals Tc and CG of the DLC3. SST 09843-18040 Tc (4) CG C52361 Read the number of blinks of the ABS warning light and VSC warning light. HINT:



See the list of DTC. (See page 05-779 ) If the check result is OK, the ABS warning light link goes off when the brake pedal is once depressed. If every sensor is normal, the normal blinking patterns are output. (A cycle of 0.25 seconds ON and 0.25 seconds OFF is repeated.) If 2 or more malfunctions are detected at the same time, the lowest numbered code will be displayed first. Malfunction Code (Example Code 71, 72) 71 0.5 sec. 72 2.5 sec. ON OFF 4 sec. Repeat 0.5 sec. 1.5 sec. (5) After performing the check, disconnect the SST from terminals Ts and CG, Tc and CG of the DLC3 and turn the ignition switch to the off position. Author
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: 964 05-775 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 8. SENSOR SIGNAL CHECK (TEST MODE) (USING HAND-HELD TESTER) NOTICE: After replacing the yaw rate sensor (deceleration sensor) and/or brake actuator assembly (skid control ECU), perform zero point calibration of the yaw rate sensor and deceleration sensor. (See step 10.) HINT:
If the ignition switch is turned from ON to the ACC or LOCK position during test mode, DTC of sensor check function will be erased.
During test mode, ECU records all DTC of sensor check function. By preforming sensor signal check, the codes are erased if normality is confirmed. The codes left over are the codes where an abnormality was found. (a) Procedures for signal check: (1) Turn the ignition switch off. (2) Check that the shift lever position is in the P position. (3) Connect the hand-held tester to the DLC3. (4) Perform the signal check (test mode) by following the prompts on the tester screen. [System Selection Screen] ”DIAGNOSIS” - ”OBD/MOBD” - Select the vehicle ”ABS/VSC” - ”SIGNAL CHECK” (5) 0.13 sec. 0.13 sec. Check that the ABS warning light and VSC warning light blink. HINT: If the ABS warning light and VSC warning light do not blink, inspect the ABS warning light circuit and VSC warning light circuit. ON Trouble area See Page OFF ABS warning light circuit 05-840 or 05-844 VSC warning light circuit 05-847 or 05-851 BR3904 (b) Check the master cylinder pressure sensor: (1) Leave the vehicle in a stationary condition and the brake pedal in a free condition for 1 second or more and quickly depress the brake pedal with a force of 98 N (10 kgf, 22 lbf) or more for 1 second or more. HINT: At this time, the ABS warning light remains on for 3 seconds. Author
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: 965 05-776 DIAGNOSTICS (c) Start Position Within ± 5° - ABS WITH EBD & BA & TRAC & VSC SYSTEM 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: End Position F02135



(d) 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. 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 further 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 CALIBRATION OF YAW RATE SENSOR AND/OR BRAKE ACTUATOR 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. Author
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: 966 05-777 DIAGNOSTICS DLC3 - ABS WITH EBD & BA & TRAC & VSC SYSTEM (2) Ts (c) CG C52361 Using SST, connect and disconnect terminals Ts and CG of the DLC3 4 times or more within 8 seconds. SST 09843-18040 (3) Remove the SST from the terminals of the DLC3. 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] ”DIAGNOSIS” - ”OBD/MOBD” - Select the vehicle - ”ABS/VSC” - ”RESET MEMORY” F46259 (e) (f) Perform the signal check (test mode) by following the prompts on the tester screen. [System Selection Screen] ”DIAGNOSIS” - ”OBD/MOBD” - Select the vehicle - ”ABS/VSC” - ”SIGNAL CHECK” 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. Author
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: 967 05-778 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM HINT: If the VSC warning light does not blink, perform the zero point calibration again. (g) Turn the ignition switch off. Author
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: 968 05-786 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05CD2-13 PROBLEM SYMPTOMS TABLE If there are no DTCs output but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. NOTICE: When replacing the skid control ECU, sensor, etc., turn the ignition switch off. Symptoms Suspected Areas See page 1. Check the DTC again and make sure that the normal code is output. 2. IG power source circuit and ground circuit. 3. Speed sensor circuit ABS does not operate BA does not operate EBD does not operate 4. Check the ABS & TRAC actuator with a hand-held tester. If abnormal, check the hydraulic circuit for leakage. 5. If the symptoms still occur even after the above circuits in suspected areas are inspected and proved to be normal, replace the skid control ECU. 1. Check the DTC again and make sure that the normal code is output. 2. Speed sensor circuit ABS does not operate efficiently BA does not operate efficiently EBD does not operate efficiently 3. Stop lamp switch circuit 4. Check the ABS & TRAC actuator with a hand-held tester. If abnormal, check the hydraulic circuit for leakage. 5. If the symptoms still occur even after the above circuits in suspected areas are inspected and proved to be normal, replace the skid control ECU. 05-765 05-827 05-788 05-795 32-36 05-765 05-788 05-795 32-36 ABS warning light abnormal Remain ON 1. ABS warning light circuit 2. Skid control ECU 05-840 - ABS warning light abnormal Does not light up 1. ABS warning light circuit 2. Skid control ECU 05-844 05-765 DTC of ABS check cannot be done 1. Check the DTC again and make sure that the normal code is output. 2. TC terminal circuit 3. If the symptoms still occur even after the above circuits in suspected areas are inspected and proved to be normal, replace the skid control ECU. Sensor signal check cannot be done 1. TS terminal circuit 2. Skid control ECU 05-873 - 1. Check the DTC again and make sure that the normal code is output. 2. IG power source circuit and ground circuit. 3. Check the hydraulic circuit for leakage. 4. Speed sensor circuit 05-765 VSC and/or TRAC does not operate 5. Deceleration sensor circuit 6. Yaw rate sensor circuit 7. Steering sensor circuit 8. If the symptoms still occur even after the above circuits in suspected areas are inspected and proved to be normal, replace the skid control ECU. SLIP indicator light abnormal 1. SLIP indicator light circuit 2. Skid control ECU Author
: 05-868 05-827 05-788 05-795 05-815 05-824 05-824 05-821 05-863 - Date
: 976 05-787 DIAGNOSTICS Symptoms - ABS WITH EBD & BA & TRAC & VSC SYSTEM Suspected Areas See page 05-765 TRAC OFF indicator abnormal 1. Check the DTC again and make sure that the normal code is output. 2. TRAC control switch circuit 3. If the symptoms still occur even after the above circuits in suspected areas are inspected and proved to be normal, replace the skid control ECU. 05-765 DTC of VSC check cannot be done 1. Check the DTC again and make sure that the normal code is output. 2. TC terminal circuit 3. If the symptoms still occur even after the above circuits in suspected areas are inspected and proved to be normal, replace the skid control ECU. 05-765 VSC warning light abnormal Remain ON 1. Check the DTC again and make sure that the normal code is output. 2. VSC warning circuit 3. If the symptoms still occur even after the above circuits in suspected areas are inspected and proved to be normal, replace the skid control ECU. 05-765 VSC warning light abnormal Does not light up 1. Check the DTC again and make sure that the normal code is output. 2. VSC warning circuit 3. If the symptoms still occur even after the above circuits in suspected areas are inspected and proved to be normal, replace the skid control ECU. Author
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: 05-859 05-868 05-847 05-851 977 05-866 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05CDL-18 SKID CONTROL BUZZER CIRCUIT CIRCUIT DESCRIPTION The skid control buzzer sounds and Slip Indicator blinking during VSC operation. WIRING DIAGRAM I15 Ignition SW G 2 AM1 IG1 4 W Instrument Panel J/B 7 1C ECU-IG 6 1C AM1 2 10 1D 1 1A 1 V8 Passenger Side J/B VSC Warning 4 8 20 Buzzer Y O G 4M IC4 4J 2 1 B 2 Skid Control ECU with Actuator BR-W 30 S27 BZ W ALT F7 FL Block 1 FL MAIN Battery F46317 INSPECTION PROCEDURE HINT: Start the inspection from step 1 when using the hand-held tester and start from step 2 when not using the hand-held tester. 1 (a) (b) (c) PERFORM ACTIVE TEST BY HAND-HELD TESTER(SKID CONTROL BUZZER) Connect the hand-held tester to the DLC3. Start the engine. Select the item ”VSC/BR WARN BUZ” in the ACTIVE TEST and operate the skid control buzzer on the hand-held tester. Item VSC / BR WARN BUZ (d) Vehicle Condition / Test Details Turns VSC / BRAKE warning buzzer ON / OFF Diagnostic Note Buzzer can be heard Check that skid control buzzer sounds by operating with the hand-held tester. OK: The skid control buzzer sounds in accordance with operation of the hand-held tester. NG Go to step 2 OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
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: 1056 05-867 DIAGNOSTICS 2 - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECT SKID CONTROL BUZZER ASSY 2 (a) (b) 1 (+) (-) Skid Control Buzzer F02192 Disconnect the skid control buzzer connector. Apply a battery positive voltage to terminals 1 and 2 of the skid control buzzer connector, and check that the buzzer sounds. OK: The skid control buzzer sound should be heard. NG REPLACE SKID CONTROL BUZZER ASSY OK 3 CHECK HARNESS AND CONNECTOR(SKID CONTROL BUZZER - SKID CONTROL ECU) (a) Skid Control ECU (harness side connector) S27 (b) BZ Skid Control Buzzer (harness side connector) V8 BZ (c) IG1 G26280 Disconnect the skid control buzzer connector and the skid control ECU connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-30 (BZ) - V8-1 (BZ) Below 1 Ω Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-30 (BZ) - Body ground 10 kΩ or higher NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
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: 1057 05-863 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05CDK-07 SLIP INDICATOR LIGHT CIRCUIT CIRCUIT DESCRIPTION The SLIP indicator blinks during TRAC & VSC operation. WIRING DIAGRAM Skid Control ECU with Actuator 22 S27 TRC8 S27 TRC+ 23 S27 ENG9 S27 ENG+ ECM 31 TRC- E5 25 TRC+ E5 30 ENG- E5 24 ENG+ E5 G 19 IC4 Y-B Y 7 IC4 G-B R 18 IC4 W-G V 5 IC4 W-L Combination Meter 18 E6 29 MPX2 E6 System I15 Ignition SW IG1 4 W 7 13 1K AM1 1 1A 1C 6 1C P Slip HEATER 2 FL MAIN 1 C11 Instrument Panel J/B G 2 AM1 21 C11 9 C12 MPX MPX1 Center J/B 4 3A B 7 3C B F7 FL Block 1 W 1 ALT 2 Battery F46302 Author
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: 1053 05-864 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1 when using the hand-held tester and start from step 2 when not using the hand-held tester. 1 (a) (b) (c) PERFORM ACTIVE TEST BY HAND-HELD TESTER(SLIP INDICATOR LIGHT) Connect the hand-held tester to the DLC3. Start the engine. Select the item ”SLIP INDI LIGHT” in the ACTIVE TEST and operate the SLIP indicator light on the hand-held tester. Item SLIP INDI LIGHT (d) Vehicle Condition / Test Details Turns SLIP indicator light ON / OFF Diagnostic Note Observe combination meter Check that ”ON” and ”OFF” of the SLIP indicator light are indicated on the combination meter when using the hand-held tester. OK: Turn the SLIP indicator light on or off in accordance with the hand-held tester. NG Go to step 2 OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) 2 INSPECT MULTIPLEX COMMUNCATION SYSTEM (SEE PAGE 05-2040 ) NG REPAIR SYSTEM MULTIPLEX COMMUNCATION OK Author
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: 1054 05-865 DIAGNOSTICS 3 - ABS WITH EBD & BA & TRAC & VSC SYSTEM CHECK HARNESS AND CONNECTOR(ECM - SKID CONTROL ECU) S27 Skid Control ECU (harness side connector) (a) ENG+ (b) TRC+ Disconnect the skid control ECU connector S27 and ECM connector E5. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-8 (TRC+) - E5-25 (TRC+) S27-22 (TRC-) - E5-31 (TRC-) Below 1 Ω S27-9 (ENG+) - E5-24 (ENG+) TRC- ENG- S27-23 (ENG-) - E5-30 (ENG-) ECM (c) E5 Measure the resistance according to the value(s) in the table below. Standard: Tester Connection ENG+ S27-8 (TRC+) - Body ground S27-22 (TRC-) - Body ground TRC+ 10 kΩ or higher S27-9 (ENG+) - Body ground TRCF44428 F45165 Specified Condition S27-23 (ENG-) - Body ground ENGF45351 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK 4 INSPECT COMBINATION METER ASSEMBLY(SLIP INDICATOR LIGHT) (SEE PAGE 05-1868 ) NG REPAIR OR REPLACE COMBINATION METER ASSEMBLY OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
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: 1055 05-868 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05F1X-07 TC AND CG TERMINAL CIRCUIT CIRCUIT DESCRIPTION Connecting terminals TC and CG of the DLC3 causes the ECU to display the DTC by flashing the ABS warning light. WIRING DIAGRAM Skid Control ECU with Actuator 22 S27 TRC8 S27 TRC+ ECM 31 TRC- E5 25 TRC+ E5 30 ENG- E5 24 ENG+ E5 19 IC4 7 IC4 18 IC4 5 IC4 G Y R V Y-B G-B 23 S27 ENG9 S27 ENG+ W-G W-L J16 J/C 20 TC E5 O O D D D3 DLC3 TC 13 Passenger Side J/B CG W-B 4 6 4C 1 4N 7 4L W-B W-B IC F46319 Author
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: 1058 05-869 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE 1 D3 DLC3 INSPECT DLC3 TERMINAL VOLTAGE(DLC3 TERMINAL VOLTAGE) (a) (b) TC CG Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester Connection Specified Condition D3-13 (TC) - D3-4 (CG) 10 to 14 V C52361 NG Go to step 4 OK 2 D3 DLC3 CHECK HARNESS AND CONNECTOR(ECM - DLC3) (a) (b) TC (c) ECM Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition E5-20 (TC) - D3-13 (TC) Below 1 Ω Measure the resistance according to the value(s) in the table below. Standard: Wire Harness View Tester Connection Specified Condition D3-13 (TC) - Body ground 10 kΩ or higher E5 TC NG I37937 REPAIR OR CONNECTOR REPLACE HARNESS OR OK Author
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: 1059 05-870 DIAGNOSTICS 3 - ABS WITH EBD & BA & TRAC & VSC SYSTEM CHECK HARNESS AND CONNECTOR(ECM - SKID CONTROL ECU) (a) Skid Control ECU S27 (harness side connector) ENG+ (b) ENG- (c) ECM Wire Harness View E5 Disconnect the skid control ECU connector and the ECM connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition E5-24 (ENG+) - S27-9 (ENG+) Below 1 Ω E5-30 (ENG-) - S27-23 (ENG-) Below 1 Ω Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-9 (ENG+) - Body ground 10 kΩ or higher S27-23 (ENG-) - Body ground 10 kΩ or higher ENG+ ENGG26436 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) 4 D3 DLC3 CHECK HARNESS AND CONNECTOR(DLC 3 - BODY GROUND) (a) (b) TC CG C52361 Disconnect the skid control ECU connector. Measure the resistance according to the value(s) in the table below. Standard: NG Tester Connection Specified Condition D3-4 (CG) - Body ground Below 1 Ω REPAIR OR CONNECTOR REPLACE HARNESS OR OK Author
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: 1060 05-871 DIAGNOSTICS 5 D3 DLC3 ABS WITH EBD & BA & TRAC & VSC SYSTEM CHECK HARNESS AND CONNECTOR(ECM - DLC3) (a) (b) TC (c) ECM - Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition E5-20 (TC) - D3-13 (TC) Below 1 Ω Measure the resistance according to the value(s) in the table below. Standard: Wire Harness View Tester Connection Specified Condition D3-13 (TC) - Body ground 10 kΩ or higher E5 TC I37937 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK Author
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: 1061 05-872 DIAGNOSTICS 6 - ABS WITH EBD & BA & TRAC & VSC SYSTEM CHECK HARNESS AND CONNECTOR(ECM - SKID CONTROL ECU) (a) Skid Control ECU S27 (harness side connector) ENG+ (b) ENG- (c) ECM Wire Harness View E5 Disconnect the skid control ECU connector and the ECM connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition E5-24 (ENG+) - S27-9 (ENG+) Below 1 Ω E5-30 (ENG-) - S27-23 (ENG-) Below 1 Ω Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-9 (ENG+) - Body ground 10 kΩ or higher S27-23 (ENG-) - Body ground 10 kΩ or higher ENG+ ENGG26436 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
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: 1062 05-784 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05CD1-12 TERMINALS OF ECU SKID CONTROL ECU S27 F45080 Symbols (Terminals No.) BM (S27-2) - GND (Y1-1) FR+ (S27-3) - FR- (S27-17) FSW+ (S27-7) - GND1 (S27-32) Wiring Color W-L - W-B R-Y - LG G-W - W-B Terminal Description Condition Specified Condition Motor relay test input IG switch ON, pump motor running 10 to 14 V Front RH wheel speed signal input IG switch ON, slowly turn right front wheel AC generation FSW switch input IG switch ON, brake pedal released 2 to 4 V FL+ (S27-18) - FL- (S27-4) O -P Front LH wheel speed signal input IG switch ON, slowly turn left front wheel AC generation RR+ (S27-5) - RR- (S27-19) Y - BR Rear RH wheel speed signal input IG switch ON, slowly turn right rear wheel AC generation RL+ (S27-20) - RL- (S27-6) Y-G - G Rear LH wheel speed signal input IG switch ON, slowly turn left rear wheel AC generation TRC+ (S27-8) - TRC(S27-22) G-B - Y-B ECM communication output IG switch ON Pulse generation ENG+ (S27-9) - ENG(S27-23) W-L - W-G ECM communication input IG switch ON Pulse generation NEO (S27-10) - GND1 (S27-32) V - W-B Engine rpm signal input Engine idling Pulse generation CANH (S27-11) - CANL (S27-25) B-W CAN communication line IG switch OFF 54 to 67 Ω D/G (S27-13) - GND1 (S27-32) GR-B - W-B Diagnosis tester communication line IG switch ON 10 to 14 V SP1 (S27-12) - GND1 (S27-32) BR-R - W-B Speed signal output Vehicle drives at about 20 km/h (12 mph) Fail safe motor relay output IG switch ON 10 to 14 V MRF (S27-14) - R+ (S27-45) G-R - B-O Pulse generation MR (S27-15) - R+ (S27-45) LG - B-O Motor relay output IG switch ON, pump motor running 10 to 14 V +BS (S27-31) - GND1 (S27-32) B - W-B Solenoid relay power supply Always 10 to 14 V Sensor check input IG switch ON 10 to 14 V Stop light switch ON (Brake pedal pushed) 8 to 14 V Stop light switch OFF (Brake pedal released) Below 1.5 V TS (S27-24) - GND1 (S27-32) STP (S27 (S27-27) 27) - GND1 (S27-32) P-B - W-B G Y - W-B G-Y WB St light Stop li ht switch it h input i t Author
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: 974 05-785 DIAGNOSTICS PKB (S27 (S27-28) 28) - GND1 (S27-32) WA (S27-29) (S27 29) - GND1 (S27-32) BZ (S27-30) - GND1 (S27-32) R W - W-B R-W WB R L - W-B R-L WB BR-W - W-B - ABS WITH EBD & BA & TRAC & VSC SYSTEM Parking brake switch in input ABS warning i lilight ht output t t Buzzer output IG switch ON, parking brake switch ON Below 1.5 V IG switch ON, parking brake switch OFF 10 to 14 V IG switch ON, ABS warning light ON 6 to 11 V IG switch ON, ABS warning light OFF Below 2.0 V IG switch ON, VSC buzzer sounds Below 1.0 ↔ 10 to 14 V IG switch ON, VSC buzzer does not sound 10 to 14 V VSCW (S27-36) - GND1 (S27-32) L-Y - W-B VSC warning light output IG switch ON, VSC warning light ON CSW* (S27-43) - GND1 (S27-32) L-R - W-B TRAC OFF switch input TRAC OFF switch OFF 10 to 14 V IG switch ON, BRAKE warning light ON 6 to 11 V IG switch ON, BRAKE warning light OFF Below 2.0 V BRL (S27 (S27-44) 44) - GND1 (S27-32) LG B - W-B LG-B WB B k warning Brake i lilight ht output t t Below 2.0 V R+ (S27-45) - GND1 (S27-32) B-O - W-B Power supply for motor relay IG switch ON 10 to 14 V IG1 (S27-46) - GND1 (S27-32) B-R - W-B IG1 power supply IG switch ON 10 to 14 V *: 2WD only Author
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: 975 05-859 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05H3X-03 TRAC OFF INDICATOR LIGHT, TRAC OFF SWITCH CIRCUIT CIRCUIT DESCRIPTION The skid control ECU detects the track control main switch ON/OFF signal and turns the track off light on/off. This is the TRAC control main switch. When the TRAC control switch is pressed, the TRAC control does not operate and the TRAC OFF light comes on. WIRING DIAGRAM ECM 31 TRC- E5 25 TRC+ E5 30 ENG- E5 24 ENG+ E5 19 IC4 7 IC4 18 IC4 5 IC4 G Y R V Skid Control ECU with Actuator 22 S27 TRC8 S27 TRC+ 23 S27 ENG9 S27 ENG+ Y-B G-B W-G W-L Combination Meter 18 MPX1 E6 29 MPX2 E6 21 C11 9 C12 MPX System I15 Ignition SW 1 C11 TRAC OFF Center J/B Instrument Panel J/B G 7 1C HEATER 13 1K W 6 1C AM1 1 1A 2 AM1 IG1 4 F7 FL Block 2 1 P B 4 3A 7 3C B W 1 ALT 2 T6 Trac Off SW 1 FL MAIN W-B (*1) 13 W IF3 4 (*1) Center J/B 4 3J 17 IC4 W (*1) 13 3F L-R (*1) 43 S27 CSW W-B Battery IB *1 : 2WD F46300 Author
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: 1049 05-860 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1 when using the hand-held tester and start from step 2 when not using the hand-held tester. 1 (a) (b) (c) PERFORM ACTIVE TEST BY HAND-HELD TESTER(TRAC OFF INDICATOR LIGHT) Connect the hand-held tester to the DLC3. Start the engine. Select the item ”TRAC OFF LIGHT” in the ACTIVE TEST and operate the TRAC OFF indicator light on the hand-held tester. Item VSC / TRAC OFF IND (d) Vehicle Condition / Test Details Diagnostic Note Observe combination meter Turns VSC / TRAC OFF indicator ON / OFF Check that ”ON” and ”OFF” of the TRAC OFF indicator light are indicated on the combination meter when using the hand-held tester. OK: Turn the TRAC OFF indicator light on or off in accordance with the hand-held tester. NG Go to step 6 OK 2 INSPECT TRACTION CONTROL SWITCH (a) (b) (c) T6 4 Remove the TRAC control switch. Disconnect the TRAC control switch connector T6. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection 1 T6 4 - T6-1 T6-4 T6 1 F00052 NG Switch Condition Specified Condition Pushed in (ON) Below 1 Ω Released (OFF) 10 kΩ or higher REPLACE TRACTION CONTROL SWITCH OK Author
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: 1050 05-861 DIAGNOSTICS 3 - ABS WITH EBD & BA & TRAC & VSC SYSTEM CHECK HARNESS AND CONNECTOR(SKID CONTROL ECU - TRAC OFF SWITCH) (a) Skid Control ECU (harness side connector) S27 (b) TRAC Control Switch (harness side connector) E CSW Disconnect the skid control ECU connector S27 and the TRAC control switch connector T6. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-43 (CSW) - T6-4 (+) Below 1 Ω S27-43 (CSW) - Body ground 10 kΩ or higher T6-1 (E) - Body ground Below 1 Ω T6 + NG F46260 REPAIR OR CONNECTOR REPLACE HARNESS OR OK 4 INSPECT MULTIPLEX COMMUNCATION SYSTEM (SEE PAGE 05-2040 ) NG REPAIR SYSTEM MULTIPLEX COMMUNCATION OK Author
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: 1051 05-862 DIAGNOSTICS 5 - ABS WITH EBD & BA & TRAC & VSC SYSTEM CHECK HARNESS AND CONNECTOR(SKID CONTROL ECU - ECM) S27 Skid Control ECU (harness side connector) (a) ENG+ (b) TRC+ Disconnect the skid control ECU connector S27 and ECM connector E5. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-8 (TRC+) - E5-25 (TRC+) S27-22 (TRC-) - E5-31 (TRC-) Below 1 Ω S27-9 (ENG+) - E5-24 (ENG+) TRC- ENG- S27-23 (ENG-) - E5-30 (ENG-) ECM (c) E5 Measure the resistance according to the value(s) in the table below. Standard: Tester Connection ENG+ S27-8 (TRC+) - Body ground S27-22 (TRC-) - Body ground TRC+ 10 kΩ or higher S27-9 (ENG+) - Body ground TRCF44428 F45165 Specified Condition S27-23 (ENG-) - Body ground ENGF45351 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK 6 INSPECT COMBINATION METER ASSEMBLY (SEE PAGE 05-1868 ) NG REPAIR OR REPLACE COMBINATION METER ASSEMBLY OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
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: 1052 05-873 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05F1Y-08 TS AND CG TERMINAL CIRCUIT CIRCUIT DESCRIPTION In the sensor check mode, a malfunction of the speed sensor that cannot be detected when the vehicle is stopped is detected while driving. Transition to the sensor check mode can be performed by connecting terminals TS and CG of the DLC3 and turning the ignition switch from off to the ON position. WIRING DIAGRAM Passenger Side J/B W-B 7 4L 1 4N 6 4C D3 Data Link Connector 3 W-B 4 CG TS W 12 Skid Control ECU with Actuator 8 IC4 P-B 24 S27 TS W-B IC F46320 INSPECTION PROCEDURE 1 DLC3 INSPECT DLC3 TERMINAL VOLTAGE(TS TERMINAL) (a) (b) TS D3 CG Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester Connection Specified Condition D3-12 (TS) - D3-4 (CG) 10 to 14 V C52361 NG Go to step 3 OK Author
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: 1063 05-874 DIAGNOSTICS 2 ABS WITH EBD & BA & TRAC & VSC SYSTEM CHECK HARNESS AND CONNECTOR(DLC3 - BODY GROUND) (a) (b) Skid Control ECU (harness side connector) S27 (c) D3 DLC3 - Disconnect the skid control ECU connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-24 (TS) - D3-12 (TS) Below 1 Ω TS Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition TS S27-24 (TS) - Body ground 10 kΩ or higher G24767 C52361 I37493 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) 3 CHECK HARNESS AND CONNECTOR(BODY GROUND - DLC3) (a) DLC3 D3 CG C52361 Measure the resistance according to the value(s) in the table below. Standard: NG Tester Connection Specified Condition D3-4 (CG) - Body ground Below 1 Ω REPAIR OR CONNECTOR REPLACE HARNESS OR OK Author
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: 1064 05-875 DIAGNOSTICS 4 (a) (b) (c) G24767 C52361 ABS WITH EBD & BA & TRAC & VSC SYSTEM CHECK HARNESS AND CONNECTOR(SKID CONTROL ECU - DLC3) Skid Control ECU (harness side connector) S27 D3 DLC3 - Disconnect the skid control ECU connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-24 (TS) - D3-12 (TS) Below 1 Ω TS Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition TS S27-24 (TS) - Body ground 10 kΩ or higher I37493 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
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: 1065 05-847 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05CDH-11 VSC WARNING LIGHT CIRCUIT (REMAINS ON) CIRCUIT DESCRIPTION If the ECU stores DTC, the VSC warning light comes on in the combination meter. WIRING DIAGRAM 16 IF3 P 5 IC2 V Skid Control ECU with Actuator 36 L-Y S27 VSCW Combination Meter 7 C12 13 C11 9 IL1 SB VSC J6 J/C Passenger Side J/B 4 4M 4 4J 1 4E 2 4H P P E E 10 IC4 GR 10 1D ECU-IG 7 1C W 6 1G IGN 1 1C 1 1A AM1 F7 FL Block W B 1 ALT 2 1 L-Y AM2 10 6 1C 46 S27 IG1 I15 Ignition SW Instrument Panel J/B Y B-R G 4 IG1 AM1 2 GR 6 IG2 AM2 7 W 2 1 IC1 Y FL MAIN Battery F46303 Author
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: 1037 05-848 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE 1 (a) CHECK DTC Is DTC output for ABS and VSC? DTC is not output A DTC is output B B REPAIR CIRCUIT INDICATED BY OUTPUT CODE A 2 INSPECT CHECK IF SKID CONTROL ECU CONNECTOR IS SECURELY CONNECTED NG CONNECT CONNECTOR TO ECU NG INSPECT CHARGING SYSTEM (SEE PAGE 19-12 (2AZ-FE) OR 19-36 (3MZ-FE)) OK 3 (a) INSPECT BATTERY Check the battery voltage. Standard: Tester Connection Specified Condition Battery terminal ((+) - (-)) 11 to 14 V OK Author
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: 1038 05-849 DIAGNOSTICS 4 - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECT SKID CONTROL ECU TERMINAL VOLTAGE(IG1 TERMINAL) WHEN USING HAND-HELD TESTER: (a) Connect the hand-held tester to the DLC3. (b) Start the engine. (c) Select the DATA LIST mode on the hand-held tester. (d) Check the voltage condition output from the ECU displayed on the hand-held tester. Item IG VOLTAGE Measurement Item / Range (Display) ECU power supply voltage / TOO LOW / NORMAL Normal Condition NORMAL: 9.5 V or over UNDER: Below 9.5 V OK: ”Normal” is displayed. WHEN NOT USING HAND-HELD TESTER: (a) Disconnect the skid control ECU connector. (b) Turn the ignition switch to the ON position. (c) Measure the voltage according to the value(s) in the table below. Standard: Skid Control ECU (harness side connector) S27 GND1 IG1 G24767 Tester Connection Specified Condition S27-46 (IG1) - S27-32 (GND1) 11 to 14 V NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK Author
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: 1039 05-850 DIAGNOSTICS 5 - ABS WITH EBD & BA & TRAC & VSC SYSTEM CHECK HARNESS AND CONNECTOR(SKID CONTROL ECU - COMBINATION METER) (a) Skid Control ECU (harness side connector) (b) S27 (c) VSCW Combination Meter (harness side view) C12 Disconnect the skid control ECU connector and combination meter connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition C12 - 7 - S27-36 (VSCW) Below 1 Ω Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-36 (VSCW) - Body ground 10 kΩ or higher NG F46287 REPAIR OR CONNECTOR REPLACE HARNESS OR OK 6 CHECK HARNESS AND CONNECTOR(SKID CONTROL ECU - BODY GROUND) Skid Control ECU (harness side connector) (a) (b) S27 Disconnect the skid control ECU connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-32 (GND1) - Body ground Below 1 Ω GND1 G24767 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
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: 1040 05-851 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM 05F1U-05 VSC WARNING LIGHT CIRCUIT (DOES NOT LIGHT UP) CIRCUIT DESCRIPTION If the ECU stores DTC, the VSC warning light comes on in the combination meter. WIRING DIAGRAM 16 IF3 P 5 IC2 V Skid Control ECU with Actuator 36 L-Y S27 VSCW Combination Meter 7 C12 13 C11 9 IL1 SB VSC J6 J/C Passenger Side J/B 4 4M 4 4J 1 4E 2 4H P P E E 10 IC4 GR 10 1D ECU-IG 7 1C W 6 1G IGN 1 1C 1 1A AM1 F7 FL Block W B 1 ALT 2 1 L-Y AM2 10 6 1C 46 S27 IG1 I15 Ignition SW Instrument Panel J/B Y B-R G 4 IG1 AM1 2 GR 6 IG2 AM2 7 W 2 1 IC1 Y FL MAIN Battery F46303 Author
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: 1041 05-852 DIAGNOSTICS - ABS WITH EBD & BA & TRAC & VSC SYSTEM INSPECTION PROCEDURE 1 CHECK VSC WARNING LIGHT WHEN USING HAND-HELD TESTER: (a) Connect the hand-held tester to the DLC3 and start the engine. (b) Select the item ”VSC WARN LIGHT” in the ACTIVE TEST and operate the VSC warning light on the hand-held tester. (c) Check that ”ON” and ”OFF” of the VSC warning light are indicated on the combination meter when using the hand-held tester. Item VSC WARN LIGHT Vehicle Condition / Test Details Turns VSC warning light ON / OFF Diagnostic Note Observe combination meter OK: Turn the VSC warning light ON or OFF in accordance with the hand-held tester. WHEN NOT USING HAND-HELD TESTER: Skid Control ECU (a) Turn the ignition switch off and disconnect the connector (harness side connector) S27 from the skid control ECU. (b) Ground the terminal VSCW of skid control ECU. (c) Turn the ignition switch to the ON position. (d) Check that the VSC warning light. OK: Turn the light ON or OFF in accordance with the conVSCW necting condition of terminal VSCW and body G24767 ground. NG CHECK AND REPAIR VSC WARNING LIGHT CIRCUIT (SEE PAGE 05-1868 ) OK Author
: Date
: 1042 05-853 DIAGNOSTICS 2 - ABS WITH EBD & BA & TRAC & VSC SYSTEM CHECK HARNESS AND CONNECTOR(SKID CONTROL ECU - COMBINATION METER) (a) Skid Control ECU (harness side connector) (b) S27 (c) VSCW Combination Meter (harness side view) C12 Disconnect the skid control ECU connector and combination meter connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition C12 - 7 - S27-36 (VSCW) Below 1 Ω Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition S27-36 (VSCW) - Body ground 10 kΩ or higher F46287 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37 ) Author
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: 1043 05-1998 DIAGNOSTICS DTC B2780 - ENGINE IMMOBILIZER SYSTEM 05A2A-06 PUSH SWITCH/KEY UNLOCK WARNING SWITCH MALFUNCTION CIRCUIT DESCRIPTION This DTC will be output if the transponder key ECU does not detect that the unlock warning switch is ON even when the ignition switch is ON (under normal condition, the unlock warning switch is ON when the ignition switch is ON). DTC No. DTC Detection Condition Trouble Area Unlock warning switch ON is not detected when ignition switch is ON B2780
Unlock warning switch assy
Wire harness
Transponder key ECU assy WIRING DIAGRAM Transponder Key ECU Assy K4 Unlock Warning Switch Assy W-B 9 4G 7 1 2 J6 Junction Connector G D D G 10 T14 KSW Passenger Side J/B 4L W-B IC B51715 B79970 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2188 05-1999 DIAGNOSTICS - ENGINE IMMOBILIZER SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1 when using the hand-held tester and start from step 2 when not using the hand-held tester. 1 (a) (b) (c) READ VALUE OF HAND-HELD TESTER (TRANSPONDER KEY ECU (SWITCH CONDITION)) Connect the hand-held tester to the DLC3. Turn the ignition switch ON with the key that cannot start the engine. On the hand-held tester, select the following menu item: DIAGNOSIS/ENHANCED OBD II/DATA LIST/IMMOBILISER/KEY SW. Read the values. OK: ”ON” (Key is in ignition key cylinder) appears on the screen. Item Measurement Item/ Display (Range) Normal Condition Diagnostic Note KEY SW Unlock warning switch signal /ON or OFF ON: Key is in ignition key cylinder OFF: No key is in ignition key cylinder - NG Go to step 2 OK REPLACE TRANSPONDER KEY ECU ASSY 2 INSPECT UNLOCK WARNING SWITCH ASSY (a) (b) Not pushed Pushed Remove the unlock warning switch. Measure the resistance of the unlock warning switch. Standard: Tester Connection Switch Position 1-2 Pushed Below 1 Ω 1-2 Not pushed 10 kΩ or higher 2 1 4 3 B51581 NG Specified Condition REPLACE UNLOCK WARNING SWITCH ASSY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2189 05-2000 DIAGNOSTICS 3 - ENGINE IMMOBILIZER SYSTEM CHECK WIRE HARNESS (TRANSPONDER KEY ECU ASSY - UNLOCK WARNING SWITCH ASSY) (a) (b) Wire Harness Side T14 Transponder Key ECU Assy Disconnect the T14 ECU and K4 switch connectors. Measure the resistance between the wire harness side connectors. Standard: Symbols (Terminal No.) Specified Condition T14-10 (KSW) - K4-2 Below 1 Ω KSW K4 Unlock Warning Switch Assy NG B63404 B65748 B78556 REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE TRANSPONDER KEY ECU ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2190 05-2001 DIAGNOSTICS DTC B2784 - ENGINE IMMOBILIZER SYSTEM 05A2C-09 ANTENNA COIL OPEN/SHORT CIRCUIT DESCRIPTION The transponder key coil is built into the transponder key amplifier and receives a key code signal from the transponder chip in the key. This signal is amplified by the amplifier, then it is output to the transponder key ECU assy. DTC No. B2784 DTC Detection Condition Trouble Area
Wire harness
Transponder key amplifier
Transponder key ECU assy Antenna coil is open/short WIRING DIAGRAM T14 Transponder Key ECU Assy T7 Transponder Key Amplifier ANT1 B 8 CODE 4 GR 11 TXCT 5 W 12 GND R 13 VC5 CODE Amplifier Transponder Key Coil 1 VC5 7 ANT2 TXCT AGND B62676 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2191 05-2002 DIAGNOSTICS - ENGINE IMMOBILIZER SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1 when using the hand-held tester and start from step 2 when not using the hand-held tester. 1 (a) (b) (c) READ VALUE OF HAND-HELD TESTER (IMMOBILIZER ECU (TRANSPONDER KEY ECU ASSY) (SWITCH CONDITION)) Connect the hand-held tester to the DLC3. Turn the ignition switch ON with the key that does not start the engine. Select the item ”ANTENNA COIL” on the hand-held tester. OK: ”NORMAL” (Antenna coil is normal) appears on the screen. Item Measurement Item/ Display (Range) ANTENNA COIL Antenna coil condition /NORMAL or FAIL Normal Condition Diagnostic Note NORMAL: Antenna coil is normal FAIL: Antenna coil is abnormal NG - Go to step 2 OK REPLACE TRANSPONDER KEY ECU ASSY 2 CHECK WIRE HARNESS (TRANSPONDER KEY ECU ASSY - TRANSPONDER KEY AMPLIFIER) (TRANSPONDER KEY ECU ASSY OR TRANSPONDER KEY AMPLIFIER - BODY GROUND) (a) (b) Wire Harness Side Disconnect the T14 ECU and T7 amplifier connectors. Measure the resistance of the wire harness side connectors. Standard: T14 Transponder Key ECU Assy T7 Transponder Key Amplifier Tester Connection Specified Condition T14-8 (VC5) - T7-1 (VC5) Below 1 Ω T14-11 (CODE) - T7-4 (CODE) Below 1 Ω T14-12 (TXCT) - T7-5 (TXCT) Below 1 Ω T14-13 (AGND) - T7-7 (GND) Below 1 Ω T14-8 (VC5) or T7-1 (VC5) Body ground 10 kΩ or higher T14-11 (CODE) or T7-4 (CODE) Body ground 10 kΩ or higher T14-12 (TXCT) or T7-5 (TXCT) Body ground 10 kΩ or higher T14-13 (AGND) or T7-7 (GND) Body ground 10 kΩ or higher B63404 B55013 B64974 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE TRANSPONDER KEY AMPLIFIER 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2192 05-2003 DIAGNOSTICS DTC B2793 - ENGINE IMMOBILIZER SYSTEM 052IH-1 1 TRANSPONDER CHIP MALFUNCTION CIRCUIT DESCRIPTION This DTC is output when trouble is found in a key during the key code registration or the key code is not registered normally. Replace the key when the key code registration is not performed normally and this DTC is detected. DTC No. B2793 DTC Detection Condition Trouble Area
Key Transponder chip malfunction INSPECTION PROCEDURE 1 (a) (b) (c) CHECK DTC Delete the DTC. Insert the key into the ignition key cylinder. Check that no code is output. OK NO PROBLEM NG 2 (a) (b) RE-REGISTER KEY Delete the DTC. Re-register the key, and check that the engine starts with the key. OK NORMAL NG REPLACE KEY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2193 05-2004 DIAGNOSTICS DTC B2794 - ENGINE IMMOBILIZER SYSTEM 052II-10 UNMATCHED ENCRYPTION CODE CIRCUIT DESCRIPTION This DTC is output when a key with an incomplete key code is inserted into the ignition key cylinder. DTC No. B2794 DTC Detection Condition Key with incomplete key code is inserted Trouble Area
Key INSPECTION PROCEDURE 1 REPLACE KEY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2194 05-2005 DIAGNOSTICS DTC B2795 - ENGINE IMMOBILIZER SYSTEM 052IJ-12 UNMATCHED KEY CODE CIRCUIT DESCRIPTION This DTC is output when a key with a key code that has not been registered in the ECU is inserted into the ignition key cylinder. DTC No. B2795 DTC Detection Condition Trouble Area
Key Key with unregistered key code is inserted INSPECTION PROCEDURE 1 DELETE DTC AND INSERT ALL PRESENTLY AVAILABLE KEYS TO CHECK WHETHER ENGINE STARTS OR NOT OK NO PROBLEM (BECAUSE OF KEY RE-REGISTRATION) NG REPLACE KEY THAT DOES NOT START ENGINE 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2195 05-2006 DIAGNOSTICS - ENGINE IMMOBILIZER SYSTEM 05A2G-10 DTC B2796 NO COMMUNICATION IN IMMOBILIZER SYSTEM DTC B2798 COMMUNICATION MALFUNCTION NO. 2 CIRCUIT DESCRIPTION This code is stored in the memory when a key that does not have a transponder chip is inserted or if communication between the key and transponder key ECU assy is impossible. DTC No. DTC Detection Condition Trouble Area B2796 No communication
Key
Wire harness
Transponder key amplifier
Transponder key ECU assy B2798 Communication error
Key WIRING DIAGRAM T14 Transponder Key ECU Assy T7 Transponder Key Amplifier ANT1 B 8 CODE 4 GR 11 TXCT 5 W 12 GND R 13 VC5 CODE Amplifier Transponder Key Coil 1 VC5 7 ANT2 TXCT AGND B62676 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2196 05-2007 DIAGNOSTICS - ENGINE IMMOBILIZER SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1 when using the hand-held tester and start from step 2 when not using the hand-held tester. 1 (a) (b) (c) READ VALUE OF HAND-HELD TESTER (IMMOBILISER ECU (TRANSPONDER KEY ECU ASSY) (SWITCH CONDITION)) Connect the hand-held tester to the DLC3. Turn the ignition switch ON with the key that does not start the engine. Select the item ”IMMOBILIZER” on the hand-held tester. OK: ”SET” (Ignition switch ON) appears on the screen. Item Measurement Item/ Display (Range) IMMOBILIZER Immobilizer system status /SET or UNSET OK Normal Condition Diagnostic Note UNSET: Without key SET: Ignition switch ON - NORMAL NG 2 (a) CHECK WHETHER ENGINE STARTS WITH OTHER KEYS Check whether the engine starts with the other keys for the vehicle. OK RE-REGISTER OR REPLACE KEY THAT WILL NOT START ENGINE NG HINT: Start the inspection from step 3 when using the hand-held tester and start from step 4 when not using the hand-held tester. 3 (a) (b) (c) READ VALUE OF HAND-HELD TESTER (IMMOBILIZER ECU (TRANSPONDER KEY ECU ASSY) (SWITCH CONDITION)) Connect the hand-held tester to the DLC3. Turn the ignition switch ON with the key that does not start the engine. On the hand-held tester, select the following menu item: DIAGNOSIS/ENHANCED OBD II/DATA LIST/IMMOBILIZER/ANTENNA COIL. Read the values. OK: ”NORMAL” (Antenna coil is normal) appears on the screen. Item Measurement Item/ Display (Range) ANTENNA COIL Antenna coil condition /NORMAL or FAIL NG Normal Condition Diagnostic Note NORMAL: Antenna coil is normal FAIL: Antenna coil is abnormal - CHECK AND REPLACE TRANSPONDER KEY ECU ASSY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2197 05-2008 DIAGNOSTICS 4 - ENGINE IMMOBILIZER SYSTEM CHECK WIRE HARNESS (TRANSPONDER KEY ECU ASSY - TRANSPONDER KEY AMPLIFIER) (TRANSPONDER KEY ECU ASSY OR TRANSPONDER KEY AMPLIFIER - BODY GROUND) (a) (b) Wire Harness Side Disconnect the T14 ECU and T7 amplifier connectors. Measure the resistance of the wire harness side connectors. Standard: T14 Transponder Key ECU Assy T7 Transponder Key Amplifier Tester Connection Specified Condition T14-8 (VC5) - T7-1 (VC5) Below 1 Ω T14-11 (CODE) - T7-4 (CODE) Below 1 Ω T14-12 (TXCT) - T7-5 (TXCT) Below 1 Ω T14-13 (AGND) - T7-7 (GND) Below 1 Ω T14-8 (VC5) or T7-1 (VC5) Body ground 10 kΩ or higher T14-11 (CODE) or T7-4 (CODE) Body ground 10 kΩ or higher T14-12 (TXCT) or T7-5 (TXCT) Body ground 10 kΩ or higher T14-13 (AGND) or T7-7 (GND) Body ground 10 kΩ or higher B63404 B55013 B64974 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 5 (a) CHECK OPERATION OF TRANSPONDER KEY AMPLIFIER After replacing the transponder key amplifier with a normally functioning amplifier, check that the engine starts. NG REPLACE TRANSPONDER KEY ECU ASSY OK REPLACE TRANSPONDER KEY AMPLIFIER 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2198 05-2009 DIAGNOSTICS DTC B2797 - ENGINE IMMOBILIZER SYSTEM 052IL-10 COMMUNICATION MALFUNCTION NO.1 CIRCUIT DESCRIPTION This DTC is output when an error occurs in normal communication. HINT: Some noise exists in the communication line. DTC No. B2797 DTC Detection Condition Trouble Area Keys are positioned too close to each other, or noise occurred in communication line
Key
Wire harness
Transponder key amplifier
Transponder key ECU assy WIRING DIAGRAM T7 Transponder Key Amplifier CODE T14 Transponder Key ECU Assy GR 4 11 CODE B52550 INSPECTION PROCEDURE 1 (a) CHECK OPERATION OF TRANSPONDER KEY AMPLIFIER After replacing the transponder key amplifier with a normally functioning amplifier, check that the engine starts. OK NORMAL (TRANSPONDER KEY AMPLIFIER DEFECTIVE) NG REPLACE TRANSPONDER KEY ECU ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2199 05-2010 DIAGNOSTICS DTC B2799 - ENGINE IMMOBILIZER SYSTEM 052IM-12 ENGINE IMMOBILIZER SYSTEM MALFUNCTION CIRCUIT DESCRIPTION This DTC is output when the ECM detects errors in communication between the transponder key ECU assy and the ECM, or in the communication lines. This DTC is also output when an engine start is attempted while the ECU communication ID between the transponder key ECU assy and the ECM is different. Before troubleshooting for this DTC, make sure that there is no DTC detected in the transponder key ECU. If there is a key code-related DTC detected in the transponder key ECU assy, repair it first. DTC No. B2799 DTC Detection Condition Trouble Area
Error in communication between ECM and transponder key ECU assy, and in communication line
Communication ID is different during communication with transponder key ECU
Wire harness
Transponder key ECU assy
Transponder key amplifier
ECM WIRING DIAGRAM T14 Transponder Key ECU Assy E6 ECM IMI IMO 27 B 6 26 V 7 EFIO EFII B66227 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2200 05-201 1 DIAGNOSTICS - ENGINE IMMOBILIZER SYSTEM INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (TRANSPONDER KEY ECU ASSY - ECM) (TRANSPONDER KEY ECU ASSY OR ECM - BODY GROUND) (a) (b) Wire Harness Side T14 Transponder Key ECU Assy Disconnect the T14 ECU and E6 ECM connectors. Measure the resistance between the wire harness side connectors. Standard: Symbols (Terminal No.) EFIO (T14-6) - IMI (E6-27) Below 1 Ω EFII (T14-7) - IMO (E6-26) Below 1 Ω (c) E6 ECM Y B66220 Specified Condition Measure the resistance between the T14 or E6 wire harness side connector and the body ground. Standard: Symbols (Terminal No.) Specified Condition EFIO (T14-6) or IMI (E6-27) Body ground 10 kΩ or higher EFII (T14-7) or IMO (E6-26) Body ground 10 kΩ or higher B66229 OK REPAIR OR CONNECTOR REPLACE HARNESS AND NG 2 (a) CHECK OPERATION OF TRANSPONDER KEY AMPLIFIER After replacing the transponder key amplifier with a normally functioning amplifier, check that the engine starts. NG REPLACE TRANSPONDER KEY ECU ASSY OK NORMAL (TRANSPONDER KEY AMPLIFIER DEFECTIVE) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2201 05-1985 DIAGNOSTICS - ENGINE IMMOBILIZER SYSTEM ENGINE IMMOBILIZER SYSTEM 052IA-27 HOW TO PROCEED WITH TROUBLESHOOTING HINT: Use this procedure to troubleshoot the engine immobilizer system. 1 VEHICLE BROUGHT TO WORKSHOP 2 CUSTOMER PROBLEM ANALYSIS CHECK AND SYMPTOM CHECK (see page 05-1987 ) 3 CRANK ENGINE FOR MORE THAN 10 SECONDS 4 CHECK DTC (a) (b) (c) Check for DTCs and note any codes that are output. Delete the DTC. Recheck for DTCs. Try to prompt the DTC (SFI system and engine immobilizer system) by simulating the original activity that the DTC suggested. (1) If the DTC does not reoccur, proceed to A. (2) If the DTC (SFI system) reoccurs, proceed to B. (3) If the DTC (engine immobilizer system) reoccur, proceed to C. B Go to SFI SYSTEM (2AZ-FE engine: See page 05-1 ) (3MZ-FE engine: See page 05-362 ) C Go to step 8 A 5 READ VALUE OF HAND-HELD TESTER (IMMOBILIZER ECU (TRANSPONDER KEY ECU ASSY) (SWITCH CONDITION)) (a) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the hand-held tester main switch ON. (c) Select the item ”KEY SW” in the ”DATA LIST” and read its value displayed on the hand-held tester. Transponder key ECU assy: Item Measurement Item/ Display (Range) Normal Condition Diagnostic Note KEY Switch Unlock warning switch signal /ON or OFF ON: Key is in ignition key cylinder OFF: No key is in ignition key cylinder - NG Go to DTC B2780 (see page 05-1998 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2175 05-1986 DIAGNOSTICS - ENGINE IMMOBILIZER SYSTEM OK 6 (a) (b) PROBLEM SYMPTOMS TABLE (see page 05-1997 ) When the problem is not listed on the problem symptoms table, proceed to A. When the problem is listed on the problem symptoms table, proceed to B. B Go to step 8 A 7 (a) PERFORM TROUBLESHOOTING ACCORDING TO MALFUNCTION SYMPTOM Pre-check (see page 05-1988 ) (1) Inspect with the hand-held tester (ECU data monitor). (2) Inspect with the hand-held tester (ACTIVE TEST). Terminals of ECU (see page 05-1993 ) (b) 8 ADJUST, REPAIR OR REPLACE END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2176 05-1987 DIAGNOSTICS - ENGINE IMMOBILIZER SYSTEM 052IB-13 CUSTOMER PROBLEM ANALYSIS CHECK ENGINE IMMOBILIZER SYSTEM Check Sheet Inspector’s : Name VIN Production Date Customer’s Name / / Licence Plate No. Date Vehicle Brought In / / Date Problem First Occurred Frequency Problem Occurs Weather Conditions When Problem Occurred Symptoms Weather km miles Odometer Reading / / Intermittent ( Constant times a day/month) Only once Fine Cloudy Rainy Snowy Various/Others Outdoor Temperature Hot Warm Cold (Approx.
C ( Cool
F) Immobilizer is not set. (Engine starts with key codes other than the registered key code.) Engine does not start. 1st Time Normal code Malfunction code (Code ) 2nd Time Normal code Malfunction code (Code ) DTC Check 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2177 05-1991 DIAGNOSTICS - ENGINE IMMOBILIZER SYSTEM 052ID-13 DIAGNOSTIC TROUBLE CODE CHART 1. TRANSPONDER KEY ECU DIAGNOSTIC TROUBLE CODE CHART DTC No. (See Page) Detection Item Trouble Area B2780 (05-1998 ) Push Switch/Key Unlock Warning Switch Malfunction
Unlock warning switch
Wire harness
Transponder key ECU assy B2784 (05-2001 ) Antenna Coil Open/Short
Wire harness
Transponder key amplifier
Transponder key ECU assy B2793 (05-2003 ) Transponder Chip Malfunction
Key B2794 (05-2004 ) Unmatched Encryption Code
Key B2795 (05-2005 ) Unmatched Key Code
Key No Communication in Immobilizer System
Key
Transponder key amplifier
Wire harness
Transponder key ECU assy B2797 (05-2009 ) Communication Malfunction No. 1
Key
Wire harness
Transponder key amplifier
Transponder key ECU assy B2798 (05-2006 ) Communication Malfunction No. 2
Key B2796 (05-2006 ) 2. ECM DIAGNOSTIC TROUBLE CODE CHART NOTICE: The DTC for the immobilizer system is specified. If the other codes are output, check the DTC chart of the engine control system. DTC No. (See Page) B2799 (05-2010 ) Detection Item Engine Immobilizer System Malfunction Trouble Area
Wire harness
Key
Transponder key ECU assy
Transponder key amplifier (Transponder key coil)
ECM 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2181 05-1992 DIAGNOSTICS - ENGINE IMMOBILIZER SYSTEM 052IE-12 LOCATION Transponder Key ECU Assy Unlock Warning Switch Assy ECM Transponder Key Amplifier B78736 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2182 05-1988 DIAGNOSTICS - ENGINE IMMOBILIZER SYSTEM 05A23-07 PRE-CHECK 1. (a) DIAGNOSIS SYSTEM Description (1) The ECM controls the function of the immobilizer system on this vehicle. Data of the immobilizer system and the Diagnostic Trouble Code (DTC) can be read in the Data Link Connector 3 (DLC3) of the vehicle. When trouble occurs in the immobilizer system, even though the security indicator lamp does not turn on, DTCs can be checked. Therefore, when there seems to be trouble with the immobilizer system, use the hand-held tester to check for trouble and troubleshoot it. (b) 1 2 3 4 5 6 7 8 Inspect the DLC3. The vehicle’s ECM uses the ISO 9141-2 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 9141-2 format. 9 10 11 12 13 14 15 16 DLC3 B50154 Standard: Terminal No. Condition Specified Condition 7 (Bus + Line) - 5 (Signal ground) During communication Pulse generation 4 (Chassis Ground) - Body ground Constant Below 1 Ω 5 (Signal Ground) - Body ground Constant Below 1 Ω 16 (B+) - Body ground Constant 10 to 14 V HINT: Connect the cable of the hand-held tester to the DLC3, turn the ignition switch ON and attempt to use the hand-held tester. If the screen displays UNABLE TO CONNEC TO TO VEHICLE, a problem exists in the vehicle side or the tester side.
If communication is normal when the tester is connected to other vehicle, inspect the DLC3 of the original vehicle.
If communication is still impossible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester’s instruction manual. 2. CHECK DIAGNOSIS (a) Using the hand-held tester, check for DTC. NOTICE: Hand-held tester only: When the diagnosis system is changed from normal mode to check mode, all DTCs and freeze frame data recorded in normal mode will be erased. Before changing modes, always check the DTCs and freeze frame data, and make a note of them. (1) Prepare the hand-held tester. (2) Connect the hand-held tester to the DLC3 under the instrument panel lower pad. (3) Turn the ignition switch ON and push the hand-held tester switch ON. (4) Use the hand-held tester to check for DTCs and freeze frame data, and make a note of them (for operating instructions, see the hand-held tester instruction book). (5) Confirm the details of the DTCs. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2178 05-1989 DIAGNOSTICS (b) - ENGINE IMMOBILIZER SYSTEM Either of the following procedures will erase the DTCs and freeze frame data. (1) Operating the hand-held tester to erase the codes (see the instruction manual for the hand-held tester). (2) Disconnecting the battery terminals or ECU-B fuse. DATA LIST 3. HINT: Using the hand-held tester DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to shorten labor time. (a) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch ON. (c) Read the DATA LIST according to the display on the tester. Transponder key ECU assy: Item Measurement Item/ Display (Range) KEY SW Unlock warning switch signal/ ON or OFF IG SW Ignition switch signal/ ON or OFF IMMOBILISER Immobilizer system status/ SET or UNSET RESPONSE Transponder chip data/ NG or OK NG: Data error OK: Data OK FRAME Transponder chip data/ NG or OK NG: Data error OK: Data OK SERIAL NUMBER Transponder chip data/ NG or OK NG: Data error OK: Data OK ENCRYPT CODE Transponder chip data/ NG or OK NG: Data error OK: Data OK STATUS Transponder chip data/ NG or OK NG: Data error OK: Data OK BCC Transponder chip signal/ NG or OK SUB KEY Sub-key code signal/ NOMATCH or MATCH NOMATCH: Unmatched sub-key code is sent MATCH: Sub-key code is sent MASTER KEY Master key code signal/ NOMATCH or MATCH NOMATCH: Unmatched master key code is sent MATCH: Master key code is sent REGIST SUB CODE REGIST MAS CODE Normal Condition OFF: Key is in ignition key cylinder ON: No key is in ignition key cylinder OFF: Ignition switch is in OFF or ACC position ON: Ignition switch is in ON position UNSET: Without key SET: Ignition switch ON NG: Incorrect data sending OK: Correct data sending Number of registered sub-key/ min. 0, max. 15 Number of registered sub-key Number of registered master key/ min. 0, max. 15 Number of registered master key REG CODE SPACE Memory space for key codes registration/ NOT FUL or FULL ANTENNA COIL Antenna coil condition/ NORMAL or FAIL NOT FUL: Possible to resister more key codes FULL: Cannot register any more key codes NORMAL: Antenna coil is normal FAIL: Antenna coil is malfunctioning 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2179 05-1990 DIAGNOSTICS - ENGINE IMMOBILIZER SYSTEM 4. ACTIVE TEST HINT: Performing the hand-held tester ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to shorten labor time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch ON. (c) Perform the ACTIVE TEST according to the display on the tester. Transponder key ECU assy: Item Test Details SECURITY INDIC Turn security indicator ON/OFF 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2180 05-1997 DIAGNOSTICS - ENGINE IMMOBILIZER SYSTEM 052IG-12 PROBLEM SYMPTOMS TABLE Problem Symptom Suspected Area See Page 1. Key 05-2003 05-2004 05-2005 05-2006 05-2009 05-2001 05-2006 05-2010 05-1998 05-2001 05-2006 05-2009 05-2010 2. Transponder key amplifier Engine does not start 3. Transponder key ECU assy 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2187 05-1993 DIAGNOSTICS - ENGINE IMMOBILIZER SYSTEM 05A27-21 TERMINALS OF ECU 1. CHECK TRANSPONDER KEY AMPLIFIER T7 B65593 (a) Disconnect the T7 amplifier connector, and measure the resistance between the terminal of the wire harness side connector and body ground. Standard: Symbols (Terminal No.) Wiring Color Condition GND (T7-7) Body ground R - Body ground Standard Below 1 Ω Constant If the result is not as specified, there may be a malfunction on the wire harness side. (b) Reconnect the T7 amplifier connector, and measure the resistance and voltage of each terminal of the connector. Standard: Symbols (Terminal No.) VC5 (T7-1) - Wiring Color Condition Standard B-R No key in ignition key cylinder → With key 0 V → 10 to 14 V CODE(T7-4) GND (T7-7) GR - R No key in ignition key cylinder → With key Pulse generation (see waveform 1) TXCT (T7-5) GND (T7-7) W-R No key in ignition key cylinder → With key Pulse generation (see waveform 2) GND (T7-7) Body ground R - Body ground GND (T7-7) Below 1 Ω Constant If the result is not as specified, the amplifier may have a malfunction. 20 ms 5V (c) Inspect using an oscilloscope. Waveform 1 (Reference): Terminal CODE - GND Tool Setting 5 V/DIV., 20 ms/DIV. Condition Ignition switch ON B55023 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2183 05-1994 DIAGNOSTICS ENGINE IMMOBILIZER SYSTEM Waveform 2 (Reference): 10 ms 10 V - Terminal TXCT - GND Tool Setting 10 V/DIV., 10 ms/DIV. Condition Ignition switch ON B55024 2. CHECK TRANSPONDER KEY ECU ASSY T14 B50659 (a) Disconnect the T14 ECU connector, and measure the voltage and resistance between each terminal of the wire harness side connector. Standard: Symbols (Terminal No.) Wiring Color AGND (T14-13) Body ground Condition Specified Condition R - Body ground Constant Below 1 Ω +B (T14-1) GND (T14-14) P - W-B Constant 10 to 14 V IG (T14-2) AGND (T14-13) P-R Ignition switch OFF → ON KSW (T14-10) AGND (T14-13) G-R No key in ignition key cylinder → With key 0 V → 10 to 14 V 10 kΩ or higher → Below 1 Ω If the result is not as specified, there may be a malfunction on the wire harness side. (b) Reconnect the T14 ECU connector, and measure the voltage between each terminal of the connector. Standard: Symbols (Terminal No.) Wiring Color KSW (T14-10) AGND (T14-13) Condition Specified Condition G-R No key in ignition key cylinder → With key 10 to 14 V → 0 V VC5 (T14-8) AGND (T14-13) B-R Ignition switch OFF → ON 0 V → 4.5 to 5.5 V TXCT (T14-12) AGND (T14-13) W-R Ignition switch OFF → ON Pulse generation (see waveform 1) CODE (T14-11) AGND (T14-13) GR - R Ignition switch OFF → ON Pulse generation (see waveform 2) EFIO (T14-6) AGND (T14-13) B-R Ignition switch OFF → ON Pulse generation (see waveform 3) EFII (T14-7) AGND (T14-13) V-R Ignition switch OFF → ON Pulse generation (see waveform 4) If the result is not as specified, the ECU may have a malfunction. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2184 05-1995 DIAGNOSTICS 5V 20 ms (c) - ENGINE IMMOBILIZER SYSTEM Inspect using an oscilloscope. Waveform 1 (Reference): Terminal TXCT - GND Tool Setting 5 V/DIV., 20 ms/DIV. Condition Ignition switch ON B52544 5V 20 ms Waveform 2 (Reference): Terminal CODE - GND Tool Setting 5 V/DIV., 20 ms/DIV. Condition Ignition switch ON B52545 10 V 100 ms Waveform 3 (Reference): Terminal EFIO - GND Tool Setting 10 V/DIV., 100 ms/DIV. Condition Ignition switch ON B52547 10 V 100 ms Waveform 4 (Reference): Terminal EFII - GND Tool Setting 10 V/DIV., 100 ms/DIV. Condition Constant B52548 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2185 05-1996 DIAGNOSTICS 3. - ENGINE IMMOBILIZER SYSTEM CHECK ECM E7 E8 E6 E9 E5 B50745 (a) Disconnect the E6 and E7 ECM connectors, and measure the voltage and resistance between each terminal of the wire harness side connectors. Standard: Symbols (Terminal No.) Wiring Color Condition Specified Condition IMI (E6-27) E1 (E9-1)*1 (E7-1)*2 B - BR No key in ignition key cylinder → With key Pulse generation (see waveform 1) IMO (E6-26) E1 (E9-1)*1 (E7-1)*2 V - BR No key in ignition key cylinder → With key Pulse generation (see waveform 2) E1 (E9-1)*1 (E7-1)*2 Body ground BR - Body ground Below 1 Ω Constant If the result is not as specified, there may be a malfunction on the wire harness side. *1: 2AZ-FE *2: 3MZ-FE 10 V 100 ms (b) Inspect using an oscilloscope. Waveform 1 (Reference): Terminal IMI - GND Tool Setting 10 V/DIV., 100 ms/DIV. Condition Ignition switch ON B52547 10 V 100 ms Waveform 2 (Reference): Terminal IMO - GND Tool Setting 10 V/DIV., 100 ms/DIV. Condition Constant B52548 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2186 05-1233 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 0525D-05 B0100/13 SHORT IN D SQUIB CIRCUIT CIRCUIT DESCRIPTION The D squib circuit consists of the airbag sensor assy center, the spiral cable sub-assy and the horn button assy. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B0100/13 is recorded when a short circuit is detected in the D squib circuit. DTC No. B0100/13 DTC Detecting Condition Trouble Area
Short circuit between D+ wire harness and D- wire harness of D squib
D squib malfunction
Spiral cable sub-assy malfunction
Airbag sensor assy center malfunction
Horn button assy (D squib)
Spiral cable sub-assy
Airbag sensor assy center
Cowl wire WIRING DIAGRAM Airbag Sensor Assy Center D Squib 2 1 Y-B 14 A17 D+ 1 2 Y 13 A17 D- 1 4 Y-R 16 A17 D2+ 2 3 Y-G 17 A17 D2- A20 Spiral Cable Sub-assy H43063 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1423 05-1234 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 (a) (b) (c) (d) CHECK CONNECTOR Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the horn button assy. Check that the spiral cable sub-assy connectors (on the horn button assy side) are not damaged. OK: The lock button is not disengaged, or the claw of the lock is not deformed or damaged. NG REPLACE SPIRAL CABLE SUB-ASSY (SEE PAGE 60-26 ) OK 2 CHECK D SQUIB CIRCUIT(AIRBAG SENSOR ASSY CENTER - HORN BUTTON ASSY) (a) D Squib F E Spiral Cable Sub-assy D C B Airbag A Sensor Assy Center D- (b) (c) Disconnect the connector from the airbag sensor assy center. Release the activation prevention mechanism built into connector ”B” (see page 05-1207 ). Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition D+ - D- Always 1 MΩ or Higher D+ Color: Black H01001 C89244 H41475 NG Go to step 5 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1424 05-1235 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER D Squib F E Spiral Cable Sub-assy D C (a) (b) Airbag Sensor Assy Center (c) (d) (e) (f) DTC B0100/13 DLC3 (g) CG H01002 H10600 H40103 TC H40030 Connect the connectors to the airbag sensor assy center. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0100/13 is not output. HINT: Codes other than code B0100/13 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1425 05-1236 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK HORN BUTTON ASSY(D SQUIB) D Squib F E Spiral Cable Sub-assy D C (a) (b) Airbag Sensor Assy Center (c) (d) (e) DLC3 DTC B0100/13 CG (i) TC H01003 H10600 H40103 (f) (g) (h) H40031 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Connect the connectors to the horn button assy. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0100/13 is not output. HINT: Codes other than code B0100/13 may be output at this time, but they are not related to this check. NG REPLACE HORN BUTTON ASSY (SEE PAGE 60-17 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1426 05-1237 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK COWL WIRE Cowl Wire D Squib F E Spiral Cable Sub-assy D C B (a) Airbag Sensor A Assy Center A20 Disconnect the cowl wire connector from the spiral cable sub-assy . HINT: The activation prevention mechanism of connector ”B” has already been released. (b) Measure the resistance according to the value(s) in the table below. Standard: D+ Tester connection Condition Specified condition A20-1 (D+) - A20-2 (D-) Always 1 MΩ or Higher D- NG H43066 H41440 REPAIR OR REPLACE COWL WIRE OK 6 CHECK SPIRAL CABLE SUB-ASSY (a) D Squib F E Spiral Cable Sub-assy D C B Airbag Sensor A Assy Center (b) Release the activation prevention mechanism built into connector ”D” (see page 05-1207 ). Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition D+ - D- Always 1 MΩ or Higher DD+ Color: Black NG H01000 C89244 H41479 REPLACE SPIRAL CABLE SUB-ASSY (SEE PAGE 60-26 ) 0K USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1427 05-1238 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 0525E-04 B0101/14 OPEN IN D SQUIB CIRCUIT CIRCUIT DESCRIPTION The D squib circuit consists of the airbag sensor assy center, the spiral cable sub-assy and the horn button assy. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B0101/14 is recorded when an open circuit is detected in the D squib circuit. DTC No. B0101/14 DTC Detecting Condition Trouble Area
Open circuit in D+ wire harness or D- wire harness of D squib
D squib malfunction
Spiral cable sub-assy malfunction
Airbag sensor assy center malfunction
Horn button assy (D squib)
Spiral cable sub-assy
Airbag sensor assy center
Cowl wire WIRING DIAGRAM see page 05-1233 . INSPECTION PROCEDURE 1 CHECK D SQUIB CIRCUIT(AIRBAG SENSOR ASSY CENTER - HORN BUTTON ASSY) (a) (b) D Squib F E Spiral Cable Sub-assy DC B Airbag Sensor A Assy Center D- (c) (d) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the horn button assy. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition D+ - D- Always Below 1 Ω D+ Color: Black H01001 C89244 H41475 NG Go to step 4 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1428 05-1239 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER D Squib F E Spiral Cable Sub-assy D- DC Airbag Sensor Assy Center D+ Service Wire Color: Black DTC B0101/14 DLC3 CG H01002 C89252 H10600 W02044 TC H44124 (a) Connect the connector to the airbag sensor assy center. (b) Using a service wire, connect D+ and D- of connector ”E”. NOTICE:
Twist the end of the service wire in order to insert it into the connector.
Do not forcibly insert the twisted service wire into the terminals of the connector when connecting. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Clear the DTCs stored in memory (see page 05-1215 ). (f) Turn the ignition switch to the LOCK position. (g) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (h) Check the DTCs (see page 05-1215 ). OK: DTC B0101/14 is not output. HINT: Codes other than code B0101/14 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1429 05-1240 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK HORN BUTTON ASSY(D SQUIB) (a) (b) D Squib FE Spiral Cable Sub-assy DC Airbag Sensor Assy Center (c) (d) (e) (f) DTC B0101/14 DLC3 (g) (h) (i) CG TC H01003 H10600 W02044 H40036 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”E”. Connect the connectors to the horn button assy. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0101/14 is not output. HINT: Codes other than code B0101/14 may be output at this time, but they are not related to this check. NG REPLACE HORN BUTTON ASSY (SEE PAGE 60-17 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1430 05-1241 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK COWL WIRE (a) Cowl Wire D Squib F E Spiral Cable Sub-assy D C B Airbag Sensor A Assy Center (b) A20 Disconnect the cowl wire connector from the spiral cable sub-assy . Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A20-1 (D+) - A20-2 (D-) Always Below 1 Ω D+ DH41440 NG H43066 REPAIR OR REPLACE COWL WIRE OK 5 CHECK SPIRAL CABLE SUB-ASSY (a) D Squib F E Spiral Cable Sub-assy D C B Airbag Sensor A Assy Center Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition D+ - D- Always Below 1 Ω DD+ Color: Black NG H01000 C89244 H41479 REPLACE SPIRAL CABLE SUB-ASSY (SEE PAGE 60-26 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1431 05-1242 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 0525F-20 B0102/11 SHORT IN D SQUIB CIRCUIT (TO GROUND) CIRCUIT DESCRIPTION The D squib circuit consists of the airbag sensor assy center, the spiral cable sub-assy and the horn button assy. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B0102/11 is recorded when a short to ground is detected in the D squib circuit. DTC No. B0102/11 DTC Detecting Condition Trouble Area
Short circuit in D squib wire harness (to ground)
D squib malfunction
Spiral cable sub-assy malfunction
Airbag sensor assy center malfunction
Horn button assy (D squib)
Spiral cable sub-assy
Airbag sensor assy center
Cowl wire WIRING DIAGRAM see page 05-1233 . INSPECTION PROCEDURE 1 CHECK D SQUIB CIRCUIT(AIRBAG SENSOR ASSY CENTER - HORN BUTTON ASSY) (a) (b) D Squib F E Spiral Cable Sub-assy DC B Airbag Sensor A Assy Center DD+ Color: Black H01001 C89244 (c) (d) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the horn button assy. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition D+ - Body ground Always 1 MΩ or Higher D- - Body ground Always 1 MΩ or Higher H41475 NG Go to step 4 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1432 05-1243 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER D Squib F E Spiral Cable Sub-assy DC Airbag Sensor Assy Center D+ D- Service Wire Color: Black DLC3 CG H01002 C89252 H10600 C91338 DTC B0102/11 TC H44123 (a) Connect the connector to the airbag sensor assy center. (b) Using a service wire, connect D+ and D- of connector ”E”. NOTICE:
Twist the end of the service wire in order to insert it into the connector.
Do not forcibly insert the twisted service wire into the terminals of the connector when connecting. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Clear the DTCs stored in memory (see page 05-1215 ). (f) Turn the ignition switch to the LOCK position. (g) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (h) Check the DTCs (see page 05-1215 ). OK: DTC B0102/11 is not output. HINT: Codes other than code B0102/11 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1433 05-1244 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK HORN BUTTON ASSY(D SQUIB) (a) (b) D Squib FE Spiral Cable Sub-assy DC Airbag Sensor Assy Center (c) (d) (e) (f) DTC B0102/11 DLC3 (g) (h) (i) CG H01003 H10600 W02042 TC H40037 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”E”. Connect the connectors to the horn button assy. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0102/11 is not output. HINT: Codes other than code B0102/11 may be output at this time, but they are not related to this check. NG REPLACE HORN BUTTON ASSY (SEE PAGE 60-17 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1434 05-1245 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK COWL WIRE (a) Cowl Wire D Squib F E Spiral Cable Sub-assy D C B Airbag Sensor A Assy Center (b) A20 D+ Disconnect the cowl wire connector from the spiral cable sub-assy . Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A20-1 (D+) Body ground Always 1 MΩ or Higher A20-2 (D-) Body ground Always 1 MΩ or Higher D- NG H43066 H41440 REPAIR OR REPLACE COWL WIRE OK 5 CHECK SPIRAL CABLE SUB-ASSY (a) Cowl Wire D Squib F E Spiral Cable Sub-assy D C B Airbag Sensor A Assy Center Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition D+ - Body ground Always 1 MΩ or Higher D- - Body ground Always 1 MΩ or Higher DD+ Color: Black NG H01000 C89244 H41479 REPLACE SPIRAL CABLE SUB-ASSY (SEE PAGE 60-26 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1435 05-1246 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 0525G-17 B0103/12 SHORT IN D SQUIB CIRCUIT (TO B+) CIRCUIT DESCRIPTION The D squib circuit consists of the airbag sensor assy center, the spiral cable sub-assy and the horn button assy. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B0103/12 is recorded when a short to B+ is detected in the D squib circuit. DTC No. B0103/12 DTC Detecting Condition Trouble Area
Short circuit in D squib wire harness (to B+)
D squib malfunction
Spiral cable sub-assy malfunction
Airbag sensor assy center malfunction
Horn button assy (D squib)
Spiral cable sub-assy
Airbag sensor assy center
Cowl wire WIRING DIAGRAM see page 05-1233 . INSPECTION PROCEDURE 1 CHECK D SQUIB CIRCUIT(AIRBAG SENSOR ASSY CENTER - HORN BUTTON ASSY) (a) (b) D Squib F E Spiral Cable Sub-assy DC B Airbag Sensor A Assy Center (d) (e) (f) DD+ Color: Black H01001 C89244 (c) H41475 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the horn button assy. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition D+ - Body ground Ignition switch ON Below 1 V D- - Body ground Ignition switch ON Below 1 V NG Go to step 4 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1436 05-1247 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER H42141 (a) (b) D Squib F E Spiral Cable Sub-assy D- DC Airbag Sensor Assy Center D+ Service Wire Color: Black DTC B0103/12 DLC3 CG H01002 C89252 H10600 TC H44122 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connector to the airbag sensor assy center. (d) Using a service wire, connect D+ and D- of connector ”E”. NOTICE:
Twist the end of the service wire in order to insert it into the connector.
Do not forcibly insert the twisted service wire into the terminals of the connector when connecting. (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (see page 05-1215 ). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (see page 05-1215 ). OK: DTC B0103/12 is not output. HINT: Codes other than code B0103/12 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1437 05-1248 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK HORN BUTTON ASSY(D SQUIB) (a) (b) D Squib FE Spiral Cable Sub-assy DC Airbag Sensor Assy Center (c) (d) (e) (f) DLC3 CG DTC B0103/12 (g) (h) (i) TC H01003 H10600 W02043 H40038 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”E”. Connect the connectors to the horn button assy. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0103/12 is not output. HINT: Codes other than code B0103/12 may be output at this time, but they are not related to this check. NG REPLACE HORN BUTTON ASSY (SEE PAGE 60-17 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1438 05-1249 DIAGNOSTICS 4 F E Spiral Cable Sub-assy D C B Airbag Sensor A Assy Center (a) (b) (c) (d) A20 (e) (f) D+ DH41440 SUPPLEMENTAL RESTRAINT SYSTEM CHECK COWL WIRE Cowl Wire D Squib - H43066 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the cowl wire connector from the spiral cable sub-assy . Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A20-1 (D+) Body ground Ignition switch ON Below 1 V A20-2 (D-) Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE COWL WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1439 05-1250 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK SPIRAL CABLE SUB-ASSY (a) Cowl Wire D Squib F E Spiral Cable Sub-assy D C B Airbag Sensor A Assy Center Measure the voltage according to the value(s) in the table below when the ignition switch is in the ON position. Standard: Tester connection Condition Specified condition D+ - Body ground Ignition switch ON Below 1 V D- - Body ground Ignition switch ON Below 1 V DD+ Color: Black H01000 C89244 H41479 NG REPLACE SPIRAL CABLE SUB-ASSY (SEE PAGE 60-26 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1440 05-1251 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 0525H-05 B0105/53 SHORT IN P SQUIB CIRCUIT CIRCUIT DESCRIPTION The P squib circuit consists of the airbag sensor assy center and the front passenger airbag assy. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B0105/53 is recorded when a short circuit is detected in the P squib circuit. DTC No. B0105/53 DTC Detecting Condition Trouble Area
Short circuit between P+ wire harness and P- wire harness of P squib
P squib malfunction
Airbag sensor assy center malfunction
Front passenger airbag assy (P squib)
Airbag sensor assy center
Cowl wire WIRING DIAGRAM Airbag Sensor Assy Center A19 P Squib Y-B 1 Y 2 10 A17 P+ 11 A17 P- H01454 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1441 05-1252 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 CHECK COWL WIRE(P SQUIB CIRCUIT) (a) (b) Cowl Wire P Squib D C B Airbag Sensor A Assy Center (c) (d) A19 (e) P+ P- R14286 H41424 H41932 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the front passenger airbag assy. Release the activation prevention mechanism built into connector ”B” (see page 05-1207 ). Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A19-1 (P+) A19-2 (P-) Always 1 MΩ or Higher NG REPAIR OR REPLACE COWL WIRE OK 2 CHECK AIR BAG SENSOR ASSY CENTER (a) (b) P Squib D C Airbag Sensor Assy Center (c) DTC B0105/53 DLC3 (d) (e) (f) (g) CG H01023 H10600 H01077 TC H42107 Connect the connector to the airbag sensor assy center. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0105/53 is not output. HINT: Codes other than code B0105/53 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1442 05-1253 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT PASSENGER AIRBAG ASSY(P SQUIB) (a) (b) P Squib DC DLC3 CG Airbag Sensor Assy Center (c) (d) (e) DTC B0105/53 (f) (g) (h) TC H01024 H10600 H01077 H40041 (i) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Connect the connector to the front passenger airbag assy. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0105/53 is not output. HINT: Codes other than code B0105/53 may be output at this time, but they are not related to this check. NG REPLACE FRONT PASSENGER AIRBAG ASSY (SEE PAGE 60-29 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1443 05-1254 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 0525I-04 B0106/54 OPEN IN P SQUIB CIRCUIT CIRCUIT DESCRIPTION The P squib circuit consists of the airbag sensor assy center and the front passenger airbag assy. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B0106/54 is recorded when an open circuit is detected in the P squib circuit. DTC No. DTC Detecting Condition Trouble Area
Open circuit in P+ wire harness or P- wire harness of P squib
P squib malfunction
Airbag sensor assy center malfunction B0106/54
Front passenger airbag assy (P squib)
Airbag sensor assy center
Cowl wire WIRING DIAGRAM see page 05-1251 . INSPECTION PROCEDURE 1 CHECK COWL WIRE(P SQUIB CIRCUIT) (a) (b) Cowl Wire P Squib D C B Airbag Sensor A Assy Center (c) (d) A19 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the front passenger airbag assy. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A19-1 (P+) - A19-2 (P-) Always Below 1 Ω P+ R14286 H41424 P- H41932 NG REPAIR OR REPLACE COWL WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1444 05-1255 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER (a) (b) Cowl Wire P Squib Airbag Sensor Assy Center D C (c) A19 (d) P- (e) (f) (g) P+ SST DLC3 DTC B0106/54 HINT: Codes other than code B0106/54 may be output at this time, but they are not related to this check. CG H01023 H16855 H10600 H01078 (h) Connect the connector to the airbag sensor assy center. Using SST, connect A19-1 (P+) and A19-2 (P-) of connector ”C”. SST 09843-18040 Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0106/54 is not output. TC H41934 NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1445 05-1256 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT PASSENGER AIRBAG ASSY(P SQUIB) (a) (b) P Squib DC Airbag Sensor Assy Center (c) (d) (e) DLC3 DTC B0106/54 (g) (h) (i) CG TC H01024 H10600 H01078 (f) H40043 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the SST from connector ”C”. Connect the connector to the front passenger airbag assy. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0106/54 is not output. HINT: Codes other than code B0106/54 may be output at this time, but they are not related to this check. NG REPLACE FRONT PASSENGER AIRBAG ASSY (SEE PAGE 60-29 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1446 05-1257 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 0525J-17 B0107/51 SHORT IN P SQUIB CIRCUIT (TO GROUND) CIRCUIT DESCRIPTION The P squib circuit consists of the airbag sensor assy center and the front passenger airbag assy. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B0107/51 is recorded when a short to ground is detected in the P squib circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in P squib wire harness (to ground)
P squib malfunction
Airbag sensor assy center malfunction B0107/51
Front passenger airbag assy (P squib)
Airbag sensor assy center
Cowl wire WIRING DIAGRAM see page 05-1251 . INSPECTION PROCEDURE 1 CHECK COWL WIRE(P SQUIB CIRCUIT) (a) (b) Cowl Wire P Squib D C B Airbag Sensor A Assy Center (c) (d) A19 P+ R14286 H41424 P- H41932 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the front passenger airbag assy. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A19-1 (P+) Body ground Always 1 MΩ or Higher A19-2 (P-) Body ground Always 1 MΩ or Higher NG REPAIR OR REPLACE COWL WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1447 05-1258 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER (a) (b) Cowl Wire P Squib Airbag Sensor Assy Center D C (c) A19 (d) PP+ (e) (f) (g) SST DTC B0107/51 DLC3 HINT: Codes other than code B0107/51 may be output at this time, but they are not related to this check. CG H01023 H40538 H40579 H10600 H01075 (h) Connect the connector to the airbag sensor assy center. Using SST, connect A19-1 (P+) and A19-2(P-) of connector ”C”. SST 09843-18040 Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0107/51 is not output. TC H44680 NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1448 05-1259 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT PASSENGER AIRBAG ASSY(P SQUIB) (a) (b) P Squib DC DLC3 CG H01024 H10600 Airbag Sensor Assy Center (c) (d) (e) DTC B0107/51 (g) (h) (i) TC H01075 (f) H40045 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the SST from connector ”C”. Connect the connector to the front passenger airbag assy. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0107/51 is not output. HINT: Codes other than code B0107/51 may be output at this time, but they are not related to this check. NG REPLACE FRONT PASSENGER AIRBAG ASSY (SEE PAGE 60-29 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1449 05-1260 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 0525K-17 B0108/52 SHORT IN P SQUIB CIRCUIT (TO B+) CIRCUIT DESCRIPTION The P squib circuit consists of the airbag sensor assy center and the front passenger airbag assy. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B0108/52 is recorded when a short to B+ is detected in the P squib circuit. DTC No. DTC Detecting Condition B0108/52 Trouble Area
Short circuit in P squib wire harness (to B+)
P squib malfunction
Airbag sensor assy center malfunction
Front passenger airbag assy (P squib)
Airbag sensor assy center
Cowl wire WIRING DIAGRAM see page 05-1251 . INSPECTION PROCEDURE 1 CHECK COWL WIRE(P SQUIB CIRCUIT) (a) (b) Cowl Wire P Squib D C B Airbag Sensor A Assy Center (c) (d) (e) (f) A19 P+ R14286 H41424 P- H41932 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the front passenger airbag assy. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A19-1 (P+) Body ground Ignition switch ON Below 1 V A19-2 (P-) Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE COWL WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1450 05-1261 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER (a) (b) Cowl Wire Airbag Sensor Assy Center P Squib D C A19 (c) (d) P- (e) P+ (f) SST DLC3 DTC B0108/52 (g) (h) (i) (j) CG H01023 H40538 H10600 TC H01076 H40581 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Connect the connector to the airbag sensor assy center. Using SST, connect A19-1 (P+) and A19-2 (P-) of connector ”C”. SST 09843-18040 Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0108/52 is not output. HINT: Codes other than code B0108/52 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1451 05-1262 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT PASSENGER AIRBAG ASSY(P SQUIB) (a) (b) P Squib DC DLC3 CG H01024 H10600 Airbag Sensor Assy Center (c) (d) DTC B0108/52 (f) (e) (g) (h) (i) TC H01076 H40047 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the SST from connector ”C”. Connect the connector to the front passenger airbag assy. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0108/52 is not output. HINT: Codes other than code B0108/52 may be output at this time, but they are not related to this check. NG REPLACE FRONT PASSENGER AIRBAG ASSY (SEE PAGE 60-29 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1452 05-1263 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 0525L-04 B0110/43 SHORT IN SIDE SQUIB (RH) CIRCUIT CIRCUIT DESCRIPTION The side squib RH circuit consists of the airbag sensor assy center and the separate type front seat back assy (side squib RH). The circuit instructs the SRS to deploy when deployment conditions are met. DTC B0110/43 is recorded when a short circuit is detected in the side squib RH circuit. DTC No. B0110/43 DTC Detecting Condition Trouble Area
Short circuit between SFR+ wire harness and SFR- wire harness of side squib RH
Side squib (RH) malfunction
Airbag sensor assy center malfunction
Separate type front seat back assy (Side squib RH)
Airbag sensor assy center
Floor wire WIRING DIAGRAM Airbag Sensor Assy Center S19 Side Squib (RH) 1 Y-B (*1) 2 Y (*1) 5 A18 SFR+ 6 A18 SFR- *1: w/ Curtain Shield Airbag H01454 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1453 05-1264 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 CHECK FLOOR WIRE(SIDE SQUIB RH CIRCUIT) (a) (b) Floor Wire Side Squib RH C A D Airbag Sensor Assy Center B (c) (d) S19 (e) SFR- SFR+ H40977 H01019 H42497 H42849 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the separate type front seat back assy (side squib RH). Release the activation prevention mechanism built into connector ”B” (see page 05-1207 ). Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition S19-1 (SFR+) S19-2 (SFR-) Always 1 MΩ or Higher NG REPAIR OR REPLACE FLOOR WIRE OK 2 CHECK AIR BAG SENSOR ASSY CENTER (a) (b) Side Squib RH Airbag Sensor Assy Center (c) (d) (e) (f) D C DLC3 DTC B0110/43 (g) CG H01020 H10600 H01069 TC H42111 Connect the connector to the airbag sensor assy center. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0110/43 is not output. HINT: Codes other than code B0110/43 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1454 05-1265 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK SEPARATE TYPE FRONT SEAT BACK ASSY(SIDE SQUIB RH) (a) (b) Side Squib RH Airbag Sensor Assy Center (c) (d) DC DLC3 (e) DTC B0110/43 (f) (g) (h) CG H01021 H10600 H01069 TC H40979 (i) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Connect the connector to the separate type front seat back assy (side squib RH). Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0110/43 is not output. HINT: Codes other than code B0110/43 may be output at this time, but they are not related to this check. NG REPLACE SEPARATE TYPE FRONT SEAT BACK ASSY(SEE PAGE 72-1 1, 72-19 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1455 05-1266 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 0525M-04 B0111/44 OPEN IN SIDE SQUIB (RH) CIRCUIT CIRCUIT DESCRIPTION The side squib RH circuit consists of the airbag sensor assy center and the separate type front seat back assy (side squib RH). The circuit instructs the SRS to deploy when deployment conditions are met. DTC B0111/44 is recorded when an open circuit is detected in the side squib RH circuit. DTC No. DTC Detecting Condition Trouble Area
Open circuit in SFR+ wire harness or SFR- wire harness of side squib RH
Side squib (RH) malfunction
Airbag sensor assy center malfunction B0111/44
Separate type front seat back assy (Side squib RH)
Airbag sensor assy center
Floor wire WIRING DIAGRAM see page 05-1263 . INSPECTION PROCEDURE 1 CHECK FLOOR WIRE(SIDE SQUIB RH CIRCUIT) (a) (b) Floor Wire Side Squib RH C A D SFR+ H40977 H01019 H42497 B Airbag Sensor Assy Center (c) (d) S19 SFR- H42849 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait at least for 90 seconds. Disconnect the connectors from the airbag sensor assy center and the separate type front seat back assy (side squib RH). Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition S19-1 (SFR+) S19-2 (SFR-) Always Below 1 Ω NG REPAIR OR REPLACE FLOOR WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1456 05-1267 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER (a) (b) Floor Wire Airbag Sensor Assy Center Side Squib RH C D S19 SFR+ SFR- Service Wire DLC3 CG H01020 H42496 H10600 H01070 DTC B0111/44 TC H42850 Connect the connector to the airbag sensor assy center. Using a service wire, connect S19-1 (SFR+) and S19-2 (SFR-) of connector ”C”. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Clear the DTCs stored in memory (see page 05-1215 ). (f) Turn the ignition switch to the LOCK position. (g) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (h) Check the DTCs (see page 05-1215 ). OK: DTC B0111/44 is not output. HINT: Codes other than code B0111/44 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1457 05-1268 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK SEPARATE TYPE FRONT SEAT BACK ASSY(SIDE SQUIB RH) (a) (b) Side Squib RH Airbag Sensor Assy Center (c) (d) (e) DC DLC3 CG H01021 H10600 H01070 DTC B0111/44 (f) (g) (h) (i) TC H40981 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”C”. Connect the connector to the separate type front seat back assy (side squib RH). Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0111/44 is not output. HINT: Codes other than code B0111/44 may be output at this time, but they are not related to this check. NG REPLACE SEPARATE TYPE FRONT SEAT BACK ASSY (SEE PAGE 72-1 1, 72-19 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1458 05-1269 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 0525N-16 B0112/41 SHORT IN SIDE SQUIB (RH) CIRCUIT (TO GROUND) CIRCUIT DESCRIPTION The side squib RH circuit consists of the airbag sensor assy center and the separate type front seat back assy (side squib RH). The circuit instructs the SRS to deploy when deployment conditions are met. DTC B0112/41 is recorded when a short to ground is detected in the side squib RH circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in side squib (RH) wire harness (to ground)
Side squib (RH) malfunction
Airbag sensor assy center malfunction B0112/41
Separate type front seat back assy (Side squib RH)
Airbag sensor assy center
Floor wire WIRING DIAGRAM see page 05-1263 . INSPECTION PROCEDURE 1 CHECK FLOOR WIRE(SIDE SQUIB RH CIRCUIT) (a) (b) Floor Wire Side Squib RH C A D Airbag Sensor Assy Center (c) (d) B S19 SFR+ H40977 H01019 H42497 SFR- Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the separate type front seat back assy (side squib RH). Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition S19-1 (SFR+) Body ground Always 1 MΩ or Higher S19-2 (SFR-) Body ground Always 1 MΩ or Higher H42849 NG REPAIR OR REPLACE FLOOR WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1459 05-1270 DIAGNOSTICS 2 SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER (a) (b) Floor Wire Airbag Sensor Assy Center Side Squib RH C D S19 SFR+ SFR- Service Wire DLC3 CG H01020 H42496 H10600 - H01067 DTC B0112/41 TC H42851 Connect the connector to the airbag sensor assy center. Using a service wire, connect S19-1 (SFR+) and S19-2 (SFR-) of connector ”C”. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Clear the DTCs stored in memory (see page 05-1215 ). (f) Turn the ignition switch to the LOCK position. (g) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (h) Check the DTCs (see page 05-1215 ). OK: DTC B0112/41 is not output. HINT: Codes other than code B0112/41 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1460 05-1271 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK SEPARATE TYPE FRONT SEAT BACK ASSY(SIDE SQUIB RH) (a) (b) Side Squib RH Airbag Sensor Assy Center (c) (d) (e) DC DLC3 CG DTC B0112/41 (g) (h) (i) TC H01021 H10600 H01067 (f) H40983 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”C”. Connect the connector to the separate type front seat back assy (side squib RH). Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0112/41 is not output. HINT: Codes other than code B0112/41 may be output at this time, but they are not related to this check. NG REPLACE SEPARATE TYPE FRONT SEAT BACK ASSY (SEE PAGE 72-1 1, 72-19 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1461 05-1272 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 0525O-17 B0113/42 SHORT IN SIDE SQUIB (RH) CIRCUIT (TO B+) CIRCUIT DESCRIPTION The side squib RH circuit consists of the airbag sensor assy center and the separate type front seat back assy (side squib RH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0113/42 is recorded when a short to B+ is detected in the side squib RH circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in side squib (RH) wire harness (to B+)
Side squib (RH) malfunction
Airbag sensor assy center malfunction B0113/42
Separate type front seat back assy (Side squib RH)
Airbag sensor assy center
Floor wire WIRING DIAGRAM see page 05-1263 . INSPECTION PROCEDURE 1 CHECK FLOOR WIRE(SIDE SQUIB RH CIRCUIT) (a) (b) Floor Wire Side Squib RH C A D SFR+ H40977 H01019 H42497 B Airbag Sensor Assy Center (c) (d) S19 (e) (f) SFR- H42849 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the separate type front seat back assy (side squib RH). Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition S19-1 (SFR+) Body ground Ignition switch ON Below 1 V S19-2 (SFR-) Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE FLOOR WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1462 05-1273 DIAGNOSTICS 2 SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER (a) (b) Floor Wire Side Squib RH S19 C Airbag Sensor Assy Center D SFR+ SFRService Wire DLC3 CG H01020 H42496 H10600 - H01068 DTC B0113/42 TC H42852 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least for 90 seconds. (c) Connect the connector to the airbag sensor assy center. (d) Using a service wire, connect S19-1 (SFR+) and S19-2 (SFR-) of connector ”C”. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (see page 05-1215 ). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (see page 05-1215 ). OK: DTC B0113/42 is not output. HINT: Codes other than code B0113/42 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1463 05-1274 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK SEPARATE TYPE FRONT SEAT BACK ASSY(SIDE SQUIB RH) (a) (b) Side Squib RH Airbag Sensor Assy Center (c) (d) (e) DC DLC3 CG DTC B0113/42 (g) (h) (i) TC H01021 H10600 H01068 (f) H40985 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”C”. Connect the connector to the separate type front seat back assy (side squib RH). Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0113/42 is not output. HINT: Codes other than code B0113/42 may be output at this time, but they are not related to this check. NG REPLACE SEPARATE TYPE FRONT SEAT BACK ASSY (SEE PAGE 72-1 1, 72-19 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1464 05-1275 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 0525P-04 B0115/47 SHORT IN SIDE SQUIB (LH) CIRCUIT CIRCUIT DESCRIPTION The side squib LH circuit consists of the airbag sensor assy center and the separate type front seat back assy (side squib LH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0115/47 is recorded when a short circuit is detected in the side squib LH circuit. DTC No. B0115/47 DTC Detecting Condition Trouble Area
Short circuit between SFL+ wire harness and SFL- wire harness of side squib LH
Side squib (LH) malfunction
Airbag sensor assy center malfunction
Separate type front seat back assy (Side squib LH)
Airbag sensor assy center
Floor wire No.2 WIRING DIAGRAM Airbag Sensor Assy Center S18 Side Squib LH 1 Y-B (*1) 2 Y (*1) 12 A16 SFL+ 11 A16 SFL- *1: w/ Curtain Shield Airbag H01454 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1465 05-1276 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 CHECK FLOOR WIRE NO.2(SIDE SQUIB LH CIRCUIT) Side Squib LH A D C (a) (b) Floor Wire No.2 B Airbag Sensor Assy Center (c) S18 (d) SFL+ (e) SFL- H01016 H42497 H42853 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the separate type front seat back assy (side squib LH). Release the activation prevention mechanism built into connector ”B” (see page 05-1207 ). Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition S18-1 (SFL+) S18-2 (SFL-) Always 1 MΩ or Higher NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 2 CHECK AIR BAG SENSOR ASSY CENTER (a) (b) Side Squib LH D C (c) Airbag Sensor Assy Center (d) (e) (f) DLC3 DTC B0115/47 CG (g) TC H01017 H10600 H01073 H42153 Connect the connector to the airbag sensor assy center. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0115/47 is not output. HINT: Codes other than code B0115/47 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1466 05-1277 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK SEPARATE TYPE FRONT SEAT BACK ASSY(SIDE SQUIB LH) (a) (b) Side Squib LH DC Airbag Sensor Assy Center (c) (d) (e) DLC3 DTC B0115/47 CG (f) (g) (h) TC H01018 H10600 H01073 H40988 (i) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Connect the connector to the separate type front seat back assy (side squib LH). Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0115/47 is not output. HINT: Codes other than code B0115/47 may be output at this time, but they are not related to this check. NG REPLACE SEPARATE TYPE FRONT SEAT BACK ASSY (SEE PAGE 72-1 1, 72-19 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1467 05-1278 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 0525Q-04 B0116/48 OPEN IN SIDE SQUIB (LH) CIRCUIT CIRCUIT DESCRIPTION The side squib LH circuit consists of the airbag sensor assy center and the separate type front seat back assy (side squib LH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0116/48 is recorded when an open circuit is detected in the side squib LH circuit. DTC No. DTC Detecting Condition Trouble Area
Open circuit in SFL+ wire harness or SFL- wire harness of side squib LH
Side squib (LH) malfunction
Airbag sensor assy center malfunction B0116/48
Separate type front seat back assy (Side squib LH)
Airbag sensor assy center
Floor wire No.2 WIRING DIAGRAM see page 05-1275 . INSPECTION PROCEDURE 1 CHECK FLOOR WIRE NO.2(SIDE SQUIB LH CIRCUIT) Side Squib LH A D C (a) (b) Floor Wire No.2 B Airbag Sensor Assy Center (c) (d) S18 SFL+ H01016 H42497 SFL- H42853 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the separate type front seat back assy (side squib LH). Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition S18-1 (SFL+) S18-2 (SFL-) Always Below 1 Ω NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1468 05-1279 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER D S18 (a) (b) Floor Wire No.2 Side Squib LH C Airbag Sensor Assy Center SFL- SFL+ Service Wire DLC3 CG DTC B0116/48 TC H01017 H42496 H10600 H01074 H42854 Connect the connector to the airbag sensor assy center. Using a service wire, connect S18-1 (SFL+) and S18-2 (SFL-) of connector ”C”. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Clear the DTCs stored in memory (see page 05-1215 ). (f) Turn the ignition switch to the LOCK position. (g) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (h) Check the DTCs (see page 05-1215 ). OK: DTC B0116/48 is not output. HINT: Codes other than code B0116/48 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1469 05-1280 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK SEPARATE TYPE FRONT SEAT BACK ASSY(SIDE SQUIB LH) (a) (b) Side Squib LH DC Airbag Sensor Assy Center (c) (d) (e) DLC3 CG DTC B0116/48 (g) (h) (i) TC H01018 H10600 H01074 (f) H40990 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”C”. Connect the connector to the separate type front seat back assy (side squib LH). Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0116/48 is not output. HINT: Codes other than code B0116/48 may be output at this time, but they are not related to this check. NG REPLACE SEPARATE TYPE FRONT SEAT BACK ASSY (SEE PAGE 72-1 1, 72-19 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1470 05-1281 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 0525R-17 B0117/45 SHORT IN SIDE SQUIB (LH) CIRCUIT (TO GROUND) CIRCUIT DESCRIPTION The side squib LH circuit consists of the airbag sensor assy center and the separate type front seat back assy (side squib LH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0117/45 is recorded when a short to ground is detected in the side squib LH circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in side squib (LH) wire harness (to ground)
Side squib (LH) malfunction
Airbag sensor assy center malfunction B0117/45
Separate type front seat back assy (Side squib LH)
Airbag sensor assy center
Fioor wire No.2 WIRING DIAGRAM see page 05-1275 . INSPECTION PROCEDURE 1 CHECK FLOOR WIRE NO.2(SIDE SQUIB LH CIRCUIT) Side Squib LH A D C (a) (b) Floor Wire No.2 B Airbag Sensor Assy Center (c) (d) S18 SFL+ H01016 H42497 SFL- Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the separate type front seat back assy (side squib LH). Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition S18-1 (SFL+) Body ground Always 1 MΩ or Higher S18-2 (SFL-) Body ground Always 1 MΩ or Higher H42853 NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1471 05-1282 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER Side Squib LH D C S18 SFL+ Floor Wire No.2 Airbag Sensor Assy Center SFL- Service Wire DLC3 CG DTC B0117/45 TC H01017 H42496 H10600 H01071 H42855 (a) (b) Connect the connector to the airbag sensor assy center. Using a service wire, connect S18-1 (SFL+) and S18-2 (SFL-) of connector ”C”. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Clear the DTCs stored in memory (see page 05-1215 ). (f) Turn the ignition switch to the LOCK position. (g) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (h) Check the DTCs (see page 05-1215 ). OK: DTC B0117/45 is not output. HINT: Codes other than code B0117/45 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1472 05-1283 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK SEPARATE TYPE FRONT SEAT BACK ASSY(SIDE SQUIB LH) (a) (b) Side Squib LH DC Airbag Sensor Assy Center (c) (d) (e) DLC3 CG DTC B0117/45 (g) (h) (i) TC H01018 H10600 H01071 (f) H40992 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”C”. Connect the connector to the separate type front seat back assy (side squib LH). Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0117/45 is not output. HINT: Codes other than code B0117/45 may be output at this time, but they are not related to this check. NG REPLACE SEPARATE TYPE FRONT SEAT BACK ASSY(SEE PAGE 72-1 1, 72-19 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1473 05-1284 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 0525S-16 B0118/46 SHORT IN SIDE SQUIB (LH) CIRCUIT (TO B+) CIRCUIT DESCRIPTION The side squib LH circuit consists of the airbag sensor assy center and the separate type front seat back assy (side squib LH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0118/46 is recorded when a short to B+ is detected in the side squib LH circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in side squib (LH) wire harness (to B+)
Side squib (LH) malfunction
Airbag sensor assy center malfunction B0118/46
Separate type front seat back assy (Side squib LH)
Airbag sensor assy center
Floor wire No.2 WIRING DIAGRAM see page 05-1275 . INSPECTION PROCEDURE 1 CHECK FLOOR WIRE NO.2(SIDE SQUIB LH CIRCUIT) Side Squib LH A D C (a) (b) Floor Wire No.2 B Airbag Sensor Assy Center (c) (d) S18 SFL+ H01016 H42497 (e) (f) SFL- H42853 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the separate type front seat back assy (side squib LH). Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition S18-1 (SFL+) Body ground Ignition switch ON Below 1 V S18-2 (SFL-) Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1474 05-1285 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER Airbag Sensor Assy Center D C S18 SFL+ (a) (b) Floor Wire No.2 Side Squib LH SFL- Service Wire DLC3 CG DTC B0118/46 TC H01017 H42496 H10600 H01072 H42856 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connector to the airbag sensor assy center. (d) Using a service wire, connect S18-1 (SFL+) and S18-2 (SFL-) of connector ”C”. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (see page 05-1215 ). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (see page 05-1215 ). OK: DTC B0118/46 is not output. HINT: Codes other than code B0118/46 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1475 05-1286 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK SEPARATE TYPE FRONT SEAT BACK ASSY(SIDE SQUIB LH) (a) (b) Side Squib LH DC DLC3 CG (c) (d) Airbag Sensor Assy Center (e) DTC B0118/46 (g) (h) (i) TC H01018 H10600 H01072 (f) H40994 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”C”. Connect the connector to the separate type front seat back assy (side squib LH). Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0118/46 is not output. HINT: Codes other than code B0118/46 may be output at this time, but they are not related to this check. NG REPLACE SEPARATE TYPE FRONT SEAT BACK ASSY (SEE PAGE 72-1 1, 72-19 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1476 05-1287 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IVB-01 B0126/27 SEAT BELT BUCKLE SWITCH (LH) MALFUNCTION CIRCUIT DESCRIPTION The seat belt buckle switch LH circuit consists of the airbag sensor assy center and the front seat inner belt assy LH (seat belt buckle switch LH). DTC B0126/27 is recorded when a malfunction is detected in the seat belt buckle switch LH circuit. DTC No. B0126/27 DTC Detecting Condition Trouble Area
Short circuit in front seat inner belt assy LH wire harness (to B+)
Short circuit in front seat inner belt assy LH wire harness (to ground)
Open circuit in LBE+ wire harness or LBE- wire harness of front seat inner belt assy LH
Front seat inner belt assy LH malfunction
Airbag sensor assy center malfunction
Front seat inner belt assy LH (Seat belt buckle switch LH)
Airbag sensor assy center
Floor wire No.2 WIRING DIAGRAM B19 Buckle SW (Driver’s Side) Airbag Sensor Assy Center G 1 R 3 19 11 A16 A16 (*1) (*2) LBE+ 6 2 A16 A16 (*1) (*2) LBE- *1: w/ Curtain Shield Airbag *2: w/o Curtain Shield Airbag H43056 H44106 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1477 05-1288 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 CHECK DTC (a) Front Seat Inner Belt Assy LH Airbag Sensor Assy Center (b) (c) (d) (e) DLC3 DTC B0126/27 Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0126/27 is not output. HINT: Codes other than code B0126/27 may be output at this time, but they are not related to this check. CG TC C85269 H10600 C85273 H41027 NG Go to step 2 OK USE SIMULATION METHOD TO CHECK 2 (a) (b) (c) CHECK CONNECTION OF CONNECTORS Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Check that the connectors are properly connected to the airbag sensor assy center and the front seat inner belt assy LH. OK: The connectors are connected. NG CONNECT CONNECTORS, THEN GO TO STEP 1 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1478 05-1289 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FLOOR WIRE NO.2(OPEN) (a) Floor Wire No.2 A Airbag Sensor Assy Center D C B Front Seat Inner Belt Assy LH Service Wire B19 1 A16 LBE(*1) LBE+ 3 Disconnect the connectors from the airbag sensor assy center and the front seat inner belt assy LH. (b) Using a service wire, connect B19-1 and B19-3 of connector ”C”. NOTICE: Do not forcibly insert a service wire into the terminal of the connector when connecting. (c) Measure the resistance according to the value(s) in the table below. Standard: w/ Curtain shield airbag (*1): LBE- A16 (*2) Tester connection Condition Specified condition A16-19 (LBE+) A16-2 (LBE-) Always Below 1 Ω w/o Curtain shield airbag (*2): Tester connection Condition Specified condition A16-11 (LBE+) A16-6 (LBE-) Always Below 1 Ω LBE+ H43342 H42459 H44468 NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 4 CHECK FLOOR WIRE NO.2(TO B+) (a) (b) Floor Wire No.2 Airbag Sensor Assy Center Front Seat Inner Belt Assy LH LBE- A16 (*2) (*1) A16 LBELBE+ LBE+ H42459 Disconnect the service wire from connector ”C”. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position. (d) Measure the voltage according to the value(s) in the table below. Standard: w/ Curtain shield airbag (*1): Tester connection Condition Specified condition A16-19 (LBE+) Body ground Ignition switch ON Below 1 V A16-2 (LBE-) Body ground Ignition switch ON Below 1 V w/o Curtain shield airbag (*2): Tester connection Condition Specified condition A16-11 (LBE+) Body ground Ignition switch ON Below 1 V A16-6 (LBE-) Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1479 05-1290 DIAGNOSTICS 5 SUPPLEMENTAL RESTRAINT SYSTEM CHECK FLOOR WIRE NO.2(TO GROUND) (a) (b) Floor Wire No.2 Airbag Sensor Assy Center Front Seat Inner Belt Assy LH LBE- - (*1) A16 LBE- A16 (*2) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Standard: w/ Curtain shield airbag (*1): LBE+ Tester connection Condition Specified condition A16-19 (LBE+) Body ground Always 1 MΩ or Higher A16-2 (LBE-) Body ground Always 1 MΩ or Higher w/o Curtain shield airbag (*2): LBE+ H42459 Tester connection Condition Specified condition A16-11 (LBE+) Body ground Always 1 MΩ or Higher A16-6 (LBE-) Body ground Always 1 MΩ or Higher NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 6 CHECK FLOOR WIRE NO.2(SHORT) (a) Measure the resistance according to the value(s) in the table below. Standard: w/ Curtain shield airbag (*1): Floor Wire No.2 Airbag Sensor Assy Center Front Seat Inner Belt Assy LH LBE- A16 (*2) (*1) A16 LBELBE+ Tester connection Condition Specified condition A16-19 (LBE+) A16-2 (LBE-) Always 1 MΩ or Higher w/o Curtain shield airbag (*2): Tester connection Condition Specified condition A16-11 (LBE+) A16-6 (LBE-) Always 1 MΩ or Higher LBE+ H42459 NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1480 05-1291 DIAGNOSTICS 7 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT INNER BELT ASSY LH (a) Front Seat Inner Belt Assy LH Airbag Sensor Assy Center (b) (c) (d) (e) (f) DTC B0126/27 DLC3 (g) CG C85269 H10600 TC C85273 H41027 Connect the connectors to the front seat inner belt assy LH and the airbag sensor assy center. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0126/27 is not output. HINT: Codes other than code B0126/27 may be output at this time, but they are not related to this check. NG Go to step 8 OK USE SIMULATION METHOD TO CHECK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1481 05-1292 DIAGNOSTICS 8 (a) (b) (c) - SUPPLEMENTAL RESTRAINT SYSTEM REPLACE FRONT SEAT INNER BELT ASSY LH Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Replace the front seat inner belt assy LH (see page 72-1 1, 72-19 ). 9 CHECK AIR BAG SENSOR ASSY CENTER (a) Front Seat Inner Belt Assy LH C85269 H10600 (b) (c) (d) (e) DTC B0126/27 DLC3 CG Airbag Sensor Assy Center (f) TC C85273 H41027 Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0126/27 is not output. HINT: Codes other than code B0126/27 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1482 05-1293 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 0525T-05 B0130/63 SHORT IN P/T SQUIB (RH) CIRCUIT CIRCUIT DESCRIPTION The P/T squib RH circuit consists of the airbag sensor assy center and the front seat outer belt assy RH (seat belt pretensioner RH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0130/63 is recorded when a short circuit is detected in the P/T squib RH circuit. DTC No. B0130/63 DTC Detecting Condition Trouble Area
Short circuit between PR+ wire harness and PR- wire harness of squib
P/T squib (RH) malfunction
Airbag sensor assy center malfunction
Front seat outer belt assy RH (P/T squib RH)
Airbag sensor assy center
Floor wire WIRING DIAGRAM Airbag Sensor Assy Center P14 P/T Squib (RH) Y-B 9 5 A18 A18 PR+ (*1) (*2) 1 Y 2 10 6 A18 A18 PR(*1) (*2) *1: w/ Curtain Shield Airbag *2: w/o Curtain Shield Airbag H01454 H44107 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1483 05-1294 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 (a) (b) (c) (d) CHECK CONNECTOR Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the front seat outer belt assy RH. Check that the floor wire connector (on the front seat outer belt assy RH side) is not damaged. OK: The lock button is not disengaged, or the claw of the lock is not deformed or damaged. NG REPAIR OR REPLACE FLOOR WIRE OK 2 CHECK FLOOR WIRE(P/T SQUIB RH CIRCUIT) (a) Floor Wire Airbag Sensor Assy A Center P/T Squib RH D C (b) (c) B P14 PR+ H01019 H43108 PR- H43135 Disconnect the connector from the airbag sensor assy center. Release the activation prevention mechanism built into connector ”B” (see page 05-1207 ). Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition P14-1 (PR+) P14-2 (PR-) Always 1 MΩ or Higher NG REPAIR OR REPLACE FLOOR WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1484 05-1295 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER (a) (b) Airbag Sensor Assy Center P/T Squib RH (c) (d) (e) (f) D C DLC3 DTC B0130/63 (g) CG H01020 H10600 H01082 TC H42114 Connect the connector to the airbag sensor assy center. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0130/63 is not output. HINT: Codes other than code B0130/63 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1485 05-1296 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT OUTER BELT ASSY RH(P/T SQUIB RH) (a) (b) P/T Squib RH Airbag Sensor Assy Center (c) (d) (e) DC DLC3 CG DTC B0130/63 TC H01021 H10600 H01082 H40050 (f) (g) (h) (i) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Connect the connector to the front seat outer belt assy RH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0130/63 is not output. HINT: Codes other than code B0130/63 may be output at this time, but they are not related to this check. NG REPLACE FRONT SEAT OUTER BELT ASSY RH (SEE PAGE 61-4 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1486 05-1297 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 0525U-05 B0131/64 OPEN IN P/T SQUIB (RH) CIRCUIT CIRCUIT DESCRIPTION The P/T squib RH circuit consists of the airbag sensor assy center and the front seat outer belt assy RH (seat belt pretensioner RH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0131/64 is recorded when an open circuit detected in the P/T squib RH circuit. DTC No. DTC Detecting Condition Trouble Area
Open circuit in PR+ wire harness or PR- wire harness of squib
P/T squib (RH) malfunction
Airbag sensor assy center malfunction B0131/64
Front seat outer belt assy RH (P/T squib RH)
Airbag sensor assy center
Floor wire WIRING DIAGRAM see page 05-1293 . INSPECTION PROCEDURE 1 CHECK FLOOR WIRE(P/T SQUIB RH CIRCUIT) (a) (b) Floor Wire Airbag Sensor Assy A Center P/T Squib RH D C (c) (d) B P14 PR+ H01019 H43108 PR- H43135 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait at least for 90 seconds. Disconnect the connectors from the airbag sensor assy center and the front seat outer belt assy RH. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition P14-1 (PR+) P14-2 (PR-) Always Below 1 Ω NG REPAIR OR REPLACE FLOOR WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1487 05-1298 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER P/T Squib (RH) C (a) (b) Airbag Sensor Assy Center D P14 PR+ DLC3 PR- DTC B0131/64 CG TC H01020 H43107 H10600 H01083 H46293 Connect the connector to the airbag sensor assy center. Using a service wire, connect P14-1 (PR+) and P14-2 (PR-) of connector ”C”. NOTICE:
Twist the end of the service wire in order to insert it into the connector.
Do not forcibly insert the twisted service wire into the terminals of the connector when connecting. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Clear the DTCs stored in memory (see page 05-1215 ). (f) Turn the ignition switch to the LOCK position. (g) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (h) Check the DTCs (see page 05-1215 ). OK: DTC B0131/64 is not output. HINT: Codes other than code B0131/64 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1488 05-1299 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT OUTER BELT ASSY RH(P/T SQUIB RH) (a) (b) P/T Squib RH Airbag Sensor Assy Center (c) (d) (e) DC DLC3 (f) DTC B0131/64 (g) (h) (i) CG TC H01021 H10600 H01083 H40051 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”C”. Connect the connector to the front seat outer belt assy RH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0131/64 is not output. HINT: Codes other than code B0131/64 may be output at this time, but they are not relevant to this check. NG REPLACE FRONT SEAT OUTER BELT ASSY RH (SEE PAGE 61-4 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1489 05-1300 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 0525V-19 B0132/61 SHORT IN P/T SQUIB (RH) CIRCUIT (TO GROUND) CIRCUIT DESCRIPTION The P/T squib RH circuit consists of the airbag sensor assy center and the front seat outer belt assy RH (seat belt pretensioner RH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0132/61 is recorded when a short to ground is detected in the P/T squib RH circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in P/T squib (RH) wire harness (to ground)
P/T squib (RH) malfunction
Airbag sensor assy center malfunction B0132/61
Front seat outer belt assy RH (P/T squib RH)
Airbag sensor assy center
Floor wire WIRING DIAGRAM see page 05-1293 . INSPECTION PROCEDURE 1 CHECK FLOOR WIRE(P/T SQUIB RH CIRCUIT) (a) (b) Floor Wire Airbag Sensor Assy A Center P/T Squib RH D C (c) (d) B P14 PR+ H01019 H43108 PR- H43135 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait at least for 90 seconds. Disconnect the connectors from the airbag sensor assy center and the front seat outer belt assy RH. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition P14-1 (PR+) Body ground Always 1 MΩ or Higher P14-2 (PR-) Body ground Always 1 MΩ or Higher NG REPAIR OR REPLACE FLOOR WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1490 05-1301 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER (a) (b) Floor Wire Airbag Sensor Assy Center P/T Squib RH D C P14 PR+ PRService Wire DTC B0132/61 DLC3 CG H01020 H43107 H10600 H01079 TC H43137 Connect the connector to the airbag sensor assy center. Using a service wire, connect P14-1 (PR+) and P14-2 (PR-) of connector ”C”. NOTICE:
Twist the end of the service wire in order to insert it into the connector.
Do not forcibly insert the twisted service wire into the terminals of the connector when connecting. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Clear the DTCs stored in memory (see page 05-1215 ). (f) Turn the ignition switch to the LOCK position. (g) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (h) Check the DTCs (see page 05-1215 ). OK: DTC B0132/61 is not output. HINT: Codes other than code B0132/61 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1491 05-1302 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT OUTER BELT ASSY RH(P/T SQUIB RH) (a) (b) P/T Squib RH Airbag Sensor Assy Center (c) (d) (e) DC DTC B0132/61 DLC3 CG (g) (h) (i) TC H01021 H10600 H01079 (f) H40053 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”C”. Connect the connector to the front seat outer belt assy RH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0132/61 is not output. HINT: Codes other than code B0132/61 may be output at this time, but they are not related to this check. NG REPLACE FRONT SEAT OUTER BELT ASSY RH (SEE PAGE 61-4 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1492 05-1303 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 0525W-19 B0133/62 SHORT IN P/T SQUIB (RH) CIRCUIT (TO B+) CIRCUIT DESCRIPTION The P/T squib RH circuit consists of the airbag sensor assy center and the front seat outer belt assy RH (seat belt pretensioner RH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0133/62 is recorded when a short to B+ is detected in the P/T squib RH circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in seat belt pretensioner (RH) wire harness (to B+)
P/T squib (RH) malfunction
Airbag sensor assy center malfunction B0133/62
Front seat outer belt assy RH (P/T squib RH)
Airbag sensor assy center
Floor wire WIRING DIAGRAM see page 05-1293 . INSPECTION PROCEDURE 1 CHECK FLOOR WIRE(P/T SQUIB RH CIRCUIT) (a) (b) Floor Wire Airbag Sensor Assy A Center P/T Squib RH D C (c) (d) B (e) (f) P14 PR+ H01019 H43108 PR- H43135 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the front seat outer belt assy RH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition P14-1 (PR+) Body ground Ignition switch ON Below 1 V P14-2 (PR-) Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE FLOOR WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1493 05-1304 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER (a) (b) Floor Wire P/T Squib RH P14 PR+ C Airbag Sensor Assy Center D PRService Wire DLC3 CG H01020 H43107 H10600 H01081 DTC B0133/62 TC H43138 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connector to the airbag sensor assy center. (d) Using a service wire, connect P14-1 (PR+) and P14-2 (PR-) of connector ”C”. NOTICE:
Twist the end of the service wire in order to insert it into the connector.
Do not forcibly insert the twisted service wire into the terminal of the connector when connecting. (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (see page 05-1215 ). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (see page 05-1215 ). OK: DTC B0133/62 is not output. HINT: Codes other than code B0133/62 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1494 05-1305 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT OUTER BELT ASSY RH(P/T SQUIB RH) (a) (b) P/T Squib RH Airbag Sensor Assy Center (c) (d) DTC B0133/62 (f) (e) DC DLC3 (g) (h) (i) TC CG H01021 H10600 H01081 H40055 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”C”. Connect the connector to the front seat outer belt assy RH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0133/62 is not output. HINT: Codes other than code B0133/62 may be output at this time, but they are not related to this check. NG REPLACE FRONT SEAT OUTER BELT ASSY RH (SEE PAGE 61-4 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1495 05-1306 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 0525X-04 B0135/73 SHORT IN P/T SQUIB (LH) CIRCUIT CIRCUIT DESCRIPTION The P/T squib LH circuit consists of the airbag sensor assy center and the front seat outer belt assy LH (seat belt pretensioner LH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0135/73 is recorded when a short circuit is detected in the P/T squib LH circuit. DTC No. DTC Detecting Condition Trouble Area B0135/73
Short circuit between PL+ wire harness and PL- wire harness of P/T squib LH
P/T squib (LH) malfunction
Airbag sensor assy center malfunction
Front seat outer belt assy LH (P/T squib LH)
Airbag sensor assy center
Floor wire No.2 WIRING DIAGRAM Airbag Sensor Assy Center P13 P/T Squib (LH) Y-B 1 Y 2 2 8 A16 PL+ A16 (*1) (*2) 7 1 A16 A16 PL(*1) (*2) *1: w/ Curtain Shield Airbag *2: w/o Curtain Shield Airbag H01454 H44104 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1496 05-1307 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 (a) (b) (c) (d) CHECK CONNECTOR Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connector from the front seat outer belt assy LH. Check that the floor wire No.2 connector (on the front seat outer belt assy LH side) is not damaged. OK: The lock button is not disengaged, or the claw of the lock is not deformed or damaged. NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 2 CHECK FLOOR WIRE NO.2(P/T SQUIB LH CIRCUIT) (a) P/T Squib (LH) Airbag Sensor Assy Center (b) (c) P13 PL+ H01016 H43108 PL- H43139 Disconnect the connector from the airbag sensor assy center. Release the activation prevention mechanism built into connector ”B” (see page 05-1207 ). Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition P13-1 (PL+) P13-2 (PL-) Always 1 MΩ or Higher NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1497 05-1308 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER (a) (b) P/T Squib LH D C DLC3 Airbag Sensor Assy Center (c) (d) (e) (f) DTC B0135/73 (g) CG TC H01017 H10600 H01086 H40057 Connect the connector to the airbag sensor assy center. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0135/73 is not output. HINT: Codes other than code B0135/73 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1498 05-1309 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT OUTER BELT ASSY LH(P/T SQUIB LH) (a) (b) P/T Squib LH DC Airbag Sensor Assy Center (c) (d) (e) DLC3 DTC B0135/73 (f) (g) (h) CG H01018 H10600 H01086 TC H40058 (i) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Connect the connector to the front seat outer belt assy LH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0135/73 is not output. HINT: Codes other than code B0135/73 may be output at this time, but they are not related to this check. NG REPLACE FRONT SEAT OUTER BELT ASSY LH (SEE PAGE 61-4 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1499 05-1310 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 0525Y-04 B0136/74 OPEN IN P/T SQUIB (LH) CIRCUIT CIRCUIT DESCRIPTION The P/T squib LH circuit consists of the airbag sensor assy center and the front seat outer belt assy LH (seat belt pretensioner LH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0136/74 is recorded when an open circuit is detected in the P/T squib LH circuit. DTC No. DTC Detecting Condition Trouble Area
Open circuit in PL+ wire harness or PL- wire harness of P/T squib LH
P/T squib (LH) malfunction
Airbag sensor assy center malfunction B0136/74
Front seat outer belt assy LH (P/T squib LH)
Airbag sensor assy center
Floor wire No.2 WIRING DIAGRAM see page 05-1306 . INSPECTION PROCEDURE 1 CHECK FLOOR WIRE NO.2(P/T SQUIB LH CIRCUIT) P/T Squib LH (a) (b) Floor Wire No.2 D C B A Airbag Sensor Assy Center P13 PL+ H01016 H43108 PL- H43139 (c) (d) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the front seat outer belt assy LH. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition P13-1 (PL+) P13-2 (PL-) Always Below 1 Ω NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1500 05-131 1 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER (a) (b) Floor Wire No.2 P/T Squib LH Airbag Sensor Assy Center D C P13 PL+ PLService Wire DLC3 CG H01017 H43107 H10600 DTC B0136/74 TC H01087 H43140 Connect the connector to the airbag sensor assy center. Using a service wire, connect P13-1 (PL+) and P13-2 (PL-) of connector ”C”. NOTICE:
Twist the end of the service wire in order to insert it into the connector.
Do not forcibly insert the twisted service wire into the terminal of the connector when connecting. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Clear the DTCs stored in memory (see page 05-1215 ). (f) Turn the ignition switch to the LOCK position. (g) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (h) Check the DTCs (see page 05-1215 ). OK: DTC B0136/74 is not output. HINT: Codes other than code B0136/74 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1501 05-1312 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT OUTER BELT ASSY LH(P/T SQUIB LH) (a) (b) P/T Squib LH DC Airbag Sensor Assy Center (c) (d) (e) DLC3 DTC B0136/74 (g) (h) (i) TC CG H01018 H10600 H01087 (f) H40060 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”C”. Connect the connector to the front seat outer belt assy LH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0136/74 is not output. HINT: Codes other than code B0136/74 may be output at this time, but they are not related to this check. NG REPLACE FRONT SEAT OUTER BELT ASSY LH (SEE PAGE 61-4 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1502 05-1313 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 0525Z-19 B0137/71 SHORT IN P/T SQUIB (LH) CIRCUIT (TO GROUND) CIRCUIT DESCRIPTION The P/T squib LH circuit consists of the airbag sensor assy center and the front seat outer belt assy LH (seat belt pretensioner LH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0137/71 is recorded when a short to ground is detected in the P/T squib LH circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in P/T squib (LH) wire harness (to ground)
P/T squib (LH) malfunction
Airbag sensor assy center malfunction B0137/71
Front seat outer belt assy LH (P/T squib LH)
Airbag sensor assy center
Floor wire No.2 WIRING DIAGRAM see page 05-1306 . INSPECTION PROCEDURE 1 CHECK FLOOR WIRE NO.2(P/T SQUIB LH CIRCUIT) P/T Squib LH (a) (b) Floor Wire No.2 D C B A Airbag Sensor Assy Center P13 PL+ H01016 H43108 PL- H43139 (c) (d) Turn the ignition switch to the LOCK position. Disconnect negative (-) terminal cable from the battery, and wait at least for 90 seconds. Disconnect the connector from the airbag sensor assy center and the front seat outer belt assy LH. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition P13-1 (PL+) Body ground Always 1 MΩ or Higher P13-2 (PL-) Body ground Always 1 MΩ or Higher NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1503 05-1314 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER P/T Squib LH D Airbag Sensor Assy Center C P13 PL+ (a) (b) Floor Wire No.2 PLService Wire DLC3 CG H01017 H43107 H10600 DTC B0137/71 TC H01084 H43141 Connect the connector to the airbag sensor assy center. Using a service wire, connect P13-1 (PL+) and P13-2 (PL-) of connector ”C”. NOTICE:
Twist the end of the service wire in order to insert it into the connector.
Do not forcibly insert the twisted service wire into the terminal of the connector when connecting. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Clear the DTCs stored in memory (see page 05-1215 ). (f) Turn the ignition switch to the LOCK position. (g) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (h) Check the DTCs (see page 05-1215 ). OK: DTC B0137/71 is not output. HINT: Codes other than code B0137/71 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1504 05-1315 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT OUTER BELT ASSY LH(P/T SQUIB LH) (a) (b) P/T Squib LH DC Airbag Sensor Assy Center (c) (d) (e) DLC3 DTC B0137/71 (g) (h) (i) TC CG H01018 H10600 H01084 (f) H40062 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”C”. Connect the connector to the front seat outer belt assy LH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0137/71 is not output. HINT: Codes other than code B0137/71 may be output at this time, but they are not related to this check. NG REPLACE FRONT SEAT OUTER BELT ASSY LH (SEE PAGE 61-4 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1505 05-1316 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05260-19 B0138/72 SHORT IN P/T SQUIB (LH) CIRCUIT (TO B+) CIRCUIT DESCRIPTION The P/T squib LH circuit consists of the airbag sensor assy center and the front seat outer belt assy LH (seat belt pretensioner LH). This circuit instructs the SRS to deploy when deployment conditions are met. DTC B0137/71 is recorded when a short to ground is detected in the P/T squib LH circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in seat belt pretensioner (LH) wire harness (to B+)
P/T squib (LH) malfunction
Airbag sensor assy center malfunction B0138/72
Front seat outer belt assy LH (P/T squib LH)
Airbag sensor assy center
Floor wire No.2 WIRING DIAGRAM see page 05-1306 . INSPECTION PROCEDURE 1 CHECK FLOOR WIRE NO.2(P/T SQUIB CIRCUIT) P/T Squib LH (a) (b) Floor Wire No.2 D C B A Airbag Sensor Assy Center (c) (d) P13 PL+ H01016 H43108 (e) (f) PL- H43139 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait at least for 90 seconds. Disconnect the connectors from the airbag sensor assy center and the front seat outer belt assy LH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition P13-1 (PL+) Body ground Ignition switch ON Below 1 V P13-2 (PL-) Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1506 05-1317 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER (a) (b) P/T Squib LH Floor Wire No.2 D Airbag Sensor Assy Center C P13 PL- PL+ Service Wire DLC3 CG H01017 H43107 H10600 DTC B0138/72 TC H01085 H43142 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the connector to the airbag sensor assy center. (d) Using a service wire, connect P13-1 (PL+) and P13-2 (PL-) of connector ”C”. NOTICE:
Twist the end of the service wire in order to insert it into the connector.
Do not forcibly insert the twisted service wire into the terminal of the connector when connecting. (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (see page 05-1215 ). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (see page 05-1215 ). OK: DTC B0138/72 is not output. HINT: Codes other than code B0138/72 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1507 05-1318 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT OUTER BELT ASSY LH(P/T SQUIB LH) (a) (b) P/T Squib LH DC DLC3 Airbag Sensor Assy Center (c) (d) (e) DTC B0138/72 (g) (h) (i) TC CG H01018 H10600 H01085 (f) H40064 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”C”. Connect the connector to the front seat outer belt assy LH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B0138/72 is not output. HINT: Codes other than code B0138/72 may be output at this time, but they are not related to this check. NG REPLACE FRONT SEAT OUTER BELT ASSY LH (SEE PAGE 61-4 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1508 05-1319 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IVG-01 B1100/31 AIRBAG SENSOR ASSY CENTER MALFUNCTION CIRCUIT DESCRIPTION The airbag sensor assy center consists of a airbag sensor assy center, safing sensor, drive circuit, diagnosis circuit and ignition control, etc. It receives signals from the airbag sensor, judges whether or not the SRS must be activated, and detects diagnosis system malfunction. DTC B1100/31 is recorded when occurrence of a malfunction in the airbag sensor assy center is detected. DTC No. B1100/31 DTC Detecting Condition Trouble Area
Airbag sensor assy center malfunction
Airbag sensor assy center HINT: When a trouble code is displayed simultaneously with B1100/31, repair the malfunction indicated by this code (except B1100/31) first. INSPECTION PROCEDURE 1 CHECK AIR BAG SENSOR ASSY CENTER (a) DLC3 DTC B1100/31 (b) (c) (d) (e) CG H10600 TC H41086 Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1100/31 is not output. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK USE SIMULATION METHOD TO CHECK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1509 05-1320 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05262-05 B1135/24 HALF CONNECTION IN AIRBAG SENSOR ASSY CENTER CONNECTORS CIRCUIT DESCRIPTION The airbag sensor assy center detects partial connection of connector. DTC B1135/24 is recorded when the airbag sensor assy center detects an open in the electrical connection check mechanism of the airbag sensor connector or in the airbag sensor circuit. DTC No. B1135/24 DTC Detecting Condition Trouble Area
Malfunction of electrical connection check mechanism of airbag sensor assy center connector
Airbag sensor assy center malfunction
Electrical connection check mechanism
Airbag sensor assy center INSPECTION PROCEDURE 1 (a) (b) (c) CHECK AIRBAG SENSOR ASSY CENTER CONNECTOR Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Check the connection of the airbag sensor assy center connectors. OK: The connectors are connected. HINT: When the connectors are not firmly connected, disconnect them once and reconnect them securely. 2 CHECK AIR BAG SENSOR ASSY CENTER (a) Airbag Sensor Assy Center DLC3 CG (b) (c) (d) (e) DTC B1135/24 TC H40997 (f) Connect the negative (-) terminal cable to the battery, and wait at least for 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1135/24 is not output. HINT: Codes other than code B1135/24 may be output at this time, but they are not related to this check. NG Go to step 3 OK USE SIMULATION METHOD TO CHECK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1510 05-1321 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM PERFORM A VISUAL CHECK OF THE DISCONNECTION DETECTION PIN w/o Side and Curtain Shield Airbag: Disconnection Detection Pin (a) Check the disconnection detection pin of the connector. HINT: Compare one connector with the other 2 connectors. OK: No deformation is identified. w/ Side and Curtain Shield Airbag: Disconnection Detection Pin C83399 C81406 H41456 NG REPAIR OR REPLACE AIRBAG SENSOR ASSY CENTER CONNECTOR OK REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1511 05-1322 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IVK-01 B1140/32 SIDE AIRBAG SENSOR ASSY (RH) MALFUNCTION The side airbag sensor assy RH consists of the safing sensor, diagnosis circuit and lateral deceleration sensor, etc. It receives signals from the lateral deceleration sensor, judges whether or not the SRS must be activated, and detects diagnosis system malfunction. DTC B1140/32 is recorded when occurrence of a malfunction in the side airbag sensor assy RH (RH) is detected. DTC No. B1140/32 DTC Detecting Condition Trouble Area
Side airbag sensor assy RH
Floor wire
Airbag sensor assy center
Side airbag sensor assy RH circuit malfunction WIRING DIAGRAM S17 Side Airbag Sensor Assy RH Airbag Sensor Assy Center 1 B (*1) 4 W (*1) 3 G (*1) 2 R (*1) ESR VUPR SSR+ SSR- 15 A18 ESR 17 A18 VUPR 16 A18 SSR+ 13 A18 SSR- *1: w/ Curtain Shield Airbag H43054 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1512 05-1323 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 CHECK DTC (a) Side Airbag Sensor Assy RH DLC3 Airbag Sensor Assy Center (b) (c) (d) (e) DTC B1140/32 Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1140/32 is not output. HINT: Codes other than code B1140/32 may be output at this time, but they are not related to this check. CG TC H01012 H10600 H01065 H40442 NG Go to step 2 OK USE SIMULATION METHOD TO CHECK 2 (a) (b) (c) CHECK CONNECTION OF CONNECTORS Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait at least for 90 seconds. Check that the connector is properly connected to the airbag sensor assy center and the side airbag sensor assy RH. NG CONNECT CONNECTORS, THEN GO TO STEP 1 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1513 05-1324 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM CHECK FLOOR WIRE(OPEN) (a) Side Airbag Floor Wire Sensor Assy RH Airbag Sensor Assy A Center D C ESR - S17 VUPR SSR- (b) B A18 ESR (c) SSR+ VUPR SST SSR+ H01015 C91384 C91385 C82599 SSR- Disconnect the connectors from the airbag sensor assy center and the side airbag sensor assy RH. Using SST, connect S17-4 (VUPR) and S17-1 (ESR), and connect S17-3 (SSR+) and S17-2 (SSR-) of connector ”C”. SST 09843-18040 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A18-17 (VUPR) A18-15 (ESR) Always Below 1 Ω A18-16 (SSR+) A18-13 (SSR-) Always Below 1 Ω H42483 NG REPAIR OR REPLACE FLOOR WIRE OK 4 CHECK FLOOR WIRE(TO GROUND) Floor Wire D C Side Airbag Sensor Assy RH (a) (b) Airbag Sensor Assy A Center B A18 ESR VUPR H01015 C83438 Disconnect the SST from connector ”C”. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A18-17 (VUPR) Body ground Always 1 MΩ or Higher A18-15 (ESR) Body ground Always 1 MΩ or Higher A18-16 (SSR+) Body ground Always 1 MΩ or Higher A18-13 (SSR-) Body ground Always 1 MΩ or Higher SSR+ SSR- H42229 NG REPAIR OR REPLACE FLOOR WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1514 05-1325 DIAGNOSTICS 5 SUPPLEMENTAL RESTRAINT SYSTEM CHECK FLOOR WIRE(TO B+) Floor Wire D C (a) Airbag Sensor Assy A Center (b) (c) B Side Airbag Sensor Assy RH A18 ESR VUPR H01015 C83438 - SSR+ SSR- H42229 Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A18-17 (VUPR) Body ground Ignition switch ON Below 1 V A18-15 (ESR) Body ground Ignition switch ON Below 1 V A18-16 (SSR+) Body ground Ignition switch ON Below 1 V A18-13 (SSR-) Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE FLOOR WIRE OK 6 CHECK FLOOR WIRE(SHORT) Floor Wire D C Side Airbag Sensor Assy RH (c) B A18 ESR VUPR H01015 C83438 (a) (b) Airbag Sensor Assy A Center Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A18-17 (VUPR) A18-15 (ESR) Always 1 MΩ or Higher A18-16 (SSR+) A18-13 (SSR-) Always 1 MΩ or Higher SSR+ SSR- H42229 NG REPAIR OR REPLACE FLOOR WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1515 05-1326 DIAGNOSTICS 7 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK SIDE AIR BAG SENSOR ASSY RH Side Airbag Sensor Assy LH (a) (b) Airbag Sensor Assy Center (c) (d) DTC B1140/32 (e) (f) (g) DLC3 DTC B1141/33 CG (h) TC H01012 H10600 H01065 H01066 Connect the connector to the airbag sensor assy center. Interchange the side airbag sensor assy RH with LH and connect the connectors to them. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). Result: H42115 NG: A DTC B1140/32 is output. NG: B DTC B1141/33 is output. DTC B1140/32 and B1141/33 are not output. OK NG:A REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) NG:B REPLACE SIDE AIR BAG SENSOR ASSY RH (SEE PAGE 60-57 ) OK USE SIMULATION METHOD TO CHECK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1516 05-1327 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IVL-01 B1141/33 SIDE AIRBAG SENSOR ASSY (LH) MALFUNCTION CIRCUIT DESCRIPTION The side airbag sensor assy LH consists of the safing sensor, diagnosis circuit and lateral deceleration sensor, etc. It receives signals from the lateral deceleration sensor, judges whether or not the SRS must be activated, and detects diagnosis system malfunction. DTC B1141/33 is recorded when occurrence of a malfunction in the side airbag sensor assy LH is detected. DTC No. B1141/33 DTC Detecting Condition Trouble Area
Side airbag sensor assy LH
Floor wire No.2
Airbag sensor assy center
Side airbag sensor assy LH malfunction WIRING DIAGRAM S16 Side Airbag Sensor Assy LH Airbag Sensor Assy Center 1 B (*1) 4 W ESL VUPL 18 A16 ESL 16 A16 VUPL (*1) 3 SSL+ 17 A16 SSL+ G (*1) 2 SSL- 20 A16 SSL- R (*1) *1: w/ Curtain Shield Airbag H43054 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1517 05-1328 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 CHECK DTC (a) Side Airbag Sensor Assy LH DLC3 (b) (c) (d) Airbag Sensor Assy Center (e) DTC B1141/33 Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1141/33 is not output. HINT: Codes other than code B1141/33 may be output at this time, but they are not related to this check. CG H01007 H10600 H01066 TC H40445 NG Go to step 2 OK USE SIMULATION METHOD TO CHECK 2 (a) (b) (c) CHECK AIRBAG SENSOR ASSY CENTER CONNECTOR Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait at least for 90 seconds. Check that the connectors are properly connected to the airbag sensor assy center and the side airbag sensor assy LH. NG CONNECT CONNECTORS, THEN GO TO STEP 1 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1518 05-1329 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM CHECK FLOOR WIRE NO.2(OPEN) (a) Floor Wire No.2 A Airbag Sensor Assy Center D C B Side Airbag Sensor Assy LH S16 (b) (c) A16 ESL VUPL SSL- SSL+ VUPL SST - SST SSL+ SSL- H01010 C91385 C91384 C82600 ESL Disconnect the connectors from the airbag sensor assy center and the side airbag sensor assy LH. Using SST, connect S16-4 (VUPL) and S16-1 (ESL), and connect S16-3 (SSL+) and S16-2 (SSL-) of connector ”C”. SST 09843 - 18040 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A16-16 (VUPL) A16-18 (ESL) Always Below 1 Ω A16-17 (SSL+) A16-20 (SSL-) Always Below 1 Ω H43148 NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 4 CHECK FLOOR WIRE NO.2(TO GROUND) (a) (b) Floor Wire No.2 D C Side Airbag Sensor Assy LH B A Airbag Sensor Assy Center A16 VUPL SSLH01010 C83441 Disconnect the SST from connector ”C” Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A16-16 (VUPL) Body ground Always 1 MΩ or Higher A16-18 (ESL) Body ground Always 1 MΩ or Higher A16-17 (SSL+) Body ground Always 1 MΩ or Higher A16-20 (SSL-) Body ground Always 1 MΩ or Higher SSL+ ESL H42231 NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1519 05-1330 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FLOOR WIRE NO.2(TO B+) (a) Floor Wire No.2 D C B Side Airbag Sensor Assy LH A Airbag Sensor Assy Center (b) (c) A16 VUPL SSL- SSL+ ESL H01010 C83441 H42231 Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A16-16 (VUPL) Body ground Ignition switch ON Below 1 V A16-18 (ESL) Body ground Ignition switch ON Below 1 V A16-17 (SSL+) Body ground Ignition switch ON Below 1 V A16-20 (SSL-) Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 6 CHECK FLOOR WIRE NO.2(SHORT) (a) (b) Floor Wire No.2 D C Side Airbag Sensor Assy LH B A Airbag Sensor Assy Center (c) A16 VUPL SSLH01010 C83441 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A16-16 (VUPL) A16-18 (ESL) Always 1 MΩ or Higher A16-17 (SSL+) A16-20 (SSL-) Always 1 MΩ or Higher SSL+ ESL H42231 NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1520 05-1331 DIAGNOSTICS 7 DLC3 (a) (b) Airbag Sensor Assy Center (c) (d) DTC B1140/32 (e) (f) (g) DTC B1141/33 H01007 H10600 SUPPLEMENTAL RESTRAINT SYSTEM CHECK DTC Side Airbag Sensor Assy RH CG - TC H01065 H01066 (h) Connect the airbag sensor assy center connector. Interchange the side airbag sensor assy RH with LH and connect the connectors to them. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait at for least 60 seconds. Check the DTC (see page 05-1215 ). Result: H42116 NG: A DTC B1140/32 is output. NG: B DTC B1141/33 is output. DTC B1140/32 and B1141/33 are not output. OK NG:A REPLACE SIDE AIR BAG SENSOR ASSY LH (SEE PAGE 60-57 ) NG:B REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK USE SIMULATION METHOD TO CHECK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1521 05-1332 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IVN-01 B1148/36 FRONT AIRBAG SENSOR (RH) MALFUNCTION CIRCUIT DESCRIPTION The airbag front RH sensor circuit consists of the diagnostic circuit and the frontal deceleration sensor, etc. If the airbag sensor assy center receives signals from the frontal deceleration sensor, it judges whether or not the SRS should be activated. DTC B1148/36 is recorded when a malfunction in the airbag front RH sensor is detected. DTC No. B1148/36 DTC Detecting Condition Trouble Area
Short circuit in front airbag sensor RH wire harness (to B+)
Short circuit in front airbag sensor RH wire harness (to ground)
Open circuit in +SR wire harness or -SL wire harness of front airbag sensor RH
Airbag front RH sensor malfunction
Airbag sensor assy center malfunction
Airbag front RH sensor
Airbag sensor assy center
Cowl wire
Engine room main wire WIRING DIAGRAM A9 Airbag Front RH Sensor +SR Airbag Sensor Assy Center B-W 3 IK1 W 9 A17 +SR BR-W 4 IK1 B 20 A17 -SR 2 -SR 1 H02750 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1522 05-1333 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 CHECK DTC (a) Airbag Front RH Sensor Airbag Sensor Assy Center (b) (c) (d) (e) DLC3 DTC B1148/36 Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1148/36 is not output. HINT: Codes other than code B1148/36 may be output at this time, but they are not related to this check. CG TC H02757 H10600 H16834 H42117 NG Go to step 2 OK USE SIMULATION METHOD TO CHECK 2 (a) (b) (c) CHECK CONNECTION OF CONNECTORS Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Check that the connectors are properly connected to the airbag sensor assy center and the airbag front RH sensor. OK: The connectors are connected. NG CONNECT CONNECTORS, THEN GO TO STEP 1 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1523 05-1334 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT AIRBAG SENSOR (RH) CIRCUIT (OPEN) (a) Airbag Front F RH Sensor -SR A9 E DC B +SR Airbag Sensor A Assy Center A17 +SR -SR Disconnect the connectors from the airbag sensor assy center and the airbag front RH sensor. (b) Using a service wire, connect A9-2 (+SR) and A9-1 (SR) of connector ”E”. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (c) Measure the resistance according to the value(s) in the table below. Standard: Service Wire H03353 H08016 C81408 H41800 Tester connection Condition Specified condition A17-9 (+SR) A17-20 (-SR) Always Below 1 Ω NG Go to step 8 OK 4 CHECK FRONT AIRBAG SENSOR (RH) CIRCUIT (TO B+) Airbag Front F RH Sensor E DC B Airbag Sensor A Assy Center A17 +SR -SR H03355 C81408 H42510 (a) (b) (c) (d) Disconnect the service wire from connector ”E”. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A17-9 (+SR) Body ground Ignition switch ON Below 1 V A17-20 (-SR) Body ground Ignition switch ON Below 1 V NG Go to step 9 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1524 05-1335 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT AIRBAG SENSOR (RH) CIRCUIT (TO GROUND) Airbag Front F RH Sensor E DC B Airbag Sensor A Assy Center (a) (b) (c) A17 +SR -SR H03355 C81408 H42510 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A17-9 (+SR) Body ground Always 1 MΩ or Higher A17-20 (-SR) Body ground Always 1 MΩ or Higher NG Go to step 10 OK 6 CHECK FRONT AIRBAG SENSOR (RH) CIRCUIT (SHORT) (a) Airbag Front F RH Sensor E DC B Airbag Sensor A Assy Center Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A17-9 (+SR) A17-20 (-SR) Always 1 MΩ or Higher A17 +SR -SR H03355 C81408 H42510 NG Go to step 11 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1525 05-1336 DIAGNOSTICS 7 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG FRONT RH SENSOR Airbag Sensor Front LH DC (a) (b) Airbag Sensor Assy Center (c) (d) DTC B1148/36 (e) (f) (g) DLC3 DTC B1149/37 CG (h) TC H02757 H10600 H16834 H16835 Connect the connector to the airbag sensor assy center. Interchange the airbag front RH sensor with the airbag sensor front LH and connect the connectors to them. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). Result: H42118 NG: A DTC B1149/37 is output. NG: B DTC B1148/36 is output. DTC B1148/36 and B1149/37 are not output. OK NG:A REPLACE AIR BAG SENSOR FRONT RH (SEE PAGE 60-55 ) NG:B REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK USE SIMULATION METHOD TO CHECK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1526 05-1337 DIAGNOSTICS 8 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK ENGINE ROOM MAIN WIRE(OPEN) Engine Room Main Wire Airbag Front RH Sensor (a) Cowl Wire F E D C A9 +SR B Airbag Sensor A Assy Center IK1 -SR Disconnect the engine room main wire connector from the cowl wire. HINT: Connector ”E” has already been inserted into the service wire. (b) Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition IK1-3 (+SR) IK1-4 (-SR) Always Below 1 Ω +SR -SR H03352 NG Service Wire H43424 C81305 REPAIR OR REPLACE ENGINE ROOM MAIN WIRE OK REPAIR OR REPLACE COWL WIRE 9 CHECK ENGINE ROOM MAIN WIRE(TO B+) Engine Room Main Wire Airbag Front F RH Sensor E Cowl Wire D C B Airbag Sensor A Assy Center (a) (b) (c) (d) IK1 (e) (f) -SR H03354 C81305 +SR H43447 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the engine room main wire connector from the cowl wire. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition IK1-3 (+SR) Body ground Ignition switch ON Below 1 V IK1-4 (-SR) Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE ENGINE ROOM MAIN WIRE OK REPAIR OR REPLACE COWL WIRE 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1527 05-1338 DIAGNOSTICS 10 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK ENGINE ROOM MAIN WIRE(TO GROUND) Engine Room Main Wire Airbag Front F RH Sensor E (a) Cowl Wire D C B Airbag Sensor A Assy Center (b) IK1 Disconnect the engine room main wire connector from the cowl wire. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition IK1-3 (+SR) Body ground Always 1 MΩ or Higher IK1-4 (-SR) Body ground Always 1 MΩ or Higher +SR -SR H03354 C81305 H43447 NG REPAIR OR REPLACE ENGINE ROOM MAIN WIRE OK REPAIR OR REPLACE COWL WIRE 11 CHECK ENGINE ROOM MAIN WIRE(SHORT) Engine Room Main Wire Airbag Front F RH Sensor E (a) Cowl Wire D C B Airbag Sensor A Assy Center IK1 -SR H03354 C81305 (b) Disconnect the engine room main wire connector from the cowl wire. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition IK1-3 (+SR) IK1-4 (-SR) Always 1 MΩ or Higher +SR H43447 NG REPAIR OR REPLACE ENGINE ROOM MAIN WIRE OK REPAIR OR REPLACE COWL WIRE 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1528 05-1339 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IVO-02 B1149/37 FRONT AIRBAG SENSOR (LH) MALFUNCTION CIRCUIT DESCRIPTION The airbag sensor front LH circuit consists of the diagnostic circuit and the frontal deceleration sensor, etc. If the airbag sensor assy center receives signals from the frontal deceleration sensor, it judges whether or not the SRS should be activated. DTC B1149/37 is recorded when a malfunction is detected in the airbag sensor front LH circuit. DTC No. DTC Detecting Condition Trouble Area B1149/37
Short circuit in front airbag sensor LH wire harness (to B+)
Short circuit in front airbag sensor LH wire harness (to ground)
Open circuit in +SL wire harness or -SL wire harness of front airbag sensor LH
Airbag sensor front LH malfunction
Airbag sensor assy center malfunction
Airbag sensor front LH
Airbag sensor assy center
Cowl wire
Engine room main wire WIRING DIAGRAM A8 Airbag Sensor Front LH +SL -SL Airbag Sensor Assy Center W-R 2 IK1 G 15 A17 +SL BR 1 IK1 R 26 A17 -SL 2 1 H02750 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1529 05-1340 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 CHECK DTC (a) Airbag Sensor Front LH Airbag Sensor Assy Center (b) (c) (d) (e) DLC3 CG H02757 H10600 DTC B1149/37 HINT: Codes other than code B1149/37 may be output at this time, but they are not related to this check. TC H16835 Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1149/37 is not output. H42119 NG Go to step 2 OK USE SIMULATION METHOD TO CHECK 2 (a) (b) (c) CHECK CONNECTION OF CONNECTORS Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Check that the connector is properly connected to the airbag sensor assy center and the airbag sensor front LH. OK: The connectors are connected. NG CONNECT CONNECTORS, THEN GO TO STEP 1 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1530 05-1341 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT AIRBAG SENSOR (LH) CIRCUIT (OPEN) (a) F E DC B Airbag Sensor A Assy Center Airbag Sensor Front LH -SL A8 +SL +SL Service Wire A17 Disconnect the connectors from the airbag sensor assy center and the airbag sensor front LH. (b) Using a service wire, connect A8-2 (+SL) and A8-1 (-SL) of connector ”E”. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (c) Measure the resistance according to the value(s) in the table below. Standard: -SL H03353 H08016 C81408 H41800 Tester connection Condition Specified condition A17-15 (+SL) A17-26 (-SL) Always Below 1 Ω NG Go to step 8 OK 4 CHECK FRONT AIRBAG SENSOR (LH) CIRCUIT (TO B+) F E DC B Airbag Sensor Front LH +SL H03355 C81408 Airbag Sensor A Assy Center A17 (a) (b) (c) (d) Disconnect the service wire from connector ”E”. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A17-15 (+SL) Body ground Ignition switch ON Below 1 V A17-26 (-SL) Body ground Ignition switch ON Below 1 V -SL H42510 NG Go to step 9 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1531 05-1342 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT AIRBAG SENSOR (LH) CIRCUIT (TO GROUND) F A E DC B Airbag Sensor Assy Center (a) (b) (c) Airbag Sensor Front LH +SL A17 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A17-15 (+SL) Body ground Always 1 MΩ or Higher A17-26 (-SL) Body ground Always 1 MΩ or Higher -SL H03355 C81408 H42510 NG Go to step 10 OK 6 CHECK FRONT AIRBAG SENSOR (LH) CIRCUIT (SHORT) (a) F A E DC B Airbag Sensor Assy Center Airbag Sensor Front LH +SL H03355 C81408 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A17-15 (+SL) A17-26 (-SL) Always 1 MΩ or Higher A17 -SL H42510 NG Go to step 11 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1532 05-1343 DIAGNOSTICS 7 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR FRONT LH Airbag Front RH Sensor DC (a) (b) Airbag Sensor Assy Center (c) (d) DTC B1148/36 (e) (f) (g) DLC3 DTC B1149/37 CG (h) TC H02757 H10600 H16834 H16835 Connect the connector to the airbag sensor assy center. Interchange the airbag front sensor RH with the airbag sensor front LH and connect the connectors to them. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). Result: H42120 NG: A DTC B1149/37 is output. NG: B DTC B1148/36 is output. DTC B1148/36 and B1149/37 are not output. OK NG:A REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) NG:B REPLACE AIR BAG SENSOR FRONT LH (SEE PAGE 60-55 ) OK USE SIMULATION METHOD TO CHECK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1533 05-1344 DIAGNOSTICS 8 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK ENGINE ROOM MAIN WIRE(OPEN) Engine Room Main Wire F E D C B Airbag Sensor Front LH -SL (a) Cowl Wire Airbag Sensor A Assy Center IK1 A8 H03352 C81305 HINT: Connector ”E” has already been inserted into the service wire. (b) Measure the resistance according to the value(s) in the table below. Standard: +SL +SL -SL Service Wire H43424 Disconnect the engine room main wire connector from the cowl wire. Tester connection Condition Specified condition IK1-1 (-SL) IK1-2 (+SL) Always Below 1 Ω NG REPAIR OR REPLACE ENGINE ROOM MAIN WIRE OK REPAIR OR REPLACE COWL WIRE 9 CHECK ENGINE ROOM MAIN WIRE(TO B+) Engine Room Main Wire Cowl Wire F E Airbag Sensor Front LH D C B Airbag Sensor A Assy Center (a) (b) (c) (d) IK1 (e) (f) -SL H03354 C81305 +SL H43447 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the engine room main wire connector from the cowl wire. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition IK1-1 (-SL) Body ground Ignition switch ON Below 1 V IK1-2 (+SL) Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE ENGINE ROOM MAIN WIRE OK REPAIR OR REPLACE COWL WIRE 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1534 05-1345 DIAGNOSTICS 10 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK ENGINE ROOM MAIN WIRE(TO GROUND) Engine Room Main Wire F E (a) Cowl Wire D C Airbag Sensor Front LH B Airbag Sensor A Assy Center (b) IK1 -SL +SL H03354 C81305 H43447 Disconnect the engine room main wire connector from the cowl wire. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition IK1-1 (-SL) Body ground Always 1 MΩ or Higher IK1-2 (+SL) Body ground Always 1 MΩ or Higher NG REPAIR OR REPLACE ENGINE ROOM MAIN WIRE OK REPAIR OR REPLACE COWL WIRE 11 CHECK ENGINE ROOM MAIN WIRE(SHORT) Engine Room Main Wire F E Airbag Sensor Front LH -SL H03354 C81305 (a) Cowl Wire D C B Airbag Sensor A Assy Center IK1 (b) Disconnect the engine room main wire connector from the cowl wire. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition IK1-1 (-SL) IK1-2 (+SL) Always 1 MΩ or Higher +SL H43447 NG REPAIR OR REPLACE ENGINE ROOM MAIN WIRE OK REPAIR OR REPLACE COWL WIRE 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1535 05-1346 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IVP-03 B1150/23 OCCUPANT CLASSIFICATION SYSTEM MALFUNCTION CIRCUIT DESCRIPTION The occupant classification system circuit consists of the airbag sensor assy center and the occupant classification system. DTC B1150/23 is recorded when a malfunction is detected in the occupant classification system circuit. DTC No. B1150/23 DTC Detecting Condition Trouble Area
Floor wire
Front seat wire RH
Occupant classification ECU
Airbag sensor assy center
Occupant classification system malfunction WIRING DIAGRAM Occupant Classification ECU 8 FSR+ O6 4 FSR- O6 Airbag Sensor Assy Center 1 W B W BL1 4 BL1 B 1 3 A18 A18 FSR+ (*2) (*1) 2 10 A18 A18 FSR(*2) (*1) *1: w/ Curtain Shield Airbag *2: w/o Curtain Shield Airbag H43055 H44105 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1536 05-1347 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 (a) (b) CHECK DTC(OCCUPANT CLASSIFICATION ECU) Turn the ignition switch to the ON position, and wait for at least 10 seconds. Using the hand-held tester, check the DTCs of the occupant classification ECU (see page 05-1215 ). OK: DTC is not output. NG GO TO INSPECTION PROCEDURE OF DTC OUTPUT OK 2 CHECK DTC (AIRBAG SENSOR ASSY CENTER) (a) Occupant Classification ECU (b) (c) (d) Airbag Sensor Assy Center (e) DTC B1150/23 DLC3 Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1150/23 is not output. HINT: Codes other than code B1150/23 may be output at this time, but they are not related to this check. CG TC H44090 H02757 H10600 H44098 H44535 NG Go to step 3 OK USE SIMULATION METHOD TO CHECK 3 (a) (b) (c) CHECK CONNECTION OF CONNECTORS Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Check that the connectors are properly connected to the airbag sensor assy center and the occupant classification ECU. OK: The connectors are connected. NG CONNECT CONNECTORS, THEN GO TO STEP 1 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1537 05-1348 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK OCCUPANT CLASSIFICATION ECU CIRCUIT(OPEN) (a) Occupant Classification ECU Airbag Sensor Assy A Center F E DC B FSR- FSR+ FSR+ FSRO6 FSR+ Disconnect the connectors from the airbag sensor assy center and the occupant classification ECU. (b) Using a service wire, connect O6-8 (FSR+) and O6-4 (FSR-) of connector ”E”. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (c) Measure the resistance according to the value(s) in the table below. Standard: w/ Side and curtain shield airbag: FSRA18 (*2) A18 (*1) Condition Specified condition A18-3 (FSR+) A18-10 (FSR-) Always Below 1 Ω w/o Side and curtain shield airbag: Service Wire H44130 H44536 H41715 H43694 Tester connection *1: w/ Side and Curtain Shield Airbag *2: w/o Side and Curtain Shield Airbag H44681 Tester connection Condition Specified condition A18-1 (FSR+) A18-2 (FSR-) Always Below 1 Ω NG Go to step 8 OK 5 CHECK OCCUPANT CLASSIFICATION ECU CIRCUIT (SHORT) Occupant Classification ECU Airbag Sensor Assy A Center F E FSR- DC B FSRFSR+ FSR+ (a) (b) Disconnect the service wire from connector ”E”. Measure the resistance according to the value(s) in the table below. Standard: w/ Side and curtain shield airbag: Tester connection Condition Specified condition A18-3 (FSR+) A18-10 (FSR-) Always 1 MΩ or Higher w/o Side and curtain shield airbag: A18 w/o Side and Curtain Shield Airbag H41715 H44130 A18 w/ Side and Curtain Shield Airbag H44536 Tester connection Condition Specified condition A18-1 (FSR+) A18-2 (FSR-) Always 1 MΩ or Higher NG Go to step 9 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1538 05-1349 DIAGNOSTICS 6 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK OCCUPANT CLASSIFICATION ECU CIRCUIT (TO B+) (a) Occupant Classification ECU Airbag Sensor Assy A Center F E DC B FSRFSR+ FSR+ FSR- A18 Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (b) Turn the ignition switch to the ON position. (c) Measure the voltage according to the value(s) in the table below. Standard: w/ Side and curtain shield airbag: A18 w/o Side and Curtain Shield Airbag Condition Specified condition A18-3 (FSR+) Body ground Ignition switch ON Below 1 V A18-10 (FSR-) Body ground Ignition switch ON Below 1 V w/o Side and curtain shield airbag: w/ Side and Curtain Shield Airbag H44536 H41715 H44130 Tester connection Tester connection Condition Specified condition A18-1 (FSR+) Body ground Ignition switch ON Below 1 V A18-2 (FSR-) Body ground Ignition switch ON Below 1 V NG Go to step 10 OK 7 CHECK OCCUPANT CLASSIFICATION ECU CIRCUIT (TO GROUND) Occupant Classification ECU Airbag Sensor Assy A Center F E FSR- DC FSRFSR+ FSR+ A18 w/o Side and Curtain Shield Airbag H41715 H44130 B A18 (a) (b) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Standard: w/ Side and curtain shield airbag: Tester connection Condition Specified condition A18-3 (FSR+) Body ground Always 1 MΩ or Higher A18-10 (FSR-) Body ground Always 1 MΩ or Higher w/o Side and curtain shield airbag: w/ Side and Curtain Shield Airbag H44536 Tester connection Condition Specified condition A18-1 (FSR+) Body ground Always 1 MΩ or Higher A18-2 (FSR-) Body ground Always 1 MΩ or Higher NG Go to step 11 OK REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1539 05-1350 DIAGNOSTICS 8 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT WIRE RH(OPEN) Occupant Floor Wire Classification Front Seat ECU Wire RH F E D C Airbag Sensor Assy A Center B Disconnect the front seat wire RH connector from the floor wire. HINT: Connector ”E” has already been inserted into the service wire. (b) Measure the resistance according to the value(s) in the table below. Standard: BL1 O6 FSR+ (a) FSR- Tester connection Condition Specified condition BL1-1 (FSR+) BL1-4 (FSR-) Always Below 1 Ω FSR+ FSRH43129 H03354 H43116 Service Wire H44538 NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK REPAIR OR REPLACE FLOOR WIRE 9 CHECK FRONT SEAT WIRE RH(SHORT) Occupant Floor Wire Classification Front Seat Airbag Wire RH ECU Sensor Assy F A Center E D C B (a) (b) Disconnect the front seat wire RH connector from the floor wire. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition BL1-1 (FSR+) BL1-4 (FSR-) Always 1 MΩ or Higher BL1 FSR+ FSRH03354 H43116 H43129 NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK REPAIR OR REPLACE FLOOR WIRE 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1540 05-1351 DIAGNOSTICS 10 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT WIRE RH(TO B+) Occupant Floor Wire Classification Front Seat Airbag Wire RH ECU Sensor Assy F A Center E D C B (a) (b) (c) (d) (e) (f) BL1 FSR+ FSRH03354 H43116 H43129 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from battery, and wait for at least 90 seconds. Disconnect the front seat wire RH connector from the floor wire. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition BL1-1 (FSR+) Body ground Ignition switch ON Below 1 V BL1-4 (FSR-) Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK REPAIR OR REPLACE FLOOR WIRE 11 CHECK FRONT SEAT WIRE RH(TO GROUND) Occupant Floor Wire Classification Front Seat Airbag Wire RH ECU Sensor Assy F A Center E D C B BL1 FSR+ (a) (b) Disconnect the front seat wire RH connector from the floor wire. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition BL1-1 (FSR+) Body ground Always 1 MΩ or Higher BL1-4 (FSR-) Body ground Always 1 MΩ or Higher FSRH03354 H43116 H43129 NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK REPAIR OR REPLACE FLOOR WIRE 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1541 05-1352 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IVQ-02 B1152/28 PASSENGER AIRBAG ON/OFF INDICATOR LIGHT CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION The passenger airbag ON/OFF indicator light circuit consists of the airbag sensor assy center and the telltale lamp assy (passenger airbag ON/OFF indicator). This circuit indicates the operation condition of the front passenger airbag assy and the front seat airbag assy RH and passenger side seat belt pretensioner. DTC B1152/28 is recorded when a malfunction is detected in the passenger airbag ON/OFF indicator light circuit. DTC No. B1152/28 DTC Detecting Condition
When the airbag sensor assy center receives a line short signal, open signal, short to ground signal or B+ short signal in the passenger airbag ON/OFF indicator light circuit for 2 seconds.
Telltale lamp assy malfunction
Airbag sensor assy center malfunction Trouble Area
Telltale lamp (Passenger airbag ON/OFF indicator)
Airbag sensor assy center
Cowl wire 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1542 05-1353 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM WIRING DIAGRAM T15 Telltale Light assembly Airbag Sensor Assy Center Instrument Panel J/B AIRBAG ON PAON 14 IL1 W 7 P-AB 11 1E 5 1K Y L 2 8 1L 2 1L G B 25 A17 PAON 1 A17 P-AB AIRBAG OFF Center J/B SW1 W-B 5 IG+ R 4 10 3F 13 3F 6 3F 10 3A GR F7 F/L Block W B 1 ALT 2 W-B Instrument Panel J/B IG1 10 7 I15 Ignition SW G 1K 1C 4 IG1 AM1 2 1 1A AM1 1 2 6 1C W FL MAIN Battery IB H44547 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1543 05-1354 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 CHECK PASSENGER AIRBAG ON/OFF INDICATOR LIGHT OPERATION (a) Turn the ignition switch to the ON position. (b) Check the passenger airbag ON/OFF indicator light operation. HINT: Refer to the normal condition of the passenger airbag ON/OFF indicator light (see page 05-1207 ). A B 4 sec. 2 sec. 4 sec. 2 sec. C ON Ignition Switch OFF ON Passenger Airbag ON/OFF Indicator Light (”ON”) OFF Passenger Airbag ON ON/OFF Indicator Light (”OFF”) OFF ON/OFF condition depends on the front passenger detection results. H43700 Result: A: During period ”A” in the illustration, even if both the ”ON” and ”OFF” passenger airbag ON/OFF indicator lights normally come on, both of them do not go off during period ”B”. During periods ”A” and ”B” in the illustration, even if both the ”ON” and ”OFF” passenger airbag ON/OFF indicator lights normally come on, both of them come on during period ”C”. B: During period ”A”, neither the ”ON” nor ”OFF” passenger airbag ON/OFF indicator lights come on, or one of them does not come on. During period ”C”, even if the front passenger seat is occupied, neither the ”ON” nor ”OFF” passenger airbag ON/OFF indicator lights come on. B Go to step 6 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1544 05-1355 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK TELLTALE LAMP ASSY (PASSENGER AIRBAG ON/OFF INDICATOR LIGHT) (a) (b) (c) (d) (e) (f) H44095 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connector from the telltale lamp assy. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Check the passenger airbag ON/OFF indicator light operation. OK: The passenger airbag ON/OFF indicator light (”ON” and ”OFF”) do not come on. NG REPLACE TELLTALE LAMP ASSY (SEE PAGE 71-10 ) OK 3 CHECK WIRE HARNESS (TO GROUND) (a) Telltale Lamp D Assy A17 C B Airbag Sensor A Assy Center Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A17-1 (P-AB) Body ground Always 1 MΩ or Higher A17-25 (PAON) Body ground Always 1 MΩ or Higher P-AB PAON H01015 H43468 G27651 H40065 H44539 NG REPAIR OR REPLACE WIRE HARNESS OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1545 05-1356 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK WIRE HARNESS (SHORT) (a) Telltale Lamp D Assy C B Airbag Sensor A Assy Center A17 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A17-1 (P-AB) A17-25 (PAON) Always 1 MΩ or Higher P-AB PAON H01015 H43468 G27651 H40065 NG H44539 REPAIR OR REPLACE WIRE HARNESS OK 5 CHECK AIR BAG SENSOR ASSY CENTER Telltale Lamp Assy (a) (b) (c) Airbag Sensor Assy Center (d) DTC B1152/28 DLC3 (e) (f) (g) (h) CG H43087 H01012 H43467 H10600 H01069 TC H44541 Connect the connectors to the airbag sensor assy center. Connect the connector to the clock assy. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1152/28 is not output. HINT: Codes other than code B1152/28 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK USE SIMULATION METHOD TO CHECK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1546 05-1357 DIAGNOSTICS 6 - SUPPLEMENTAL RESTRAINT SYSTEM WIRE HARNESS (SOURCE VOLTAGE) (a) T15 (b) (c) IG+ SW1 H44540 I40606 Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage and resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition T15-4 (IG+) Body ground Ignition switch ON 10 to 14 V T15-5 (SW1) Body ground Always Below 1 Ω NG REPLACE TELLTALE LAMP ASSY OR WIRE HARNESS (TELLTALE LAMP ASSY - BATTERY) OR BATTERY OK 7 CHECK WIRE HARNESS (OPEN) Telltale Lamp D Assy C B (a) (b) Airbag Sensor A Assy Center T15 A17 P-AB P-AB PAON H44540 H01015 H43469 H43625 G27651 PAON Service Wire H44542 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Using a service wire, connect T15-2 (P-AB) and T15-7 (PAON) of connector ”C”. NOTICE: Do not forcibly insert a service wire into the terminals of connector when connecting. (d) Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A17-1 (P-AB) A17-25 (PAON) Always Below 1 Ω NG REPAIR OR REPLACE WIRE HARNESS OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1547 05-1358 DIAGNOSTICS 8 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK WIRE HARNESS (TO B+) (a) (b) Telltale Lamp D Assy A17 C B Airbag Sensor A Assy Center (c) (d) P-AB PAON H01015 H43468 G27651 H40065 H44539 Disconnect the service wire from connector ”C”. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A17-25 (PAON) Body ground Ignition switch ON Below 1 V A17-1 (P-AB) Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE WIRE HARNESS OK 9 CHECK WIRE HARNESS (AIRBAG SENSOR ASSY CENTER - BODY GROUND) (a) (b) (c) A17 E2 E1 H40065 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A17-27 (E1) Body ground Always Below 1 Ω A17-28 (E2) Body ground Always Below 1 Ω NG REPAIR OR REPLACE WIRE HARNESS OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1548 05-1359 DIAGNOSTICS 10 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER Telltale Lamp Assy (a) (b) (c) Airbag Sensor Assy Center (d) DTC B1152/28 DLC3 (e) (f) (g) (h) CG H43087 H01012 H43467 H10600 H01069 TC H44541 Connect the connectors to the airbag sensor assy center. Connect the connector to the clock assy. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1152/28 is not output. HINT: Codes other than code B1152/28 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK USE SIMULATION METHOD TO CHECK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1549 05-1360 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IVT-02 B1153/25 SEAT POSITION AIRBAG SENSOR MALFUNCTION CIRCUIT DESCRIPTION The seat position airbag sensor circuit consists of the airbag sensor assy center and the seat position airbag sensor. DTC B1153/25 is recorded when a malfunction is detected in the seat position airbag sensor circuit. DTC No. B1153/25 DTC Detecting Condition
Open circuit in LSP+ wire harness or LSP- wire harness of seat position airbag sensor
Short circuit in seat position airbag sensor wire harness (to ground)
Short circuit in seat position airbag sensor wire harness (to B+)
Seat position airbag sensor malfunction
Airbag sensor assy center malfunction Trouble Area
Seat position airbag sensor
Airbag sensor assy center
Floor wire No.2 WIRING DIAGRAM B19 Seat Position Airbag Sensor (Driver’s Side) VS GND Airbag Sensor Assy Center 3 4 A16 A16 LSP+ (*2) (*1) W 2 8 3 A16 A16 LSP(*2) (*1) B 4 *1: w/ Curtain Shield Airbag *2: w/o Curtain Shield Airbag H43119 H44103 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1550 05-1361 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 CHECK DTC (a) Seat Position Airbag Sensor DLC3 CG (b) (c) (d) Airbag Sensor Assy Center (e) DTC B1153/25 HINT: Codes other than code B1153/25 may be output at this time, but they are not related to this check. TC H01007 H10600 C91522 Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1153/25 is not output. H42468 NG Go to step 2 OK USE SIMULATION METHOD TO CHECK 2 (a) (b) (c) CHECK CONNECTION OF CONNECTORS Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Check that the connectors are properly connected to the airbag sensor assy center and the seat position airbag sensor. OK: The connectors are connected. NG CONNECT CONNECTORS, THEN GO TO STEP 1 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1551 05-1362 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FLOOR WIRE NO.2(OPEN) (a) Seat Position Airbag Sensor Floor Wire No.2 D C B A Airbag Sensor Assy Center A16 *2 B19 4 2 A16 *1 LSP+ LSP+ LSPLSP- Disconnect the connectors from the airbag sensor assy center and the seat position airbag sensor. (b) Using a service wire, connect B19-2 and B19-4 of connector ”C”. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (c) Measure the resistance according to the value(s) in the table below. Standard: w/ Side and curtain shield airbag: Service Wire *1: w/ Side and Curtain Shield Airbag *2: w/o Side and Curtain Shield Airbag H42467 Tester connection Condition Specified condition A16-4 (LSP+) A16-3 (LSP-) Always Below 1 Ω w/o Side and curtain shield airbag: Tester connection Condition Specified condition A16-3 (LSP+) A16-8 (LSP-) Always Below 1 Ω NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 4 CHECK FLOOR WIRE NO.2(TO B+) (a) (b) Disconnect the service wire from connector ”C”. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) Turn the ignition switch to the ON position. (d) Measure the voltage according to the value(s) in the table below. Standard: w/ Side and curtain shield airbag: Floor Wire No.2 D C B Seat Position Airbag Sensor A16 *2 LSP+ A Airbag Sensor Assy Center LSP- LSP+ A16 *1 LSP- *1: w/ Side and Curtain Shield Airbag *2: w/o Side and Curtain Shield Airbag H42459 Tester connection Condition Specified condition A16-4 (LSP+) Body ground Ignition switch ON Below 1 V A16-3 (LSP-) Body ground Ignition switch ON Below 1 V w/o Side and curtain shield airbag: Tester connection Condition Specified condition A16-3 (LSP+) Body ground Ignition switch ON Below 1 V A16-8 (LSP-) Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1552 05-1363 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FLOOR WIRE NO.2(TO GROUND) (a) (b) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Measure the resistance according to the value(s) in the table below. Standard: w/ Side and curtain shield airbag: Floor Wire No.2 D C B Seat Position Airbag Sensor A Airbag Sensor Assy Center LSP- A16 *2 LSP+ A16 LSP+ *1 LSP- Tester connection Condition Specified condition A16-4 (LSP+) Body ground Always 1 MΩ or Higher A16-3 (LSP-) Body ground Always 1 MΩ or Higher w/o Side and curtain shield airbag: *1: w/ Side and Curtain Shield Airbag *2: w/o Side and Curtain Shield Airbag H42459 Tester connection Condition Specified condition A16-3 (LSP+) Body ground Always 1 MΩ or Higher A16-8 (LSP-) Body ground Always 1 MΩ or Higher NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 6 CHECK FLOOR WIRE NO.2(SHORT) (a) Measure the resistance according to the value(s) in the table below. Standard: w/ Side and curtain shield airbag: Floor Wire No.2 D C B Seat Position Airbag Sensor A16 *2 LSP+ A Airbag Sensor Assy Center LSP- LSP+ A16 Condition Specified condition A16-4 (LSP+) A16-3 (LSP-) Always 1 MΩ or Higher w/o Side and curtain shield airbag: *1 LSP- *1: w/ Side and Curtain Shield Airbag *2: w/o Side and Curtain Shield Airbag Tester connection H42459 Tester connection Condition Specified condition A16-3 (LSP+) A16-8 (LSP-) Always 1 MΩ or Higher NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1553 05-1364 DIAGNOSTICS 7 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK SEAT POSITION AIR BAG SENSOR (a) Seat Position Airbag Sensor DLC3 (b) Airbag Sensor Assy Center (c) DTC B1153/25 (d) (e) (f) (g) CG H01007 H10600 C91522 TC H42468 Connect the connectors to the seat position airbag sensor and the airbag sensor assy center. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1153/25 is not output. HINT: Codes other than code B1153/25 may be output at this time, but they are not related to this check. NG Go to step 8 OK USE SIMULATION METHOD TO CHECK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1554 05-1365 DIAGNOSTICS 8 (a) (b) (c) - SUPPLEMENTAL RESTRAINT SYSTEM REPLACE SEAT POSITION AIR BAG SENSOR Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Replace the seat position airbag sensor (see page 60-61 ). 9 CHECK AIR BAG SENSOR ASSY CENTER (a) Seat Position Airbag Sensor DLC3 CG H01007 H10600 C91522 (b) Airbag Sensor Assy Center (c) (d) (e) DTC B1153/25 TC H42468 (f) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1153/25 is not output. HINT: Codes other than code B1153/25 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1555 05-1366 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IVU-01 B1154/38 AIRBAG SENSOR REAR (RH) MALFUNCTION CIRCUIT DESCRIPTION The airbag sensor rear RH consists of the safing sensor, the diagnostic circuit and the lateral deceleration sensor, etc. If the airbag sensor assy center receives signals from the lateral deceleration sensor, it judges whether or not the SRS should be activated. DTC B1154/38 is recorded when a malfunction in the airbag sensor rear RH is detected. DTC No. DTC Detecting Condition Trouble Area B1154/38
Short circuit in airbag sensor rear RH wire harness (to ground)
Short circuit in airbag sensor rear RH wire harness (to B+)
Open circuit in airbag sensor rear RH wire harness
Short circuit in airbag sensor rear RH wire harness
Airbag sensor rear RH malfunction
Airbag sensor assy center malfunction
Airbag sensor rear RH
Airbag sensor assy center
Floor wire WIRING DIAGRAM S33 Airbag Sensor Rear RH Airbag Sensor Assy Center ESCR 1 VUCR CSR- CSR+ 20 A18 ESCR B (*1) 4 W (*1) 2 G (*1) 3 R (*1) 19 A18 VUCR 4 A18 CSR- 18 A18 CSR+ *1 w/ Curtain Shield Airbag H43054 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1556 05-1367 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 CHECK DTC (a) Airbag Sensor Rear RH Airbag Sensor Assy Center (b) (c) (d) (e) DLC3 CG DTC B1154/38 HINT: Codes other than code B1154/38 may be output at this time, but they are not related to this check. TC H01012 H10600 C92968 Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1154/38 is not output. H42125 NG Go to step 2 OK USE SIMULATION METHOD TO CHECK 2 (a) (b) (c) CHECK CONNECTION OF CONNECTORS Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Check that the connectors are properly connected to the airbag sensor assy center and the airbag sensor rear RH. OK: The connectors are connected. NG CONNECT CONNECTORS, THEN GO TO STEP 1 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1557 05-1368 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FLOOR WIRE(OPEN) (a) Airbag Sensor Floor Wire Rear RH D A C Airbag Sensor Assy Center (b) A18 (c) B S33 ESCR VUCR CSR- CSR+ CSRESCR VUCR CSR+ SST H01015 C91384 C91385 C82599 Disconnect the connectors from the airbag sensor assy center and the airbag sensor rear assy RH. Using SST, connect S33-4 (VUCR) to S33-1 (ESCR), and connect S33-3 (CSR+) to S33-2 (CSR-) of connector ”C”. SST 09843-18040 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A18-19 (VUCR) A18-20 (ESCR) Always Below 1 Ω A18-18 (CSR+) A18-4 (CSR-) Always Below 1 Ω H42483 NG REPAIR OR REPLACE FLOOR WIRE OK 4 CHECK FLOOR WIRE(TO B+) Floor Wire B D (a) (b) Airbag Sensor Assy A Center (c) (d) C Airbag Sensor Rear RH CSRESCR A18 VUCR CSR+ H01015 C82599 H42484 Disconnect the SST from connector ”C”. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A18-19 (VUCR) Body ground Ignition switch ON Below 1 V A18-20 (ESCR) Body ground Ignition switch ON Below 1 V A18-18 (CSR+) Body ground Ignition switch ON Below 1 V A18-4 (CSR-) Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE FLOOR WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1558 05-1369 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FLOOR WIRE(TO GROUND) Floor Wire B D (a) (b) Airbag Sensor Assy A Center (c) C Airbag Sensor Rear RH CSRESCR A18 VUCR CSR+ H01015 C82599 H42484 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A18-19 (VUCR) Body ground Always 1 MΩ or Higher A18-20 (ESCR) Body ground Always 1 MΩ or Higher A18-18 (CSR+) Body ground Always 1 MΩ or Higher A18-4 (CSR-) Body ground Always 1 MΩ or Higher NG REPAIR OR REPLACE FLOOR WIRE OK 6 CHECK FLOOR WIRE(SHORT) Floor Wire B D (a) Airbag Sensor Assy A Center C Airbag Sensor Rear RH CSRESCR A18 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A18-19 (VUCR) A18-20 (ESCR) Always 1 MΩ or Higher A18-18 (CSR+) A18-4 (CSR-) Always 1 MΩ or Higher VUCR CSR+ H01015 C82599 H42484 NG REPAIR OR REPLACE FLOOR WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1559 05-1370 DIAGNOSTICS 7 SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR REAR RH Airbag Sensor Rear LH (a) (b) Airbag Sensor Assy Center (c) (d) DTC B1154/38 CG - TC H01012 H10600 C92968 C92969 DTC B1155/39 (e) (f) (g) (h) Connect the connector to the airbag sensor assy center. Interchange the airbag sensor rear LH with RH and connect the connectors to them. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). Result: H42126 NG: A DTC B1154/38 is output. NG: B DTC B1155/39 is output. DTC B1154/38 and B1155/39 are not output. OK NG:A REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) NG:B REPLACE AIR BAG SENSOR REAR RH (SEE PAGE 60-59 ) OK USE SIMULATION METHOD TO CHECK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1560 05-1371 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IVV-01 B1155/39 AIRBAG SENSOR REAR (LH) MALFUNCTION CIRCUIT DESCRIPTION The airbag sensor rear LH consists of the safing sensor, the diagnostic circuit and the lateral deceleration sensor, etc. If the airbag sensor assy center receives signals from the lateral deceleration sensor, it judges whether or not the SRS should be activated. DTC B1155/39 is recorded when a malfunction in the airbag sensor rear LH is detected. DTC No. DTC Detecting Condition Trouble Area B1155/39
Short circuit in airbag sensor rear LH wire harness (to ground)
Short circuit in airbag sensor rear LH wire harness (to B+)
Open circuit in airbag sensor rear LH wire harness
Short circuit in airbag sensor rear LH wire harness
Airbag sensor rear LH malfunction
Airbag sensor assy center malfunction
Airbag sensor rear LH
Airbag sensor assy center
Floor wire No.2 WIRING DIAGRAM S32 Airbag Sensor Rear LH Airbag Sensor Assy Center ESCL 1 VUCL CSL- CSL+ 13 A16 ESCL B (*1) 4 W (*1) 2 G (*1) 3 R (*1) 14 A16 VUCL 1 A16 CSL- 15 A16 CSL+ *1 w/ Curtain Shield Airbag H43054 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1561 05-1372 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 CHECK DTC (a) Airbag Sensor Rear LH (b) (c) (d) Airbag Sensor Assy Center (e) DLC3 DTC B1155/39 CG HINT: Codes other than code B1155/39 may be output at this time, but they are not related to this check. TC H01007 H10600 C92969 Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1155/39 is not output. H42127 NG Go to step 2 OK USE SIMULATION METHOD TO CHECK 2 (a) (b) (c) CHECK CONNECTION OF CONNECTORS Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Check that the connectors are properly connected to the airbag sensor assy center and the airbag sensor rear LH. OK: The connectors are connected. NG CONNECT CONNECTORS, THEN GO TO STEP 1 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1562 05-1373 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FLOOR WIRE NO.2(OPEN) (a) Floor Wire No.2 D C B Airbag Sensor Rear LH S32 ESCL VUCL CSL- CSL+ A Airbag Sensor Assy Center (b) (c) A16 CSLESCL VUCL CSL+ SST SST H01010 C91385 C91384 C82600 H43148 Disconnect the connectors from the airbag sensor assy center and the airbag sensor rear assy LH. Using SST, connect S32-1 (VUCL) to S32-4 (ESCL), and connect S32-3 (CSL+) to S32-2 (CSL-) of connector ”C”. SST 09843-18040 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A16-14 (VUCL) A16-13 (ESCL) Always Below 1 Ω A16-15 (CSL+) A16-1 (CSL-) Always Below 1 Ω NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 4 CHECK FLOOR WIRE NO.2(TO B+) (a) (b) Floor Wire No.2 D C Airbag Sensor Rear LH D A Airbag Sensor Assy Center (c) (d) A16 H01010 C82600 Disconnect the SST from connector ”C”. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition CSL- A16-14 (VUCL) Body ground Ignition switch ON Below 1 V ESCL A16-13 (ESCL) Body ground Ignition switch ON Below 1 V A16-15 (CSL+) Body ground Ignition switch ON Below 1 V A16-1 (CSL-) Body ground Ignition switch ON Below 1 V VUCL CSL+ H42486 NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1563 05-1374 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FLOOR WIRE NO.2(TO GROUND) (a) (b) Floor Wire No.2 D C B Airbag Sensor Rear LH A16 A Airbag Sensor Assy Center (c) CSLESCL VUCL CSL+ H01010 C82600 H42486 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A16-14 (VUCL) Body ground Always 1 MΩ or Higher A16-13 (ESCL) Body ground Always 1 MΩ or Higher A16-15 (CSL+) Body ground Always 1 MΩ or Higher A16-1 (CSL-) Body ground Always 1 MΩ or Higher NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 6 CHECK FLOOR WIRE NO.2(SHORT) (a) Floor Wire No.2 D C Airbag Sensor Rear LH A16 B A Airbag Sensor Assy Center Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A16-14 (VUCL) A16-13 (ESCL) Always 1 MΩ or Higher A16-15 (CSL+) A16-1 (CSL-) Always 1 MΩ or Higher CSLESCL H01010 C82600 VUCL CSL+ H42486 NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1564 05-1375 DIAGNOSTICS 7 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR REAR LH Airbag Sensor Rear RH DLC3 CG TC H01007 H10600 C92968 C92969 (a) (b) Airbag Sensor Assy Center (c) (d) DTC B1154/38 DTC B1155/39 (e) (f) (g) (h) Connect the connector to the airbag sensor assy center. Interchange the airbag sensor rear LH with RH and connect the connectors to them. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). Result: H42128 NG: A DTC B1154/38 is output. NG: B DTC B1155/39 is output. DTC B1154/38 and B1155/39 are not output. OK NG:A REPLACE AIR BAG SENSOR REAR LH (SEE PAGE 60-59 ) NG:B REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK USE SIMULATION METHOD TO CHECK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1565 05-1376 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IVW-02 B1160/83 SHORT IN CURTAIN SHIELD SQUIB (RH) CIRCUIT CIRCUIT DESCRIPTION The curtain shield squib RH circuit consists of the airbag sensor assy center and the curtain shield airbag assy RH. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1160/83 is recorded when a short circuit is detected in the curtain shield squib RH circuit. DTC No. B1160/83 DTC Detecting Condition Trouble Area
Short circuit between ICR+ wire harness and ICR- wire harness of curtain shield squib RH
Curtain shield squib RH malfunction
Airbag sensor assy center malfunction
Curtain shield airbag assy RH (Curtain shield squib RH)
Airbag sensor assy center
Floor wire
Roof wire No.2 (w/ Rear seat entertainment system) WIRING DIAGRAM Airbag Sensor Assy Center Y (*2 *3) C19 Curtain Shield Squib RH 1 Y (*1 *3) 2 Y-B (*1 *3) 2 BK2 Y (*1 *3) 1 BK2 Y-B (*1 *3) 8 A18 ICR+ 7 A18 ICR- Y-B (*2 *3) *1: w/ Rear Seat Entertainment System *2: w/o Rear Seat Entertainment System *3: w/ Curtain Shield Airbag *4: w/o Curtain Shield Airbag H43058 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1566 05-1377 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 (a) CHECK VEHICLE CONDITION Check whether or not the vehicle is equipped with the rear seat entertainment system. Result: A: w/o Rear seat entertainment system B: w/ Rear seat entertainment system B Go to step 6 A 2 (a) (b) (c) (d) CHECK CONNECTOR Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least for 90 seconds. Disconnect the connectors from the curtain shield airbag assy RH. Check that the floor wire connector (on the curtain shield airbag assy RH side) is not damaged. OK: The lock button is not disengaged, or the claw of the lock is not deformed or damaged. B REPAIR OR REPLACE FLOOR WIRE A 3 CHECK FLOOR WIRE(CURTAIN SHIELD SQUIB RH CIRCUIT) (a) Floor Wire Airbag Sensor Assy A Center Curtain Shield Squib RH D C ICR+ H41465 B (b) (c) C19 ICR- H43068 Disconnect the connector from the airbag sensor assy center. Release the activation prevention mechanism built into connector ”B” (see page 05-1207 ). Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition C19-1 (ICR+) C19-2 (ICR-) Always 1 MΩ or Higher NG REPAIR OR REPLACE FLOOR WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1567 05-1378 DIAGNOSTICS 4 SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER (a) (b) Curtain Shield Squib RH Airbag Sensor Assy Center (c) (d) (e) (f) D C DLC3 DTC B1160/83 (g) CG - TC H01020 H10600 H11644 H40956 Connect the connector to the airbag sensor assy center. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1160/83 is not output. HINT: Codes other than code B1160/83 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1568 05-1379 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK CURTAIN SHIELD AIR BAG ASSY RH(CURTAIN SHIELD SQUIB RH) (a) (b) Curtain Shield Squib RH Airbag Sensor Assy Center (c) (d) DC DLC3 (e) DTC B1160/83 (f) (g) (h) TC CG H01021 H10600 H11644 H40931 (i) Turn the ignition switch to the LOCK position. Cconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Connect the connector to the curtain shield airbag assy RH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1160/83 is not output. HINT: Codes other than code B1160/83 may be output at this time, but they are not related to this check. NG REPLACE CURTAIN SHIELD AIR BAG ASSY RH (SEE PAGE 60-38 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1569 05-1380 DIAGNOSTICS 6 (a) (b) (c) (d) - SUPPLEMENTAL RESTRAINT SYSTEM CHECK CONNECTOR Turn the ignition switch to the ON position. Disconnect the negative (-) terminal cable from the battery, and wait for at least for 90 seconds. Disconnect the connectors from the curtain shield airbag assy RH. Check that the roof wire No.2 connector (on the curtain shield airbag assy RH side) is not damaged. OK: The lock button is not disengaged, or the claw of the lock is not deformed or damaged. NG REPAIR OR REPLACE ROOF WIRE NO.2 OK 7 CHECK CURTAIN SHIELD SQUIB (RH) CIRCUIT (a) (b) Airbag Sensor Assy A Center Curtain Shield Squib RH F E ICR+ DC B ICR- (c) Disconnect the connector from the airbag sensor assy center. Release the activation prevention mechanism built into connector ”B” (see page 05-1207 ). Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition C19-1 (ICR+) C19-2 (ICR-) Always 1 MΩ or Higher C19 H42818 H43068 H43091 NG Go to step 10 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1570 05-1381 DIAGNOSTICS 8 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER (a) (b) Airbag Sensor Assy Center Curtain Shield Squib RH F E DLC3 (c) (d) (e) (f) DC DTC B1160/83 (g) CG TC H43101 H10600 H11644 H43124 Connect the connector to the airbag sensor assy center. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1160/83 is not output. HINT: Codes other than code B1160/83 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1571 05-1382 DIAGNOSTICS 9 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK CURTAIN SHIELD AIR BAG ASSY RH (a) (b) Airbag Sensor Assy Center Curtain Shield Squib RH FE (c) (d) DC (e) DLC3 DTC B1160/83 (f) (g) (h) CG TC H42819 H40931 H43092 (i) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Connect the connector to the curtain shield airbag assy RH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1160/83 is not output. HINT: Codes other than code B1160/83 may be output at this time, but they are not related to this check. NG REPLACE CURTAIN SHIELD AIR BAG ASSY RH (SEE PAGE 60-38 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1572 05-1383 DIAGNOSTICS 10 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FLOOR WIRE (a) Roof Wire No.2 Curtain Shield Squib RH F E Floor Wire D C HINT: The activation prevention mechanism of connector ”B” has already been released. (b) Measure the resistance according to the value(s) in the table below. Standard: Airbag Sensor Assy A Center B BK2 ICR- ICR+ H42820 H42497 Disconnect the floor wire connector from the roof wire No.2. Tester connection Condition Specified condition BK2-2 (ICR+) BK2-1 (ICR-) Always 1 MΩ or Higher NG H42847 REPAIR OR REPLACE FLOOR WIRE OK 11 CHECK ROOF WIRE NO.2 (a) Roof Wire No.2 Curtain Floor Wire Shield Squib RH A F E ICR- H42821 C89244 D C Airbag Sensor Assy Center (b) B C19 Release the activation prevention mechanism built into connector ”D” (see page 05-1207 ). Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition C19-1 (ICR+) C19-2 (ICR-) Always 1 MΩ or Higher ICR+ H43067 NG REPAIR OR REPLACE ROOF WIRE NO.2 OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1573 05-1384 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IVX-01 B1161/84 OPEN IN CURTAIN SHIELD SQUIB (RH) CIRCUIT CIRCUIT DESCRIPTION The curtain shield squib RH circuit consists of the airbag sensor assy center and the curtain shield airbag assy RH. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1161/84 is recorded when an open circuit is detected in the curtain shield squib RH circuit. DTC No. DTC Detecting Condition Trouble Area B1161/84
Open circuit in ICR+ wire harness or ICR- wire harness of curtain shield squib RH
Curtain shield squib RH malfunction
Airbag sensor assy center malfunction
Curtain shield airbag assy RH (Curtain shield squib RH)
Airbag sensor assy center
Floor wire
Roof wire No.2 (w/ Rear seat entertainment system) WIRING DIAGRAM see page 05-1376 . INSPECTION PROCEDURE 1 (a) CHECK VEHICLE CONDITION Check whether or not the vehicle is equipped with the rear seat entertainment system. Result: A: w/o Rear seat entertainment system B: w/ Rear seat entertainment system B Go to step 5 A 2 CHECK FLOOR WIRE(CURTAIN SHIELD SQUIB RH CIRCUIT) (a) (b) Floor Wire Airbag Sensor Assy A Center Curtain Shield Squib RH D C (c) (d) B C19 ICR+ H41465 ICR- H43068 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the curtain shield airbag assy RH. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition C19-1 (ICR+) C19-2 (ICR-) Always Below 1 Ω NG REPAIR OR REPLACE FLOOR WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1574 05-1385 DIAGNOSTICS 3 Curtain Shield Squib RH (a) (b) Airbag Sensor Assy Center C D C19 ICR+ ICR- Service Wire DLC3 H01020 C89252 H11645 SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER Floor Wire CG - DTC B1161/84 TC H10600 H42129 Connect the connector to the airbag sensor assy center. Using a service wire, connect C19-1 (ICR+) and C19-2 (ICR-) of connector ”C”. NOTICE:
Twist the end of the service wire in order to insert it into the connector.
Do not forcibly insert the twisted service wire into the terminals of the connector when connecting. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Clear the DTCs stored in memory (see page 05-1215 ). (f) Turn the ignition switch to the LOCK position. (g) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (h) Check the DTCs (see page 05-1215 ). OK: DTC B1161/84 is not output. HINT: Codes other than code B1161/84 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1575 05-1386 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK CURTAIN SHIELD AIR BAG ASSY RH(CURTAIN SHIELD SQUIB RH) (a) (b) Curtain Shield Squib RH Airbag Sensor Assy Center (c) (d) (e) DC DLC3 CG H01021 H10600 DTC B1161/84 (g) (h) (i) TC H11645 (f) H40933 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”C”. Connect the connector to the curtain shield airbag assy RH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1161/84 is not output. HINT: Codes other than code B1161/84 may be output at this time, but they are not related to this check. NG REPLACE CURTAIN SHIELD AIR BAG ASSY RH (SEE PAGE 60-38 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1576 05-1387 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK CURTAIN SHIELD SQUIB (RH) CIRCUIT (a) (b) Curtain Shield Squib RH F E DC ICR+ B Airbag Sensor Assy A Center (c) (d) ICRC19 H42818 H43068 H43091 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center assy and the curtain shield airbag assy RH. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition C19-1 (ICR+) C19-2 (ICR-) Always Below 1 Ω NG Go to step 8 OK 6 CHECK AIR BAG SENSOR ASSY CENTER Curtain Shield Squib RH F E DC (a) (b) Airbag Sensor Assy Center C19 ICR+ ICR- Service Wire DLC3 CG H43102 C89252 H11645 DTC B1161/84 TC H10600 H43125 Connect the connector to the airbag sensor assy center. Using a service wire, connect C19-1 (ICR+) and C19-2 (ICR-) of connector ”E”. NOTICE:
Twist the end of the service wire in order to insert it into the connector.
Do not forcibly insert the twisted service wire into the terminals of the connector when connecting. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Clear the DTCs stored in memory (see page 05-1215 ). (f) Turn the ignition switch to the LOCK position. (g) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (h) Clear the DTCs (see page 05-1215 ). OK: DTC B1161/84 is not output. HINT: Codes other than code B1161/84 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1577 05-1388 DIAGNOSTICS 7 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK CURTAIN SHIELD AIR BAG ASSY RH(CURTAIN SHIELD SQUIB RH) (a) (b) Curtain Shield Squib RH FE Airbag Sensor Assy Center (c) (d) (e) DC DLC3 DTC B1161/84 CG H42819 H40933 (f) (g) (h) (i) TC H43093 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”E”. Connect the connector to the curtain shield airbag assy RH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1161/84 is not output. HINT: Codes other than code B1161/84 may be output at this time, but they are not related to this check. NG REPLACE CURTAIN SHIELD AIR BAG ASSY RH (SEE PAGE 60-38 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1578 05-1389 DIAGNOSTICS 8 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FLOOR WIRE (a) Roof Wire No.2 Curtain Floor Wire Shield Squib RH F E D C Airbag Sensor Assy A Center (b) B Disconnect the floor wire connector from the roof wire No.2. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition BK2-2 (ICR+) BK2-1 (ICR-) Always Below 1 Ω BK2 ICR- ICR+ H42820 H42497 H42847 NG REPAIR OR REPLACE FLOOR WIRE OK 9 CHECK ROOF WIRE NO.2 Roof Wire No.2 Curtain Floor Wire Shield Squib RH F E D C (a) Airbag Sensor Assy A Center Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition C19-1 (ICR+) C19-2 (ICR-) Always Below 1 Ω B C19 ICR+ H42821 C89244 ICR- H43067 NG REPAIR OR REPLACE ROOF WIRE NO.2 OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1579 05-1390 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IVY-01 B1162/81 SHORT IN CURTAIN SHIELD SQUIB (RH) CIRCUIT (TO GROUND) CIRCUIT DESCRIPTION The curtain shield squib RH circuit consists of the airbag sensor assy center and the curtain shield airbag assy RH. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1162/81 is recorded when a short to ground is detected in the curtain shield squib RH circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in curtain shield squib RH wire harness (to ground)
Curtain shield squib RH malfunction
Airbag sensor assy malfunction B1162/81
Curtain shield airbag assy RH (Curtain shield squib RH)
Airbag sensor assy center
Floor wire
Roof wire No.2 (w/ Rear seat entertainment system) WIRING DIAGRAM see page 05-1376 . INSPECTION PROCEDURE 1 (a) CHECK VEHICLE CONDITION Check whether or not the vehicle is equipped with the rear seat entertainment system. Result: A: w/o Rear seat entertainment system B: w/ Rear seat entertainment system B Go to step 5 A 2 CHECK FLOOR WIRE(CURTAIN SHIELD SQUIB RH CIRCUIT) (a) (b) Floor Wire Airbag Sensor Assy A Center Curtain Shield Squib RH D C (c) (d) B C19 ICR+ H41465 ICR- H43068 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the curtain shield airbag assy RH. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition C19-1 (ICR+) Body ground Always 1 MΩ or Higher C19-2 (ICR-) Body ground Always 1 MΩ or Higher NG REPAIR OR REPLACE FLOOR WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1580 05-1391 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER Floor Wire Curtain Shield Squib RH (a) (b) Airbag Sensor Assy Center C D C19 ICR+ ICR- Service Wire DLC3 CG H01020 C89252 H10600 DTC B1162/81 TC H11642 H42130 Connect the connector to the airbag sensor assy center. Using a service wire, connect C19-1 (ICR+) and C19-2 (ICR-) of connector ”C”. NOTICE:
Twist the end of the service wire in order to insert it into the connector.
Do not forcibly insert the twisted service wire into the terminals of the connector when connecting. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Clear the DTCs stored in memory (see page 05-1215 ). (f) Turn the ignition switch to the LOCK position. (g) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (h) Check the DTCs (see page 05-1215 ). OK: DTC B1162/81 is not output. HINT: Codes other than code B1162/81 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1581 05-1392 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK CURTAIN SHIELD AIR BAG ASSY RH(CURTAIN SHIELD SQUIB RH) (a) (b) Curtain Shield Squib RH Airbag Sensor Assy Center (c) (d) (e) DC DLC3 CG DTC B1162/81 (g) (h) (i) TC H01021 H10600 H11642 (f) H40938 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”C”. Connect the connector to the curtain shield airbag assy RH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1162/81 is not output. HINT: Codes other than code B1162/81 may be output at this time, but they are not related to this check. NG REPLACE CURTAIN SHIELD AIR BAG ASSY RH (SEE PAGE 60-38 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1582 05-1393 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK CURTAIN SHIELD SQUIB (RH) CIRCUIT (a) (b) Curtain Shield Squib RH F E DC Airbag Sensor Assy A Center B (c) (d) ICR- ICR+ C19 H42818 H43068 H43091 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the curtain shield airbag assy RH. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition C19-1 (ICR+) Body ground Always 1 MΩ or Higher C19-2 (ICR-) Body ground Always 1 MΩ or Higher NG Go to step 8 OK 6 CHECK AIR BAG SENSOR ASSY CENTER Airbag Sensor Assy Center Curtain Shield Squib RH F E (a) (b) DC ICR+ C19 ICR- Service Wire DLC3 CG H43102 C89252 H10600 DTC B1162/81 TC H11642 H43126 Connect the connector to the airbag sensor assy center. Using a service wire, connect C19-1 (ICR+) and C19-2 (ICR-) of connector ”E”. NOTICE:
Twist the end of the service wire in order to insert it into the connector.
Do not forcibly insert the twisted service wire into the terminals of the connector when connecting. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Clear the DTCs stored in memory (see page 05-1215 ). (f) Turn the ignition switch to the LOCK position. (g) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (h) Check the DTCs (see page 05-1215 ). OK: DTC B1162/81 is not output. HINT: Codes other than code B1162/81 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1583 05-1394 DIAGNOSTICS 7 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK CURTAIN SHIELD AIR BAG ASSY RH(CURTAIN SHIELD SQUIB RH) (a) (b) Airbag Sensor Assy Center Curtain Shield Squib RH FE DLC3 CG (c) (d) DC (e) DTC B1162/81 (g) (h) (i) TC H42819 H40938 (f) H43094 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”E”. Connect the connector to the curtain shield airbag assy RH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1162/81 is not output. HINT: Codes other than code B1162/81 may be output at this time, but they are not related to this check. NG REPLACE CURTAIN SHIELD AIR BAG ASSY RH (SEE PAGE 60-61 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1584 05-1395 DIAGNOSTICS 8 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FLOOR WIRE (a) Roof Wire No.2 Curtain Floor Wire Shield Squib RH F E D C Airbag Sensor Assy A Center (b) B BK2 ICR- Disconnect the floor wire connector from the roof wire No.2. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition BK2-2 (ICR+) Body ground Always 1 MΩ or Higher BK2-1 (ICR-) Body ground Always 1 MΩ or Higher ICR+ H42820 H42497 NG H42847 REPAIR OR REPLACE FLOOR WIRE OK 9 CHECK ROOF WIRE NO.2 Roof Wire No.2 Curtain Floor Wire Shield Squib RH F E D C (a) Airbag Sensor Assy A Center B C19 ICR+ H42821 C89244 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition C19-1 (ICR+) Body ground Always 1 MΩ or Higher C19-2 (ICR-) Body ground Always 1 MΩ or Higher ICR- H43067 NG REPAIR OR REPLACE ROOF WIRE NO.2 OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1585 05-1396 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IVZ-01 B1163/82 SHORT IN CURTAIN SHIELD SQUIB (RH) CIRCUIT (TO B+) CIRCUIT DESCRIPTION The curtain shield squib RH circuit consists of the airbag sensor assy center and the curtain shield airbag assy RH. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1163/82 is recorded when a short to B+ is detected in the curtain shield squib RH circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in curtain shield squib RH wire harness (to B+)
Curtain shield squib RH malfunction
Airbag sensor assy center malfunction B1163/82
Curtain shield airbag assy RH (Curtain shield squib RH)
Airbag sensor assy center
Floor wire
Roof wire No.2 (w/ Rear seat entertainment system) WIRING DIAGRAM see page 05-1376 . INSPECTION PROCEDURE 1 (a) CHECK VEHICLE CONDITION Check whether or not the vehicle is equipped with the rear seat entertainment system. Result: A: w/o Rear seat entertainment system B: w/ Rear seat entertainment system B Go to step 5 A 2 CHECK FLOOR WIRE(CURTAIN SHIELD SQUIB RH CIRCUIT) (a) (b) Floor Wire Airbag Sensor Assy A Center Curtain Shield Squib RH D C (c) (d) B C19 ICR+ H41465 ICR- H43068 (e) (f) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the curtain shield airbag assy RH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition C19-1 (ICR+) Body ground Ignition switch ON Below 1 V C19-2 (ICR-) Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE FLOOR WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1586 05-1397 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER Floor Wire Curtain Shield Squib RH D C (a) (b) Airbag Sensor Assy Center C19 ICR+ ICR- Service Wire DLC3 CG H01020 C89252 H10600 DTC B1163/82 TC H11643 H42131 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connector to the airbag sensor assy center. (d) Using a service wire, connect C19-1 (ICR+) and C19-2 (ICR-) of connector ”C”. NOTICE:
Twist the end of the service wire in order to insert it into the connector.
Do not forcibly insert the twisted service wire into the terminals of the connector when connecting. (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (see page 05-1215 ). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (see page 05-1215 ). OK: DTC B1163/82 is not output. HINT: Codes other than code B1163/82 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1587 05-1398 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK CURTAIN SHIELD AIR BAG ASSY RH(CURTAIN SHIELD SQUIB RH) (a) (b) Curtain Shield Squib RH Airbag Sensor Assy Center (c) (d) (e) D C DLC3 CG H01021 H10600 DTC B1163/82 (g) (h) (i) TC H11643 (f) H40939 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”C”. Connect the connector to the curtain shield airbag assy RH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1163/82 is not output. HINT: Codes other than code B1163/82 may be output at this time, but they are not related to this check. NG REPLACE CURTAIN SHIELD AIR BAG ASSY RH (SEE PAGE 60-38 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1588 05-1399 DIAGNOSTICS 5 SUPPLEMENTAL RESTRAINT SYSTEM CHECK CURTAIN SHIELD SQUIB (RH) CIRCUIT (a) (b) Airbag Sensor Assy A Center Curtain Shield Squib RH F E DC B ICR+ (c) (d) (e) (f) ICRC19 H42818 H43068 - H43091 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the curtain shield airbag assy RH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition C19-1 (ICR+) Body ground Ignition switch ON Below 1 V C19-2 (ICR-) Body ground Ignition switch ON Below 1 V NG Go to step 8 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1589 05-1400 DIAGNOSTICS 6 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER Curtain Shield Squib RH DC F E (a) (b) Airbag Sensor Assy Center ICR+ C19 ICR- Service Wire DLC3 CG H43102 C89252 H10600 DTC B1163/82 TC H11643 H43127 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connector to the airbag sensor assy center. (d) Using a service wire, connect C19-1 (ICR+) and C19-2 (ICR-) of connector ”E”. NOTICE:
Twist the end of the service wire in order to insert it into the connector.
Do not forcibly insert the twisted service wire into the terminals of the connector when connecting. (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (see page 05-1215 ). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (see page 05-1215 ). OK: DTC B1163/82 is not output. HINT: Codes other than code B1163/82 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1590 05-1401 DIAGNOSTICS 7 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK CURTAIN SHIELD AIR BAG ASSY RH(CURTAIN SHIELD SQUIB RH) (a) (b) Airbag Sensor Assy Center Curtain Shield Squib RH FE DLC3 CG H42819 H40939 (c) (d) (e) DC DTC B1163/82 (f) (g) (h) (i) TC H43095 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”E”. Connect the connector to the curtain shield airbag assy RH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1163/82 is not output. HINT: Codes other than code B1163/82 may be output at this time, but they are not related to this check. NG REPLACE CURTAIN SHIELD AIR BAG ASSY RH (SEE PAGE 60-38 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1591 05-1402 DIAGNOSTICS 8 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FLOOR WIRE (a) (b) Roof Wire No.2 Curtain Floor Wire Shield Squib RH F E D C Airbag Sensor Assy A Center B (c) (d) (e) (f) BK2 ICR+ ICRH42820 H42497 H42847 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the floor wire connector from the roof wire No.2. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition BK2-2 (ICR+) Body ground Ignition switch ON Below 1 V BK2-1 (ICR-) Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE FLOOR WIRE OK 9 CHECK ROOF WIRE NO.2 Roof Wire No.2 Curtain Floor Wire Shield Squib RH F E D C (a) Airbag Sensor Assy A Center B C19 ICR+ H42821 C89244 ICR- H43067 Measure the voltage according to the value(s) in the table below when the ignition switch remains in the ON position. Standard: Tester connection Condition Specified condition C19-1 (ICR+) Body ground Ignition switch ON Below 1 V C19-2 (ICR-) Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE ROOF WIRE NO.2 OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1592 05-1403 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IW1-01 B1165/87 SHORT IN CURTAIN SHIELD SQUIB (LH) CIRCUIT CIRCUIT DESCRIPTION The curtain shield squib LH circuit consists of the airbag sensor assy center and the curtain shield airbag assy LH. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1165/87 is recorded when a short circuit is detected in the curtain shield squib LH circuit. DTC No. B1165/87 DTC Detecting Condition Trouble Area
Short circuit between ICL+ wire harness and ICL- wire harness of curtain shield squib LH
Curtain shield squib LH malfunction
Airbag sensor assy center malfunction
Curtain shield airbag assy LH (Curtain shield squib LH)
Airbag sensor assy center
Floor wire No.2 WIRING DIAGRAM Airbag Sensor Assy Center C18 Curtain Shield Squib LH Y 1 (*1) Y-B 2 (*1) 9 A16 ICL+ 10 A16 ICL- *1: w/ Curtain Shield Airbag H01454 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1593 05-1404 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 (a) (b) (c) (d) CHECK CONNECTOR Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait at least for 90 seconds. Disconnect the connectors from the curtain shield airbag assy LH. Check that the floor wire No.2 connector (on the curtain shield airbag assy LH side) is not damaged. OK: The lock button is not disengaged, or the claw of the lock is not deformed or damaged. NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 2 CHECK FLOOR WIRE NO.2(CURTAIN SHIELD SQUIB LH CIRCUIT) (a) Curtain Shield Squib LH D C Floor Wire No.2 (b) B ICL+ A Airbag Sensor Assy Center (c) ICL- Disconnect the connector from the airbag sensor assy center. Release the activation prevention mechanism built into connector ”B” (see page 05-1207 ). Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition C18-1 (ICL+) C18-2 (ICL-) Always 1 MΩ or Higher C18 H41469 H43069 NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1594 05-1405 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER (a) (b) Curtain Shield Squib LH D C DLC3 CG H01017 H10600 (c) Airbag Sensor Assy Center (d) (e) (f) DTC B1165/87 TC H11648 H42132 (g) Connect the connector to the airbag sensor assy center. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1165/87 is not output. HINT: Codes other than code B1165/87 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1595 05-1406 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK CURTAIN SHIELD AIR BAG ASSY LH(CURTAIN SHIELD SQUIB LH) (a) (b) Curtain Shield Squib LH DC (c) Airbag Sensor Assy Center (d) (e) DLC3 CG DTC B1165/87 (f) (g) (h) TC H01018 H10600 H11648 H42133 (i) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Connect the connector to the curtain shield airbag assy LH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1165/87 is not output. HINT: Codes other than code B1165/87 may be output at this time, but they are not related to this check. NG REPLACE CURTAIN SHIELD AIR BAG ASSY LH (SEE PAGE 60-38 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1596 05-1407 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IW3-01 B1166/88 OPEN IN CURTAIN SHIELD SQUIB (LH) CIRCUIT CIRCUIT DESCRIPTION The curtain shield squib LH circuit consists of the airbag sensor assy center and the curtain shield airbag assy LH. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1166/88 is recorded when an open circuit is detected in the curtain shield squib LH circuit. DTC No. DTC Detecting Condition Trouble Area B1166/88
Open circuit in ICL+ wire harness or ICL- wire harness of curtain shield squib LH
Curtain shield squib LH malfunction
Airbag sensor assy center malfunction
Curtain shield airbag assy LH (Curtain shield squib LH)
Airbag sensor assy center
Floor wire No.2 WIRING DIAGRAM see page 05-1403 . INSPECTION PROCEDURE 1 CHECK FLOOR WIRE NO.2(CURTAIN SHIELD SQUIB LH CIRCUIT) Curtain Shield Squib LH D C (a) (b) Floor Wire No.2 B ICL+ A Airbag Sensor Assy Center (c) (d) ICLC18 H41469 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the curtain shield airbag assy LH. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition C18-1 (ICL+) C18-2 (ICL-) Always Below 1 Ω H43069 NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1597 05-1408 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER Curtain Shield Squib LH D (a) (b) Floor Wire No.2 C C18 ICL+ Airbag Sensor Assy Center ICLService Wire DLC3 CG DTC B1166/88 TC H01017 C89252 H10600 H11649 H42134 Connect the connector to the airbag sensor assy center. Using a service wire, connect C18-1 (ICL+) and C18-2 (ICL-) of connector ”C”. NOTICE:
Twist the end of the service wire in order to insert it into the connector.
Do not forcibly insert the twisted service wire into the terminals of the connector when connecting. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Clear the DTCs stored in memory (see page 05-1215 ). (f) Turn the ignition switch to the LOCK position. (g) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (h) Check the DTCs (see page 05-1215 ). OK: DTC B1166/88 is not output. HINT: Codes other than code B1166/88 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1598 05-1409 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK CURTAIN SHIELD AIR BAG ASSY LH(CURTAIN SHIELD SQUIB LH) (a) (b) Curtain Shield Squib LH DC (c) (d) Airbag Sensor Assy Center (e) DLC3 (f) DTC B1166/88 CG H01018 H10600 (g) (h) (i) TC H11649 H40945 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”C”. Connect the connector to the curtain shield airbag assy LH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1166/88 is not output. HINT: Codes other than code B1166/88 may be output at this time, but they are not related to this check. NG REPLACE CURTAIN SHIELD AIR BAG ASSY LH (SEE PAGE 60-38 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1599 05-1410 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IW5-01 B1167/85 SHORT IN CURTAIN SHIELD SQUIB (LH) CIRCUIT (TO GROUND) CIRCUIT DESCRIPTION The curtain shield squib LH circuit consists of the airbag sensor assy center and the curtain shield airbag assy LH. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1167/85 is recorded when a short to ground is detected in the curtain shield squib LH circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in curtain shield squib LH wire harness (to ground)
Curtain shield squib LH malfunction
Airbag sensor assy malfunction B1167/85
Curtain shield airbag assy LH (Curtain shield squib LH)
Airbag sensor assy center
Floor wire No.2 WIRING DIAGRAM see page 05-1403 . INSPECTION PROCEDURE 1 CHECK FLOOR WIRE NO.2(CURTAIN SHIELD SQUIB LH CIRCUIT) Curtain Shield Squib LH D C (a) (b) Floor Wire No.2 B A Airbag Sensor Assy Center (c) (d) C18 ICL+ H41469 ICL- H43069 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the curtain shield airbag assy LH. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition C18-1 (ICL+) Body ground Always 1 MΩ or Higher C18-2 (ICL-) Body ground Always 1 MΩ or Higher NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1600 05-141 1 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER (a) (b) Floor Wire No.2 Curtain Shield Squib LH Airbag Sensor D C Assy C18 Center ICL+ ICLService Wire DLC3 CG H01017 C89252 H10600 DTC B1167/85 TC H11646 H42135 Connect the connector to the airbag sensor assy center. Using a service wire, connect C18-1 (ICL+) and C18-2 (ICL-) of connector ”C”. NOTICE:
Twist the end of the service wire in order to insert it into the connector.
Do not forcibly insert the twisted service wire into the terminals of the connector when connecting. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Clear the DTCs stored in memory (see page 05-1215 ). (f) Turn the ignition switch to the LOCK position. (g) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (h) Check the DTCs (see page 05-1215 ). OK: DTC B1167/85 is not output. HINT: Codes other than code B1167/85 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1601 05-1412 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK CURTAIN SHIELD AIR BAG ASSY LH(CURTAIN SHIELD SQUIB LH) (a) (b) Curtain Shield Squib LH DC DLC3 CG H01018 H10600 (c) (d) Airbag Sensor Assy Center (e) (f) DTC B1167/85 (g) (h) (i) TC H11646 H40947 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”C”. Connect the connector to the curtain shield airbag assy LH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1167/85 is not output. HINT: Codes other than code B1167/85 may be output at this time, but they are not related to this check. NG REPLACE CURTAIN SHIELD AIR BAG ASSY LH (SEE PAGE 60-38 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1602 05-1413 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IW7-01 B1168/86 SHORT IN CURTAIN SHIELD SQUIB (LH) CIRCUIT (TO B+) CIRCUIT DESCRIPTION The curtain shield squib LH circuit consists of the airbag sensor assy center and the curtain shield airbag assy LH. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1168/86 is recorded when a short to B+ is detected in the curtain shield squib LH circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in curtain shield squib LH wire harness (to B+)
Curtain shield squib LH malfunction
Airbag sensor assy center malfunction B1168/86
Curtain shield airbag assy LH (Curtain shield squib LH)
Airbag sensor assy center
Floor wire No.2 WIRING DIAGRAM see page 05-1403 . INSPECTION PROCEDURE 1 CHECK FLOOR WIRE NO.2(CURTAIN SHIELD SQUIB LH CIRCUIT) Curtain Shield Squib LH D C C18 ICL+ H41469 (a) (b) Floor Wire No.2 B A Airbag Sensor Assy Center (c) (d) (e) (f) ICL- H43069 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the curtain shield airbag assy LH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition C18-1 (ICL+) Body ground Ignition switch ON Below 1 V C18-2 (ICL-) Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE FLOOR WIRE NO.2 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1603 05-1414 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER Curtain Shield Squib LH D (a) (b) Floor Wire No.2 Airbag Sensor Assy Center C C18 ICL+ ICL- Service Wire DLC3 CG H01017 C89252 H10600 DTC B1168/86 TC H11647 H42136 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connector to the airbag sensor assy center. (d) Using a service wire, connect C18-1 (ICL+) and C18-2 (ICL-) of connector ”C”. NOTICE:
Twist the end of the service wire in order to insert it into the connector.
Do not forcibly insert the twisted service wire into the terminals of the connector when connecting. (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (see page 05-1215 ). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (see page 05-1215 ). OK: DTC B1168/86 is not output. HINT: Codes other than code B1168/86 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1604 05-1415 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK CURTAIN SHIELD AIR BAG ASSY LH(CURTAIN SHIELD SQUIB LH) (a) (b) Curtain Shield Squib LH DC Airbag Sensor Assy Center (c) (d) (e) DLC3 DTC B1168/86 CG (g) (h) (i) TC H01018 H10600 H11647 (f) H40949 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”C”. Connect the connector to the curtain shield airbag assy LH. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1168/86 is not output. HINT: Codes other than code B1168/86 may be output at this time, but they are not related to this check. NG REPLACE CURTAIN SHIELD AIR BAG ASSY LH (SEE PAGE 60-38 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1605 05-1416 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IWA-01 B1180/17 SHORT IN D SQUIB (DUAL STAGE - 2ND STEP) CIRCUIT CIRCUIT DESCRIPTION The D squib (Dual stage - 2nd step) circuit consists of the airbag sensor assy center, the spiral cable subassy and the horn button assy. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1180/17 is recorded when a short circuit is detected in the D squib (Dual stage - 2nd step) circuit. DTC No. B1180/17 DTC Detecting Condition
Short circuit between D2+ wire harness and D2- wire harness of D squib (Dual stage - 2nd step)
D squib (Dual stage - 2nd step) malfunction
Spiral cable sub-assy malfunction
Airbag sensor assy center malfunction Trouble Area
Horn button assy (D squib, Dual stage - 2nd step)
Spiral cable sub-assy
Airbag sensor assy center
Cowl wire WIRING DIAGRAM Airbag Sensor Assy Center D Squib Y-B 2 1 Y 1 2 Y-R 1 4 Y-G 2 3 14 A17 D+ 13 A17 D- 16 A17 D2+ 17 A17 D2- A20 Spiral Cable Sub-assy H43063 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1606 05-1417 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 (a) (b) (c) (d) CHECK CONNECTOR Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the horn button assy. Check that the spiral cable sub-assy connectors (on the horn button assy side) are not damaged. OK: The lock button is not disengaged, or the claw of the lock is not deformed or damaged. NG REPLACE SPIRAL CABLE SUB-ASSY (SEE PAGE 60-26 ) OK 2 CHECK D SQUIB CIRCUIT(DUAL STAGE - 2ND STEP, AIRBAG SENSOR ASSY CENTER - HORN BUTTON ASSY) (a) D Squib (Dual stage - 2nd step) F E D2+ Spiral Cable Sub-assy DC B Airbag Sensor A Assy Center (b) (c) Disconnect the connector from the airbag sensor assy center. Release the activation prevention mechanism built into connector ”B” (see page 05-1207 ). Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition D2+ - D2- Always 1 MΩ or Higher D2- Color: Orange H01001 C91344 H41439 NG Go to step 5 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1607 05-1418 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER D Squib (Dual stage - 2nd step) F E Spiral Cable Sub-assy DC (a) (b) Airbag Sensor Assy Center (c) (d) (e) (f) DLC3 CG - H01002 H10600 C89246 DTC B1180/17 TC H42137 (g) Connect the connector to the airbag sensor assy center. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1180/17 is not output. HINT: Codes other than code B1180/17 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1608 05-1419 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK HORN BUTTON ASSY(D SQUIB, DUAL STAGE - 2ND STEP) D Squib (Dual stage - 2nd step) FE Spiral Cable Sub-assy DC (a) (b) Airbag Sensor Assy Center (c) (d) (e) DLC3 CG H01003 H10600 DTC B1180/17 (i) TC C89246 (f) (g) (h) H42138 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Connect the connectors to the horn button assy. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1180/17 is not output. HINT: Codes other than code B1180/17 may be output at this time, but they are not related to this check. NG REPLACE HORN BUTTON ASSY (SEE PAGE 60-17 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1609 05-1420 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK COWL WIRE D Squib (Dual stage - 2nd step) Spiral Cable Sub-assy F E (a) Cowl Wire D C B Airbag Sensor A Assy Center A20 Disconnect the cowl wire connector from the spiral cable sub-assy . HINT: The activation prevention mechanism of connector ”B” has already been released. (b) Measure the resistance according to the value(s) in the table below. Standard: D2+ Tester connection Condition Specified condition A20-4 (D2+) A20-3 (D2-) Always 1 MΩ or Higher D2H41440 NG H43066 REPAIR OR REPLACE COWL WIRE OK 6 CHECK SPIRAL CABLE SUB-ASSY (a) D Squib (Dual stage - 2nd step) Spiral Cable F E Sub-assy D2+ D C B Airbag Sensor A Assy Center (b) Release the activation prevention mechanism built into connector ”D” (see page 05-1207 ). Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition D2+ - D2- Always 1 MΩ or Higher D2- Color: Orange H41441 H43065 NG REPLACE SPIRAL CABLE SUB-ASSY (SEE PAGE 60-26 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1610 05-1421 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IWC-01 B1181/18 OPEN IN D SQUIB (DUAL STAGE - 2ND STEP) CIRCUIT CIRCUIT DESCRIPTION The D squib (Dual stage - 2nd step) circuit consists of the airbag sensor assy center, the spiral cable subassy and the horn button assy. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1182/19 is recorded when a short to ground is detected in the D squib (Dual stage - 2nd step) circuit. DTC No. B1182/19 DTC Detecting Condition Trouble Area
Short circuit in D squib (Dual stage - 2nd step) wire harness (to ground)
D squib (Dual stage - 2nd step) malfunction
Spiral cable sub-assy malfunction
Airbag sensor assy center malfunction
Horn button assy (D squib, Dual stage - 2nd step)
Spiral cable sub-assy
Airbag sensor assy center
Cowl wire WIRING DIAGRAM see page 05-1416 . INSPECTION PROCEDURE 1 CHECK D SQUIB CIRCUIT(DUAL STAGE - 2ND STEP, AIRBAG SENSOR ASSY CENTER - HORN BUTTON ASSY) D Squib (Dual stage - 2nd step) Spiral Cable Sub-assy F E D2+ (a) (b) DC B Airbag Sensor A Assy Center D2- (c) (d) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the horn button assy. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition D2+ - D2- Always Below 1 Ω Color: Orange H41439 H43064 NG Go to step 4 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1611 05-1422 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER D Squib (Dual stage - 2nd step) FE (a) (b) Spiral Cable Sub-assy DC Airbag Sensor Assy Center D2- D2+ Service Wire Color: Orange DLC3 CG H01002 C89252 H10600 C91338 DTC B1182/19 TC H44127 Connect the connector to the airbag sensor assy center. Using a service wire, connect D2+ and D2- of connector ”E”. NOTICE:
Twist the end of the service wire in order to insert it into the connector.
Do not forcibly insert the twisted service wire into the terminals, of the connector when connecting. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Clear the DTCs stored in memory (see page 05-1215 ). (f) Turn the ignition switch to the LOCK position. (g) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (h) Check the DTCs (see page 05-1215 ). OK: DTC B1182/19 is not output. HINT: Codes other than code B1182/19 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1612 05-1423 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK HORN BUTTON ASSY(D SQUIB, DUAL STAGE - 2ND STEP) D Squib (Dual stage - 2nd step) FE (a) (b) Spiral Cable Sub-assy DC Airbag Sensor Assy Center (c) (d) (e) (f) DLC3 CG DTC B1182/19 TC H01003 H10600 C89253 H42142 (g) (h) (i) (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”E”. Connect the connectors to the horn button assy. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1182/19 is not output. HINT: Codes other than code B1182/19 may be output at this time, but they are not related to this check. NG REPLACE HORN BUTTON ASSY (SEE PAGE 60-17 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1613 05-1424 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK COWL WIRE D Squib (Dual stage - 2nd step) Spiral Cable Sub-assy F E (a) Cowl Wire D C B Airbag Sensor A Assy Center (b) A20 Disconnect the cowl wire connector from the spiral cable sub-assy . Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A20-4 (D2+) A20-3 (D2-) Always Below 1 Ω D2+ D2H41440 NG H43066 REPAIR OR REPLACE COWL WIRE OK 5 CHECK SPIRAL CABLE SUB-ASSY (a) D Squib (Dual stage - 2nd step) Spiral Cable Sub-assy F E D2+ D C B Airbag Sensor A Assy Center Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition D2+ - D2- Always Below 1 Ω D2- Color: Orange H41441 H43065 NG REPLACE SPIRAL CABLE SUB-ASSY (SEE PAGE 60-26 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1614 05-1425 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IWF-01 B1182/19 SHORT IN D SQUIB (DUAL STAGE - 2ND STEP) CIRCUIT (TO GROUND) CIRCUIT DESCRIPTION The D squib (Dual stage - 2nd step) circuit consists of the airbag sensor assy center, the spiral cable subassy and the horn button assy. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1182/19 is recorded when a short to ground is detected in the D squib (Dual stage - 2nd step) circuit. DTC No. B1182/19 DTC Detecting Condition Trouble Area
Short circuit in D squib (Dual stage - 2nd step) wire harness (to ground)
D squib (Dual stage - 2nd step) malfunction
Spiral cable sub-assy malfunction
Airbag sensor assy center malfunction
Horn button assy (D squib, Dual stage - 2nd step)
Spiral cable sub-assy
Airbag sensor assy center
Cowl wire WIRING DIAGRAM see page 05-1416 . INSPECTION PROCEDURE 1 CHECK D SQUIB CIRCUIT(DUAL STAGE - 2ND STEP, AIRBAG SENSOR ASSY CENTER - HORN BUTTON ASSY) D Squib (Dual stage - 2nd step) Spiral Cable Sub-assy F E D2+ (a) (b) DC B Airbag Sensor A Assy Center D2- (c) (d) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the horn button assy. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition D2+ - Body ground Always 1 MΩ or Higher D2- - Body ground Always 1 MΩ or Higher Color: Orange H41439 H43064 NG Go to step 4 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1615 05-1426 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER D Squib (Dual stage - 2nd step) FE (a) (b) Spiral Cable Sub-assy D2+ DC Airbag Sensor Assy Center D2Service Wire Color: Orange DLC3 CG H01002 H91344 H10600 C91338 DTC B1182/19 TC H44128 Connect the connector to the airbag sensor assy center. Using a service wire, connect D2+ and D2- of connector ”E”. NOTICE:
Twist the end of the service wire in order to insert it into the connector.
Do not forcibly insert the twisted service wire into the terminals of the connector when connecting. (c) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (d) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (e) Clear the DTCs stored in memory (see page 05-1215 ). (f) Turn the ignition switch to the LOCK position. (g) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (h) Check the DTCs (see page 05-1215 ). OK: DTC B1182/19 is not output. HINT: Codes other than code B1182/19 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1616 05-1427 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK HORN BUTTON ASSY(D SQUIB, DUAL STAGE - 2ND STEP) D Squib (Dual stage - 2nd step) FE (a) (b) Spiral Cable Sub-assy DC Airbag Sensor Assy Center (c) (d) (e) (f) DLC3 CG DTC B1182/19 TC H01003 H10600 C89253 H42142 (g) (h) (i) (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”E”. Connect the connectors to the horn button assy. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1182/19 is not output. HINT: Codes other than code B1182/19 may be output at this time, but they are not related to this check. NG REPLACE HORN BUTTON ASSY (SEE PAGE 60-17 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1617 05-1428 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK COWL WIRE D Squib (Dual stage - 2nd step) Spiral Cable Sub-assy F E (a) Cowl Wire D C B Airbag Sensor A Assy Center (b) A20 D2+ D2H41440 Disconnect the cowl wire connector from the spiral cable sub-assy . Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A20-4 (D2+) Body ground Always 1 MΩ or Higher A20-3 (D2-) Body ground Always 1 MΩ or Higher NG H43066 REPAIR OR REPLACE COWL WIRE OK 5 CHECK SPIRAL CABLE SUB-ASSY (a) D Squib (Dual stage - 2nd step) Spiral Cable Sub-assy F E D2+ Cowl Wire D C B Airbag Sensor A Assy Center Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition D2+ - Body ground Always 1 MΩ or Higher D2- - Body ground Always 1 MΩ or Higher D2- Color: Orange H01000 C91344 H41441 NG REPAIR SPIRAL CABLE SUB-ASSY (SEE PAGE 60-26 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1618 05-1429 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IWH-01 B1183/22 SHORT IN D SQUIB (DUAL STAGE - 2ND STEP) CIRCUIT (TO B+) CIRCUIT DESCRIPTION The D squib (Dual stage - 2nd step) circuit consists of the airbag sensor assy center, the spiral cable subassy and the horn button assy. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1183/22 is recorded when a short to B+ is detected in the D squib (Dual stage - 2nd step) circuit. DTC No. B1183/22 DTC Detecting Condition Trouble Area
Short circuit in D squib (Dual stage - 2nd step) wire harness (to B+)
D squib (Dual stage - 2nd step) malfunction
Spiral cable sub-assy malfunction
Airbag sensor assy center malfunction
Horn button assy (D squib, Dual stage - 2nd step)
Spiral cable sub-assy
Airbag sensor assy center
Cowl wire WIRING DIAGRAM see page 05-1416 . CIRCUIT INSPECTION 1 CHECK D SQUIB CIRCUIT(DUAL STAGE - 2ND STEP, AIRBAG SENSOR ASSY CENTER - HORN BUTTON ASSY) D Squib (Dual stage - 2nd step) Spiral Cable Sub-assy F E D2+ (a) (b) DC B Airbag Sensor A Assy Center (d) (e) (f) D2- Color: Orange H01001 C91344 (c) H41439 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the horn button assy. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition D2+ - Body ground Ignition switch ON Below 1 V D2- - Body ground Ignition switch ON Below 1 V NG Go to step 4 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1619 05-1430 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER (a) (b) D Squib (Dual stage - 2nd step) Spiral Cable Sub-assy F E D2+ Airbag Sensor Assy Center DC D2Service Wire Color: Orange DLC3 CG DTC B1183/22 TC H01002 C891348 H10600 C91342 H44129 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Connect the connector to the airbag sensor assy center. (d) Using a service wire, connect D2+ and D2- of connector ”E”. NOTICE:
Twist the end of the service wire in order to insert it into the connector.
Do not forcibly insert the twisted service wire into the terminals of the connector when connecting. (e) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (f) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (g) Clear the DTCs stored in memory (see page 05-1215 ). (h) Turn the ignition switch to the LOCK position. (i) Turn the ignition switch to the ON position, and wait for at least 60 seconds. (j) Check the DTCs (see page 05-1215 ). OK: DTC B1183/22 is not output. HINT: Codes other than code B1183/22 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1620 05-1431 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK HORN BUTTON ASSY(D SQUIB, DUAL STAGE - 2ND STEP) D Squib (Dual stage - 2nd step) Spiral Cable Sub-assy FE (a) (b) DC Airbag Sensor Assy Center (c) (d) (e) (f) DLC3 CG H01003 H10600 C91342 DTC B1183/22 (g) (h) (i) TC H42144 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the service wire from connector ”E”. Connect the connectors to the horn button assy. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1183/22 is not output. HINT: Codes other than code B1183/22 may be output at this time, but they are not related to this check. NG REPLACE HORN BUTTON ASSY (SEE PAGE 60-17 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1621 05-1432 DIAGNOSTICS 4 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK COWL WIRE D Squib (Dual stage - 2nd step) Spiral Cable F E Sub-assy Cowl Wire D C B Airbag Sensor A Assy Center (a) (b) (c) (d) A20 (e) (f) D2+ D2H41440 H43066 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the cowl wire connector from the spiral cable sub-assy . Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A20-4 (D2+) Body ground Ignition switch ON Below 1 V A20-3 (D2-) Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE COWL WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1622 05-1433 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK SPIRAL CABLE SUB-ASSY (a) D Squib (Dual stage - 2nd step) Spiral Cable Sub-assy F E D2+ Cowl Wire D C B Airbag Sensor A Assy Center Measure the voltage according to the value(s) in the table below when the ignition switch remains in the ON position. Standard: Tester connection Condition Specified condition D2+ - Body ground Ignition switch ON Below 1 V D2- - Body ground Ignition switch ON Below 1 V D2- Color: Orange H01000 C91344 H41441 NG REPLACE SPIRAL CABLE SUB-ASSY (SEE PAGE 60-26 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1623 05-1434 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IWI-01 B1185/57 SHORT IN P SQUIB (DUAL STAGE - 2ND STEP) CIRCUIT CIRCUIT DESCRIPTION The P squib (Dual stage - 2nd step) circuit consists of the airbag sensor assy center and the front passenger airbag assy. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1185/57 is recorded when a short circuit is detected in the P squib (Dual stage - 2nd step) circuit. DTC No. DTC Detecting Condition Trouble Area B1185/57
Short circuit between P2+ wire harness and P2- wire harness of P squib (Dual stage - 2nd step)
P squib (Dual stage - 2nd step) malfunction
Airbag sensor assy center malfunction
Front passenger airbag assy (P squib, Dual stage - 2nd step)
Airbag sensor assy center
Cowl wire WIRING DIAGRAM Airbag Sensor Assy Center A19 P Squib Y-R 8 A17 P2+ Y-G 7 A17 P2- 3 4 H01454 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1624 05-1435 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 CHECK COWL WIRE(P SQUIB, DUAL STAGE - 2ND STEP CIRCUIT) (a) (b) Cowl Wire P Squib (Dual stage - 2nd step) D C B Airbag Sensor A Assy Center (c) (d) (e) A19 P2- R14286 H41424 P2+ H41932 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the front passenger airbag assy. Release the activation prevention mechanism built into connector ”B” (see page 05-1207 ). Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A19-3 (P2+) A19-4 (P2-) Always 1 MΩ or Higher NG REPAIR OR REPLACE COWL WIRE OK 2 CHECK AIR BAG SENSOR ASSY CENTER P Squib (Dual stage - 2nd step) D C (a) (b) Airbag Sensor Assy Center (c) (d) (e) (f) DLC3 DTC B1185/57 (g) CG TC H01023 H10600 H16840 H42145 Connect the connector to the airbag sensor assy center. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1185/57 is not output. HINT: Codes other than code B1185/57 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1625 05-1436 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT PASSENGER AIRBAG ASSY(P SQUIB, DUAL STAGE - 2ND STEP) P Squib (Dual stage - 2nd step) DC DLC3 CG (a) (b) Airbag Sensor Assy Center (c) (d) (e) DTC B1185/57 (f) (g) (h) TC H01024 H10600 H16840 H42146 (i) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Connect the connector to the front passenger airbag assy. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1185/57 is not output. HINT: Codes other than code B1185/57 may be output at this time, but they are not related to this check. NG REPLACE FRONT PASSENGER AIRBAG ASSY (SEE PAGE 60-29 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1626 05-1437 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IWJ-01 B1186/58 OPEN IN P SQUIB (DUAL STAGE - 2ND STEP) CIRCUIT CIRCUIT DESCRIPTION The P squib (Dual stage - 2nd step) circuit consists of the airbag sensor assy center and the front passenger airbag assy. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1186/58 is recorded when an open circuit is detected in the P squib (Dual stage - 2nd step) circuit. DTC No. DTC Detecting Condition Trouble Area B1186/58
Open circuit in P2+ wire harness or P2- wire harness of P squib (Dual stage - 2nd step)
P squib (Dual stage - 2nd step) malfunction
Airbag sensor assy center malfunction
Front passenger airbag assy (P squib, Dual stage - 2nd step)
Airbag sensor assy center
Cowl wire WIRING DIAGRAM see page 05-1434 . INSPECTION PROCEDURE 1 CHECK COWL WIRE(P SQUIB, DUAL STAGE - 2ND STEP CIRCUIT) P Squib (Dual stage - 2nd step) D (a) (b) Cowl Wire C B Airbag Sensor A Assy Center (c) (d) A19 P2- R14286 H41424 P2+ H41932 Turn the ignition switch to the LOCK position Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the front passenger airbag assy. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A19-3 (P2+) A19-4 (P2-) Always Below 1 Ω NG REPAIR OR REPLACE COWL WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1627 05-1438 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER (a) (b) P Squib Cowl Wire (Dual stage Airbag - 2nd step) Sensor D C Assy Center (c) (d) A19 P2+ (e) (f) (g) P2SST (h) DLC3 DTC B1186/58 CG HINT: Codes other than code B1186/58 may be output at this time, but they are not related to this check. TC H01023 H16853 H10600 H16841 Connect the connector to the airbag sensor assy center. Using SST, connect A19-3 (P2+) and A19-4 (P2-) of connector ”C”. SST 09843-18040 Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1186/58 is not output. H41981 NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1628 05-1439 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT PASSENGER AIRBAG ASSY(P SQUIB, DUAL STAGE - 2ND STEP) P Squib (Dual stage - 2nd step) DC (a) (b) Airbag Sensor Assy Center (c) (d) (e) DLC3 CG H01024 H10600 DTC B1186/58 (g) (h) (i) TC H16841 (f) H42148 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the SST from connector ”C”. Connect the connector to the front passenger airbag assy. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1186/58 is not output. HINT: Codes other than code B1186/58 may be output at this time, but they are not related to this check. NG REPLACE FRONT PASSENGER AIRBAG ASSY (SEE PAGE 60-29 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1629 05-1440 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IWK-01 B1187/55 SHORT IN P SQUIB (DUAL STAGE - 2ND STEP) CIRCUIT (TO GROUND) CIRCUIT DESCRIPTION The P squib (Dual stage - 2nd step) circuit consists of the airbag sensor assy center and the front passenger airbag assy. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1187/55 is recorded when a short to ground is detected in the P squib (Dual stage - 2nd step) circuit. DTC No. B1187/55 DTC Detecting Condition Trouble Area
Short circuit in P squib (Dual stage - 2nd step) wire harness (to ground)
P squib (Dual stage - 2nd step) malfunction
Airbag sensor assy center malfunction
Front passenger airbag assy (P squib, Dual stage - 2nd step)
Airbag sensor assy center
Cowl wire WIRING DIAGRAM see page 05-1434 . INSPECTION PROCEDURE 1 CHECK COWL WIRE(P SQUIB, DUAL STAGE - 2ND STEP CIRCUIT) P Squib Cowl Wire (Dual stage - 2nd step) D C B (a) (b) Airbag Sensor A Assy Center (c) (d) A19 P2- R14286 H41424 P2+ H41932 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the front passenger airbag assy. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A19-3 (P2+) Body ground Always 1 MΩ or Higher A19-4 (P2-) Body ground Always 1 MΩ or Higher NG REPAIR OR REPLACE COWL WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1630 05-1441 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER P Squib Cowl Wire (Dual stage Airbag - 2nd step) Sensor Assy D C Center (a) (b) P2+ (d) (c) A19 (e) (f) (g) P2SST DLC3 CG (h) DTC B1187/55 HINT: Codes other than code B1187/55 may be output at this time, but they are not related to this check. TC H01023 H16853 H10600 H16838 Connect the connector to the airbag sensor assy center. Using SST, connect A19-3 (P2+) and A19-4 (P2-) of connector ”C”. SST 09843-18040 Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1187/55 is not output. H41983 NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1631 05-1442 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT PASSENGER AIRBAG ASSY(P SQUIB, DUAL STAGE - 2ND STEP) P Squib (Dual stage - 2nd step) DC (a) (b) Airbag Sensor Assy Center (c) (d) (e) DLC3 CG H01024 H10600 DTC B1187/55 (g) (h) (i) TC H16838 (f) H42150 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the SST from connector ”C”. Connect the connector to the front passenger airbag assy. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1187/55 is not output. HINT: Codes other than code B1187/55 may be output at this time, but they are not related to this check. NG REPLACE FRONT PASSENGER AIRBAG ASSY (SEE PAGE 05-1215 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1632 05-1443 DIAGNOSTICS DTC - SUPPLEMENTAL RESTRAINT SYSTEM 05IWM-01 B1188/56 SHORT IN P SQUIB (DUAL STAGE - 2ND STEP) CIRCUIT (TO B+) CIRCUIT DESCRIPTION The P squib (Dual stage - 2nd step) circuit consists of the airbag sensor assy center and the front passenger airbag assy. The circuit instructs the SRS to deploy when deployment conditions are met. DTC B1188/56 is recorded when a short to B+ is detected in the P squib (Dual stage - 2nd step) circuit. DTC No. B1188/56 DTC Detecting Condition Trouble Area
Short circuit in P squib (Dual stage - 2nd step) wire harness (to B+)
P squib (Dual stage - 2nd step) malfunction
Airbag sensor assy center malfunction
Front passenger airbag assy (P squib, Dual stage - 2nd step)
Airbag sensor assy center
Cowl wire WIRING DIAGRAM see page 05-1434 . INSPECTION PROCEDURE 1 CHECK COWL WIRE(P SQUIB, DUAL STAGE - 2ND STEP CIRCUIT) P Squib Cowl Wire (Dual stage - 2nd step) D C B (a) (b) Airbag Sensor A Assy Center (c) (d) (e) (f) A19 P2- R14286 H41424 P2+ H41932 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connectors from the airbag sensor assy center and the front passenger airbag assy. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A19-3 (P2+) Body ground Ignition switch ON Below 1 V A19-4 (P2-) Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE COWL WIRE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1633 05-1444 DIAGNOSTICS 2 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK AIR BAG SENSOR ASSY CENTER P Squib Cowl Wire (Dual stage - 2nd step) D C (a) (b) Airbag Sensor Assy Center (c) (d) A19 P2+ (e) P2- (f) SST DLC3 (g) (h) (i) DTC B1188/56 (j) CG TC H01023 H16853 H10600 H16839 H41985 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. SST 09843-18040 Connect the connector to the airbag sensor assy center. Using SST, connect A19-3 (P2+) and A19-4 (P2-) of connector ”C”. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1188/56 is not output. HINT: Codes other than code B1188/56 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1634 05-1445 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT PASSENGER AIRBAG ASSY(P SQUIB, DUAL STAGE - 2ND STEP) P Squib (Dual stage - 2nd step) DC (a) (b) Airbag Sensor Assy Center (c) (d) (e) DLC3 CG DTC B1188/56 (f) (g) (h) (i) TC H01024 H10600 H16839 H42152 (j) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the SST from connector ”C”. Connect the connector to the front passenger airbag assy. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Clear the DTCs stored in memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position, and wait for at least 60 seconds. Check the DTCs (see page 05-1215 ). OK: DTC B1188/56 is not output. HINT: Codes other than code B1188/56 may be output at this time, but they are not related to this check. NG REPLACE FRONT PASSENGER AIRBAG ASSY (SEE PAGE 60-29 ) OK USE SIMULATION METHOD TO CHECK HINT:


Before performing the simulation method, check that the airbag sensor assy center is in check mode (see page 05-1218 ). Perform the simulation method by selecting the check mode with the hand-held tester (see page 05-1218 ). After selecting the check mode, perform the simulation method by wiggling each connector of the airbag system or driving the vehicle on a city or rough road (see page 05-1218 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1635 05-1446 DIAGNOSTICS DTC B1771 - SUPPLEMENTAL RESTRAINT SYSTEM 05IWO-01 PASSENGER SIDE BUCKLE SWITCH CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION The passenger side buckle switch circuit consists of the occupant classification ECU and the front seat inner belt assy RH (buckle switch RH). DTC B1771 is recorded when a malfunction is detected in the passenger side buckle switch circuit. Troubleshoot DTC B1771 first when the DTC B1771 and B1795 are output simultaneously. DTC No. B1771 DTC Detecting Condition
When the occupant classification ECU receives a line short signal, open signal, short to ground signal or B+ short signal in the passenger side buckle switch circuit for 2 seconds.
Passenger side buckle switch malfunction
Occupant classification ECU malfunction Trouble Area
Front seat inner belt assy RH (Buckle switch RH)
Front seat wire RH
Occupant classification ECU HINT:

When DTC B1150/23 is detected as a result of troubleshooting for the supplemental restraint system, perform troubleshooting for DTC B1771 of the occupant classification system. Use the hand-held tester to check the DTC of the occupant classification ECU, otherwise the DTC cannot be read. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1636 05-1447 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM WIRING DIAGRAM Occupant Classification ECU B17 Buckle SW RH L 9 O6 BSW GR 5 O6 BGND 2 1 H43432 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1637 05-1448 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE HINT:
If troubleshooting (wire harness inspection) is difficult to perform, remove the front RH seat assy installation bolts to see the under surface of seat cushion. In the above case, hold the seat so that it does not fall down. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat only as necessary.
1 CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in memory (see page 05-1215 ). HINT:
First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory.
Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position. (e) Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1771 is not output. HINT: Codes other than code B1771 may be output at this time, but they are not related to this check. NG Go to step 2 OK USE SIMULATION METHOD TO CHECK (SEE PAGE 05-1207 ) 2 (a) (b) (c) CHECK CONNECTION OF CONNECTORS Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Check that the connectors are properly connected to the occupant classification ECU and the front seat inner belt assy RH. OK: The connectors are connected. NG CONNECT CONNECTORS, THEN GO TO STEP 1 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1638 05-1449 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT WIRE RH (TO B+) Occupant Classification ECU Front Seat Wire RH D (b) (c) (d) A C Front Seat Inner Belt Assy RH (a) B BGND O6 Disconnect the connectors from the occupant classification ECU and the front seat inner belt assy RH. Connect the negative (-) terminal cable to the battery. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition O6-9 (BSW) Body ground Ignition switch ON Below 1 V O6-5 (BGND) Body ground Ignition switch ON Below 1 V BSW H43103 H43111 H43130 NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 4 CHECK FRONT SEAT WIRE RH (OPEN) Front Seat Wire RH Occupant Classification ECU A D Front Seat Inner Belt Assy RH C B B17 O6 BGND 2 1 Service Wire H43104 H43698 H43111 BSW H43418 (a) (b) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Using a service wire, connect B17-1 and B17-2 of connector ”C”. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (d) Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition O6-9 (BSW) O6-5 (BGND) Always Below 1 Ω NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1639 05-1450 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT WIRE RH (SHORT) Occupant Classification ECU Front Seat Wire RH (a) (b) A D C Front Seat Inner Belt Assy RH B Disconnect the service wire from connector ”C”. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition O6-9 (BSW) O6-5 (BGND) Always 1 MΩ or Higher BGND O6 BSW H43103 H43111 H43130 NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 6 CHECK FRONT SEAT WIRE RH (TO GROUND) Occupant Classification ECU Front Seat Wire RH A D C Front Seat Inner Belt Assy RH B O6 H43103 H43111 BGND (a) Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition O6-9 (BSW) Body ground Always 1 MΩ or Higher O6-5 (BGND) Body ground Always 1 MΩ or Higher BSW H43130 NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1640 05-1451 DIAGNOSTICS 7 - SUPPLEMENTAL RESTRAINT SYSTEM RECHECK DTC (a) Connect the connectors to the occupant classification ECU and the front seat inner belt assy RH. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch to the ON position. (d) Clear the DTCs stored in memory (see page 05-1215 ). HINT:
First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory.
Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position. (g) Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1771 is not output. HINT: Codes other than code B1771 may be output at this time, but they are not related to this check. NG Go to step 8 OK USE SIMULATION METHOD TO CHECK (SEE PAGE 05-1207 ) 8 REPLACE FRONT SEAT INNER BELT ASSY RH (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Replace the front seat inner belt assy RH (see page 72-1 1, 72-19 ). (d) Connect the negative (-) terminal cable to the battery. (e) Turn the ignition switch to the ON position. (f) Clear the DTCs stored in memory (see page 05-1215 ). HINT:
First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory.
Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. (g) Turn the ignition switch to the LOCK position. (h) Turn the ignition switch to the ON position. (i) Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1771 is not output. HINT: Codes other than code B1771 may be output at this time, but they are not related to this check. NG Go to step 9 OK END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1641 05-1452 DIAGNOSTICS 9 (a) (b) (c) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Replace the occupant classification ECU (see page 60-64 ). PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. 11 (a) SUPPLEMENTAL RESTRAINT SYSTEM REPLACE OCCUPANT CLASSIFICATION ECU 10 (a) - PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1642 05-1453 DIAGNOSTICS DTC B1780 - SUPPLEMENTAL RESTRAINT SYSTEM 05IWP-02 OCCUPANT CLASSIFICATION SENSOR FRONT LH CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION The occupant classification sensor front LH circuit consists of the occupant classification ECU and the occupant classification sensor front LH. DTC B1780 is recorded when a malfunction is detected in the occupant classification sensor front LH circuit. DTC No. B1780 DTC Detecting Condition Trouble Area
When the occupant classification ECU receives a line short signal, open signal, short to ground signal or B+ short signal in the occupant classification sensor front LH circuit for 2 seconds.
Occupant classification sensor front LH malfunction
Occupant classification ECU malfunction
Seat adjuster frame assy (Occupant classification sensor front LH)
Front seat wire RH
Occupant classification ECU HINT:

When DTC B1150/23 is detected as a result of troubleshooting for the supplemental restraint system, perform troubleshooting for the DTC B1780 of the occupant classification system. Use the hand-held tester to check the DTC of the occupant classification ECU, otherwise the DTC cannot be read. WIRING DIAGRAM O8 Occupant Classification Sensor Front LH SVC1 SIG1 SGD1 Occupant Classification ECU R 11 O7 SVC1 SB 7 O7 SIG1 G 1 O7 SGD1 1 2 3 H43062 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1643 05-1454 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE HINT:
If troubleshooting (wire harness inspection) is difficult to perform, remove the front RH seat assy installation bolts to see the under surface of seat cushion. In the above case, hold the seat so that it does not fall down. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat only as necessary.
1 CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in memory (see page 05-1215 ). HINT:
First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory.
Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position. (e) Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1780 is not output. HINT: Codes other than code B1780 may be output at this time, but they are not related to this check. NG Go to step 2 OK USE SIMULATION METHOD TO CHECK (SEE PAGE 05-1207 ) 2 (a) (b) (c) CHECK CONNECTION OF CONNECTORS Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Check that the connectors are properly connected to the occupant classification ECU and the occupant classification sensor front LH. OK: The connectors are connected. NG CONNECT CONNECTORS, THEN GO TO STEP 1 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1644 05-1455 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT WIRE RH (TO B+) Occupant Classification ECU Occupant Classification Sensor Front LH (a) (b) (c) (d) D A C Front Seat Wire RH SGD1 B O7 SIG1 SVC1 H43105 H43111 Disconnect the connectors from the occupant classification ECU and the occupant classification sensor front LH. Connect the negative (-) terminal cable to the battery. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition O7-1 (SGD1) Body ground Ignition switch ON Below 1 V O7-7 (SIG1) Body ground Ignition switch ON Below 1 V O7-1 1 (SVC1) Body ground Ignition switch ON Below 1 V H43474 NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 4 CHECK FRONT SEAT WIRE RH (OPEN) Occupant Classification Sensor Front LH (a) (b) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Using a service wire, connect O8-1 (SVC1) and O8-3 (SGD1), and connect O8-2 (SIG1) and O8-3 (SGD1) of connector ”C”. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (d) Measure the resistance according to the value(s) in the table below. Standard: Front Seat Wire RH Occupant Classification ECU D A C B O8 Service Wire SGD1 O7 SGD1 SVC1 H43106 H43699 H43111 SIG1 SIG1 Service Wire SVC1 H43475 Tester connection Condition Specified condition O7-7 (SIG1) O7-1 (SGD1) Always Below 1 Ω O7-1 1 (SVC1) O7-1 (SGD1) Always Below 1 Ω NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1645 05-1456 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT WIRE RH (SHORT) Occupant Classification ECU Occupant Classification Sensor Front LH D (a) (b) A C Front Seat Wire RHSGD1 B O7 SIG1 SVC1 H43105 H43111 H43474 Disconnect the service wire from connector ”C”. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition O7-7 (SIG1) O7-1 (SGD1) Always 1 MΩ or Higher O7-1 1 (SVC1) O7-1 (SGD1) Always 1 MΩ or Higher O7-7 (SIG1) O7-1 1 (SVC1) Always 1 MΩ or Higher NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 6 CHECK FRONT SEAT WIRE RH (TO GROUND) Occupant Classification ECU Occupant Classification Sensor Front LH D A C Front Seat Wire RH SGD1 SIG1 H43105 H43111 B O7 SVC1 H43474 (a) Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition O7-1 (SGD1) Body ground Always 1 MΩ or Higher O7-7 (SIG1) Body ground Always 1 MΩ or Higher O7-1 1 (SVC1) Body ground Always 1 MΩ or Higher NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1646 05-1457 DIAGNOSTICS 7 (a) (b) (c) (d) HINT:
- SUPPLEMENTAL RESTRAINT SYSTEM RECHECK DTC Connect the connectors to the occupant classification ECU and the occupant classification sensor front LH. Connect the negative (-) terminal cable to the battery. Turn the ignition switch to the ON position. Clear the DTCs stored in memory (see page 05-1215 ). First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory. Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position. Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1780 is not output.
(e) (f) (g) HINT: Codes other than code B1780 may be output at this time, but they are not related to this check. NG Go to step 8 OK USE SIMULATION METHOD TO CHECK (SEE PAGE 05-1207 ) 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Replace the occupant classification ECU (see page 60-64 ). HINT: Perform the inspection using parts from a normal vehicle when possible. 9 (a) PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. NG Go to step 12 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1647 05-1458 DIAGNOSTICS 10 (a) - SUPPLEMENTAL RESTRAINT SYSTEM PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 12 OK 11 RECHECK DTC (a) Connect the negative (-) terminal cable to the battery. (b) Turn the ignition switch to the ON position. (c) Clear the DTCs stored in memory (see page 05-1215 ). HINT:
First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory.
Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. (d) Turn the ignition switch to the LOCK position. (e) Turn the ignition switch to the ON position. (f) Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1780 is not output. HINT: Codes other than code B1780 may be output at this time, but they are not related to this check. NG Go to step 12 OK END 12 (a) (b) (c) 13 (a) REPLACE SEAT ADJUSTER FRAME ASSY Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Replace the seat adjuster frame assy (see page 72-1 1, 72-19 ). PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1648 05-1459 DIAGNOSTICS 14 (a) - SUPPLEMENTAL RESTRAINT SYSTEM PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1649 05-1460 DIAGNOSTICS DTC B1781 - SUPPLEMENTAL RESTRAINT SYSTEM 05IWR-02 OCCUPANT CLASSIFICATION SENSOR FRONT RH CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION The occupant classification sensor front RH circuit consists of the occupant classification ECU and the occupant classification sensor front RH. DTC B1781 is recorded when a malfunction is detected in the occupant classification sensor front RH circuit. DTC No. B1781 DTC Detecting Condition Trouble Area
When the occupant classification ECU receives a line short signal, open signal, short to ground signal or B+ short signal in the occupant classification sensor front RH circuit for 2 seconds.
Occupant classification sensor front RH malfunction
Occupant classification ECU malfunction
Seat adjuster frame assy (Occupant classification sensor front RH)
Front seat wire RH
Occupant classification ECU HINT:

When DTC B1150/23 is detected as a result of troubleshooting for the supplemental restraint system, perform troubleshooting for DTC B1781 of the occupant classification system. Use the hand-held tester to check the DTC of the occupant classification ECU, otherwise the DTC cannot be read. WIRING DIAGRAM O9 Occupant classification Sensor Front RH SVC2 SIG2 SGD2 Occupant Classification ECU W 12 O7 SVC2 L 8 O7 SIG2 O 2 O7 SGD2 1 2 3 H43062 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1650 05-1461 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE HINT:
If troubleshooting (wire harness inspection) is difficult to perform, remove the front RH seat assy installation bolts to see the under surface of seat cushion. In the above case, hold the seat so that it does not fall down. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat only as necessary.
1 CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in memory (see page 05-1215 ). HINT:
First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory.
Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position. (e) Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1781 is not output. HINT: Codes other than code B1781 may be output at this time, but they are not related to this check. NG Go to step 2 OK USE SIMULATION METHOD TO CHECK (SEE PAGE 05-1207 ) 2 (a) (b) (c) CHECK CONNECTION OF CONNECTORS Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Check that the connectors are properly connected to the occupant classification ECU and the occupant classification sensor front RH. OK: The connectors are connected. NG CONNECT CONNECTORS, THEN GO TO STEP 1 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1651 05-1462 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT WIRE RH (TO B+) Occupant Classification ECU Occupant Classification Sensor Front RH (b) (c) (d) D A C Front Seat Wire RH O7 SGD2 B SIG2 H43105 H43111 (a) SVC2 Disconnect the connectors from the occupant classification ECU and the occupant classification sensor front RH. Connect the negative (-) terminal cable to the battery. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition O7-2 (SGD2) Body ground Ignition switch ON Below 1 V O7-8 (SIG2) Body ground Ignition switch ON Below 1 V O7-12 (SVC2) Body ground Ignition switch ON Below 1 V H43474 NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 4 CHECK FRONT SEAT WIRE RH (OPEN) A C SVC2 H43106 H43699 H43111 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Using a service wire, connect O9-1 (SVC2) and O9-3 (SGD2), and connect O9-2 (SIG2) and O9-3(SGD2) of connector ”C”. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (d) Measure the resistance according to the value(s) in the table below. Standard: Occupant Classification ECU D Service Wire (a) (b) Front Seat Wire RH Occupant Classification Sensor Front RH B O9 O7 SGD2 SGD2 SIG2 Service Wire SIG2 SVC2 H43475 Tester connection Condition Specified condition O7-8 (SIG2) O7-2 (SGD2) Always Below 1 Ω O7-12 (SVC2) O7-2 (SGD2) Always Below 1 Ω NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1652 05-1463 DIAGNOSTICS 5 SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT WIRE RH (SHORT) (a) (b) Occupant Front Seat Wire RH Classification Occupant Sensor Front RH Classification ECU D A C B O7 SGD2 H43105 H43111 - SIG2 SVC2 H43474 Disconnect the service wire from connector ”C”. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition O7-8 (SIG2) O7-2 (SGD2) Always 1 MΩ or Higher O7-12 (SVC2) O7-2 (SGD2) Always 1 MΩ or Higher O7-8 (SIG2) O7-12 (SVC2) Always 1 MΩ or Higher NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 6 CHECK FRONT SEAT WIRE RH (TO GROUND) (a) Occupant Front Seat Wire RH Classification Occupant Sensor Front RH Classification ECU D A C SGD2 H43105 H43111 SIG2 B O7 SVC2 H43474 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition O7-2 (SGD2) Body ground Always 1 MΩ or Higher O7-8 (SIG2) Body ground Always 1 MΩ or Higher O7-12 (SVC2) Body ground Always 1 MΩ or Higher NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1653 05-1464 DIAGNOSTICS 7 (a) (b) (c) (d) HINT:
- SUPPLEMENTAL RESTRAINT SYSTEM RECHECK DTC Connect the connectors to the occupant classification ECU and the occupant classification sensor front RH. Connect the negative (-) terminal cable to the battery. Turn the ignition switch to the ON position. Clear the DTCs stored in memory (see page 05-1215 ). First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory. Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position. Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1781 is not output.
(e) (f) (g) HINT: Codes other than code B1781 may be output at this time, but they are not related to this check. NG Go to step 8 OK USE SIMULATION METHOD TO CHECK (SEE PAGE 05-1207 ) 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Replace the occupant classification ECU (see page 60-64 ). HINT: Perform the inspection using parts from a normal vehicle when possible. 9 (a) PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. NG Go to step 12 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1654 05-1465 DIAGNOSTICS 10 (a) - SUPPLEMENTAL RESTRAINT SYSTEM PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 12 OK 11 RECHECK DTC (a) Connect the negative (-) terminal cable to the battery. (b) Turn the ignition switch to the ON position. (c) Clear the DTCs stored in memory (see page 05-1215 ). HINT:
First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory.
Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. (d) Turn the ignition switch to the LOCK position. (e) Turn the ignition switch to the ON position. (f) Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1781 is not output. HINT: Codes other than code B1781 may be output at this time, but they are not related to this check. NG Go to step 12 OK END 12 (a) (b) (c) 13 (a) REPLACE SEAT ADJUSTER FRAME ASSY Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Replace the seat adjuster frame assy (see page 72-1 1, 72-19 ). PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1655 05-1466 DIAGNOSTICS 14 (a) - SUPPLEMENTAL RESTRAINT SYSTEM PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1656 05-1467 DIAGNOSTICS DTC B1782 - SUPPLEMENTAL RESTRAINT SYSTEM 05IWT-02 OCCUPANT CLASSIFICATION SENSOR REAR LH CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION The occupant classification sensor rear LH circuit consists of the occupant classification ECU and the occupant classification sensor rear LH. DTC B1782 is recorded when a malfunction is detected in the occupant classification sensor rear LH circuit. DTC No. B1782 DTC Detecting Condition Trouble Area
When the occupant classification ECU receives a line short signal, open signal, short to ground signal or B+ short signal in the occupant classification sensor rear LH circuit for 2 seconds.
Occupant classification sensor rear LH malfunction
Occupant classification ECU malfunction
Seat adjuster frame assy (Occupant classification sensor rear LH)
Front seat wire RH
Occupant classification ECU HINT:

When DTC B1150/23 is detected as a result of troubleshooting for the supplemental restraint system, perform troubleshooting for DTC B1782 of the occupant classification system. Use the hand-held tester to check the DTC of the occupant classification ECU, otherwise the DTC cannot be read. WIRING DIAGRAM Occupant Classification ECU O10 Occupant Classification Sensor Rear LH SVC3 GR 5 O7 SVC3 Y 9 O7 SIG3 W 3 O7 SGD3 1 SIG3 2 SGD3 3 H43062 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1657 05-1468 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE HINT:
If troubleshooting (wire harness inspection) is difficult to perform, remove the front RH seat assy installation bolts to see the under surface of seat cushion. In the above case, hold the seat so that it does not fall down. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat only as necessary.
1 CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in memory (see page 05-1215 ). HINT:
First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory.
Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position. (e) Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1782 is not output. HINT: Codes other than code B1782 may be output at this time, but they are not related to this check. NG Go to step 2 OK USE SIMULATION METHOD TO CHECK (SEE PAGE 05-1207 ) 2 (a) (b) (c) CHECK CONNECTION OF CONNECTORS Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Check that the connectors are properly connected to the occupant classification ECU and the occupant classification sensor rear LH. OK: The connectors are connected. NG CONNECT CONNECTORS, THEN GO TO STEP 1 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1658 05-1469 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT WIRE RH(TO B+) (a) Occupant Front Seat Wire RH Classification Occupant Sensor Rear LH (b) (c) (d) Classification ECU D A C B O7 SGD3 SVC3 SIG3 H43105 H43111 Disconnect the connectors from the occupant classification ECU and the occupant classification sensor rear LH. Connect the negative (-) terminal cable to the battery. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition O7-3 (SGD3) Body ground Ignition switch ON Below 1 V O7-5 (SVC3) Body ground Ignition switch ON Below 1 V O7-9 (SIG3) Body ground Ignition switch ON Below 1 V H43474 NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 4 CHECK FRONT SEAT WIRE RH(OPEN) Occupant Classification ECU D A C B O10 Service Wire SVC3 H43106 H43699 H43111 (a) (b) Front Seat Wire RH Occupant Classification Sensor Rear LH O7 SGD3 SVC3 SGD3 SIG3 Service Wire SIG3 H43475 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Using a service wire, connect O10-1 (SVC3) and O10-3 (SGD3), and connect O10-2 (SIG3) and O10-3 (SGD3) of connector ”C”. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (d) Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition O7-5 (SVC3) O7-3 (SGD3) Always Below 1 Ω O7-9 (SIG3) O7-3 (SGD3) Always Below 1 Ω NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1659 05-1470 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT WIRE RH(SHORT) (a) (b) Occupant Front Seat Wire RH Classification Occupant Sensor Rear LH Classification ECU D A C B O7 SVC3 SGD3 Disconnect the service wire from connector ”C”. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition O7-5 (SVC3) O7-3 (SGD3) Always 1 MΩ or Higher O7-9 (SIG3) O7-3 (SGD3) Always 1 MΩ or Higher O7-5 (SVC3) O7-9 (SIG3) Always 1 MΩ or Higher SIG3 H43105 H43111 H43474 NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 6 CHECK FRONT SEAT WIRE RH(TO GROUND) (a) Occupant Front Seat Wire RH Classification Occupant Sensor Rear LH Classification ECU D A C B O7 SGD3 SVC3 Measure the resistance according to value(s) in the table below. Standard: Tester connection Condition Specified condition O7-3 (SGD3) Body ground Always 1 MΩ or Higher O7-5 (SVC3) Body ground Always 1 MΩ or Higher O7-9 (SIG3) Body ground Always 1 MΩ or Higher SIG3 H43105 H43111 H43474 NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1660 05-1471 DIAGNOSTICS 7 (a) (b) (c) (d) HINT:
- SUPPLEMENTAL RESTRAINT SYSTEM RECHECK DTC Connect the connectors to the occupant classification ECU and the occupant classification sensor rear LH. Connect the negative (-) terminal cable to the battery. Turn the ignition switch to the ON position. Clear the DTCs stored in memory (see page 05-1215 ). First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory. Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position. Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1782 is not output.
(e) (f) (g) HINT: Codes other than code B1782 may be output at this time, but they are not related to this check. NG Go to step 8 OK USE SIMULATION METHOD TO CHECK (SEE PAGE 05-1207 ) 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Replace the occupant classification ECU (see page 60-64 ). HINT: Perform the inspection using parts from a normal vehicle when possible. 9 (a) PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. NG Go to step 12 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1661 05-1472 DIAGNOSTICS 10 (a) - SUPPLEMENTAL RESTRAINT SYSTEM PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 12 OK 11 RECHECK DTC (a) Connect the negative (-) terminal cable to the battery. (b) Turn the ignition switch to the ON position. (c) Clear the DTCs stored in memory (see page 05-1215 ). HINT:
First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory.
Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. (d) Turn the ignition switch to the LOCK position. (e) Turn the ignition switch to the ON position. (f) Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1782 is not output. HINT: Codes other than code B1782 may be output at this time, but they are not related to this check. NG Go to step 12 OK END 12 (a) (b) (c) 13 (a) REPLACE SEAT ADJUSTER FRAME ASSY Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Replace the seat adjuster frame assy (see page 72-1 1, 72-19 ). PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1662 05-1473 DIAGNOSTICS 14 (a) - SUPPLEMENTAL RESTRAINT SYSTEM PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1663 05-1474 DIAGNOSTICS DTC B1783 - SUPPLEMENTAL RESTRAINT SYSTEM 05IWU-02 OCCUPANT CLASSIFICATION SENSOR REAR RH CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION The occupant classification sensor rear RH circuit consists of the occupant classification ECU and the occupant classification sensor rear RH. DTC B1783 is recorded when a malfunction is detected in the occupant classification sensor rear RH circuit. DTC No. B1783 DTC Detecting Condition Trouble Area
When the occupant classification ECU receives a line short signal, open signal, short to ground signal or B+ short signal in the occupant classification sensor rear RH circuit for 2 seconds.
Occupant classification sensor rear RH malfunction
Occupant classification ECU malfunction
Seat adjuster frame assy (Occupant classification sensor rear RH)
Front seat wire RH
Occupant classification ECU HINT:

When DTC B1150/23 is detected as a result of troubleshooting for the supplemental restraint system, perform troubleshooting for DTC B1783 of the occupant classification system. Use the hand-held tester to check the DTC of the occupant classification ECU, otherwise the DTC cannot be read. WIRING DIAGRAM Occupant Classification ECU O11 Occupant Classification Sensor Rear RH SVC4 1 SIG4 SGD4 V 6 O7 SVC4 B 10 O7 SIG4 BR 4 O7 SGD4 2 3 H43062 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1664 05-1475 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE HINT:
If troubleshooting (wire harness inspection) is difficult to perform, remove the front RH seat assy installation bolts to see the under surface of seat cushion. In the above case, hold the seat so that it does not fall down. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat only as necessary.
1 CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in memory (see page 05-1215 ). HINT:
First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory.
Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position. (e) Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1783 is not output. HINT: Codes other than code B1783 may be output at this time, but they are not related to this check. NG Go to step 2 OK USE SIMULATION METHOD TO CHECK (SEE PAGE 05-1207 ) 2 (a) (b) (c) CHECK CONNECTION OF CONNECTORS Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Check that the connectors are properly connected to the occupant classification ECU and the occupant classification sensor rear RH. OK: The connectors are connected. NG CONNECT CONNECTORS, THEN GO TO STEP 1 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1665 05-1476 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT WIRE RH (TO B+) (a) Occupant Classification Sensor Rear RH Front Seat Wire RH (b) (c) (d) Occupant Classification ECU A D C B O7 SGD4 SVC4 SIG4 H43105 H43111 Disconnect the connectors from the occupant classification ECU and the occupant classification sensor rear RH. Connect the negative (-) terminal cable to the battery. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition O7-4 (SGD4) Body ground Ignition switch ON Below 1 V O7-6 (SVC4) Body ground Ignition switch ON Below 1 V O7-10 (SIG4) Body ground Ignition switch ON Below 1 V H43474 NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 4 CHECK FRONT SEAT WIRE RH (OPEN) Occupant Classification Sensor Rear RH Occupant Classification ECU A D C Service Wire B O11 SVC4 H43106 H43699 H43111 (a) (b) Front Seat Wire RH O7 SGD4 SVC4 SGD4 SIG4 Service Wire SIG4 H43475 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Using a service wire, connect O11-1 (SVC4) and O11-3 (SGD4), and connect O11-2 (SIG4) and O11-3 (SGD4) of connector ”C”. NOTICE: Do not forcibly insert a service wire into the terminals of the connector when connecting. (d) Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition O7-6 (SVC4) O7-4 (SGD4) Always Below 1 Ω O7-10 (SIG4) O7-4 (SGD4) Always Below 1 Ω NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1666 05-1477 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT WIRE RH (SHORT) (a) (b) Occupant Front Seat Wire RH Classification Occupant Sensor Rear RH Classification ECU D A C B O7 SGD4 SVC4 Disconnect the service wire from connector ”C”. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition O7-6 (SVC4) O7-4 (SGD4) Always 1 MΩ or Higher O7-10 (SIG4) O7-4 (SGD4) Always 1 MΩ or Higher O7-6 (SVC4) O7-10 (SIG4) Always 1 MΩ or Higher SIG4 H43105 H43111 H43474 NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 6 CHECK FRONT SEAT WIRE RH (TO GROUND) (a) Occupant Front Seat Wire RH Classification Occupant Sensor Rear RH Classification ECU D A C B O7 SGD4 H43105 H43111 SVC4 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition O7-4 (SGD4) Body ground Always 1 MΩ or Higher O7-6 (SVC4) Body ground Always 1 MΩ or Higher O7-10 (SIG4) Body ground Always 1 MΩ or Higher SIG4 H43474 NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1667 05-1478 DIAGNOSTICS 7 (a) (b) (c) (d) HINT:
- SUPPLEMENTAL RESTRAINT SYSTEM RECHECK DTC Connect the connectors to the occupant classification ECU and the occupant classification sensor rear RH. Connect the negative (-) terminal cable to the battery. Turn the ignition switch to the ON position. Clear the DTCs stored in memory (see page 05-1215 ). First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory. Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position. Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1783 is not output.
(e) (f) (g) HINT: Codes other than code B1783 may be output at this time, but they are not related to this check. NG Go to step 8 OK USE SIMULATION METHOD TO CHECK (SEE PAGE 05-1207 ) 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Replace the occupant classification ECU (see page 60-64 ). HINT: Perform the inspection using parts from a normal vehicle when possible. 9 (a) PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. NG Go to step 12 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1668 05-1479 DIAGNOSTICS 10 (a) - SUPPLEMENTAL RESTRAINT SYSTEM PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 12 OK 11 RECHECK DTC (a) Connect the negative (-) terminal cable to the battery. (b) Turn the ignition switch to the ON position. (c) Clear the DTCs stored in memory (see page 05-1215 ). HINT:
First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory.
Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. (d) Turn the ignition switch to the LOCK position. (e) Turn the ignition switch to the ON position. (f) Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1783 is not output. HINT: Codes other than code B1783 may be output at this time, but they are not related to this check. NG Go to step 12 OK END 12 (a) (b) (c) 13 (a) REPLACE SEAT ADJUSTER FRAME ASSY Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Replace the seat adjuster frame assy (see page 72-1 1, 72-19 ). PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1669 05-1480 DIAGNOSTICS 14 (a) - SUPPLEMENTAL RESTRAINT SYSTEM PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1670 05-1481 DIAGNOSTICS DTC B1785 - SUPPLEMENTAL RESTRAINT SYSTEM 05IWV-01 OCCUPANT CLASSIFICATION SENSOR FRONT LH COLLISION DETECTION CIRCUIT DESCRIPTION DTC B1785 is output when the occupant classification ECU receives a collision detection signal sent by the occupant classification sensor front LH if an accident occurs. DTC B1785 is also output when the seat adjuster frame assy is subjected to a strong impact, even if an actual accident does not occur. However, when the occupant classification ECU outputs a collision detection signal, even if the vehicle is not in a collision, DTC B1785 can be cleared by ”Zero point calibration” and ”Sensitivity check”. Therefore, If DTC B1785 is output, first perform ”Zero point calibration” and ”Sensitivity check”. DTC No. B1785 DTC Detecting Condition Trouble Area
Seat adjuster frame assy malfunction
Occupant classification ECU malfunction
Occupant classification sensor front LH sensed large load
Occupant classification ECU
Seat adjuster frame assy (Occupant classification sensor front LH) HINT:
When DTC B1150/23 is detected as a result of troubleshooting for the supplemental restraint system, perform troubleshooting for DTC B1785 of the classification system. Use the hand-held tester to check the DTC of the occupant classification ECU, otherwise the DTC cannot be read.
WIRING DIAGRAM see page 05-1453 . INSPECTION PROCEDURE 1 (a) PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. NG Go to step 4 OK 2 (a) PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 4 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1671 05-1482 DIAGNOSTICS 3 (a) (b) (c) (d) (e) - SUPPLEMENTAL RESTRAINT SYSTEM CHECK DTC Turn the ignition switch to the ON position. Clear the DTCs stored in airbag sensor assy center memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position. Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1785 is not output. HINT: Codes other than code B1785 may be output at this time, but they are not related to this check. NG Go to step 4 OK END 4 REPLACE SEAT ADJUSTER FRAME ASSY (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Replace the seat adjuster frame assy (see page 72-1 1, 72-19 ). HINT: Perform the inspection using parts from a normal vehicle when possible. 5 (a) PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. NG Go to step 8 OK 6 (a) PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 8 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1672 05-1483 DIAGNOSTICS 7 (a) (b) (c) (d) HINT:
- SUPPLEMENTAL RESTRAINT SYSTEM CHECK DTC Connect the connectors to the occupant classification ECU and the occupant classification sensor front LH. Connect the negative (-) terminal cable to the battery. Turn the ignition switch to the ON position. Clear the DTCs stored in memory (see page 05-1215 ). First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory. Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position. Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1785 is not output.
(e) (f) (g) HINT: Codes other than code B1785 may be output at this time, but they are not related to this check. NG Go to step 8 OK END 8 (a) (b) (c) REPLACE OCCUPANT CLASSIFICATION ECU Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Replace the occupant classification ECU (see page 60-64 ). 9 (a) PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. 10 (a) PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1673 05-1484 DIAGNOSTICS DTC B1786 - SUPPLEMENTAL RESTRAINT SYSTEM 05IWW-01 OCCUPANT CLASSIFICATION SENSOR FRONT RH COLLISION DETECTION CIRCUIT DESCRIPTION DTC B1786 is output when the occupant classification ECU receives a collision detection signal sent by the occupant classification sensor front RH if an accident occurs. DTC B1786 is also output when the seat adjuster frame assy is subjected to a strong impact, even if an actual accident does not occur. However, when the occupant classification ECU outputs a collision detection signal, even if the vehicle is not in a collision, DTC B1786 can be cleared by ”Zero point calibration” and ”Sensitivity check”. Therefore, if DTC B1786 is output, first perform ”Zero point calibration” and ”Sensitivity check”. DTC No. B1786 DTC Detecting Condition Trouble Area
Seat adjuster frame assy malfunction
Occupant classification ECU malfunction
Occupant classification sensor front RH sensed large load
Occupant classification ECU
Seat adjuster frame assy (Occupant classification sensor front RH) HINT:
When DTC B1150/23 is detected as a result of troubleshooting for the supplemental restraint system, perform troubleshooting for DTC B1786 of the classification system. Use the hand-held tester to check the DTC of the occupant classification ECU, otherwise the DTC cannot be read.
WIRING DIAGRAM see page 05-1460 . INSPECTION PROCEDURE 1 (a) PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. NG Go to step 4 OK 2 (a) PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 4 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1674 05-1485 DIAGNOSTICS 3 (a) (b) (c) (d) (e) - SUPPLEMENTAL RESTRAINT SYSTEM CHECK DTC Turn the ignition switch to the ON position. Clear the DTCs stored in airbag sensor assy center memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position. Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1786 is not output. HINT: Codes other than code B1786 may be output at this time, but they are not related to this check. NG Go to step 4 OK END 4 REPLACE SEAT ADJUSTER FRAME ASSY (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Replace the seat adjuster frame assy (see page 72-1 1, 72-19 ). HINT: Perform the inspection using parts from a normal vehicle when possible. 5 (a) PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. NG Go to step 8 OK 6 (a) PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 8 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1675 05-1486 DIAGNOSTICS 7 (a) (b) (c) (d) HINT:
- SUPPLEMENTAL RESTRAINT SYSTEM CHECK DTC Connect the connectors to the occupant classification ECU and the occupant classification sensor front RH. Connect the negative (-) terminal cable to the battery. Turn the ignition switch to the ON position. Clear the DTCs stored in memory (see page 05-1215 ). First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory. Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position. Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1786 is not output.
(e) (f) (g) HINT: Codes other than code B1786 may be output at this time, but they are not related to this check. NG Go to step 8 OK END 8 (a) (b) (c) REPLACE OCCUPANT CLASSIFICATION ECU Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Replace the occupant classification ECU (see page 60-64 ). 9 (a) PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. 10 (a) PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1676 05-1487 DIAGNOSTICS DTC B1787 - SUPPLEMENTAL RESTRAINT SYSTEM 05IWX-01 OCCUPANT CLASSIFICATION SENSOR REAR LH COLLISION DETECTION CIRCUIT DESCRIPTION DTC B1787 is output when the occupant classification ECU receives a collision detection signal sent by the occupant classification sensor rear LH if an accident occurs. DTC B1787 is also output when the seat adjuster frame assy is subjected to a strong impact, even if an actual accident does not occur. However, when the occupant classification ECU outputs a collision detection signal, even if the vehicle is not in a collision, DTC B1787 can be cleared by ”Zero point calibration” and ”Sensitivity check”. Therefore, if DTC B1787 is output, first perform ”Zero point calibration” and ”Sensitivity check”. DTC No. B1787 DTC Detecting Condition Trouble Area
Seat adjuster frame assy malfunction
Occupant classification ECU malfunction
Occupant classification sensor rear LH sensed large load
Occupant classification ECU
Seat adjuster frame assy (Occupant classification sensor rear LH) HINT:
When DTC B1150/23 is detected as a result of troubleshooting for the supplemental restraint system, perform troubleshooting for DTC B1787 of the classification system. Use the hand-held tester to check the DTC of the occupant classification ECU, otherwise the DTC cannot be read.
WIRING DIAGRAM see page 05-1467 . INSPECTION PROCEDURE 1 (a) PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. NG Go to step 4 OK 2 (a) PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 4 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1677 05-1488 DIAGNOSTICS 3 (a) (b) (c) (d) (e) - SUPPLEMENTAL RESTRAINT SYSTEM CHECK DTC Turn the ignition switch to the ON position. Clear the DTCs stored in airbag sensor assy center memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position. Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1787 is not output. HINT: Codes other than code B1787 may be output at this time, but they are not related to this check. NG Go to step 4 OK END 4 REPLACE SEAT ADJUSTER FRAME ASSY (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Replace the seat adjuster frame assy (see page 72-1 1, 72-19 ). HINT: Perform the inspection using parts from a normal vehicle when possible. 5 (a) PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. NG Go to step 8 OK 6 (a) PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 8 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1678 05-1489 DIAGNOSTICS 7 (a) (b) (c) (d) HINT:
- SUPPLEMENTAL RESTRAINT SYSTEM CHECK DTC Connect the connectors to the occupant classification ECU and the occupant classification sensor rear LH. Connect the negative (-) terminal cable to the battery. Turn the ignition switch to the ON position. Clear the DTCs stored in memory (see page 05-1215 ). First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory. Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position. Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1787 is not output.
(e) (f) (g) HINT: Codes other than code B1787 may be output at this time, but they are not related to this check. NG Go to step 8 OK END 8 (a) (b) (c) REPLACE OCCUPANT CLASSIFICATION ECU Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Replace the occupant classification ECU (see page 60-64 ). 9 (a) PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. 10 (a) PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1679 05-1490 DIAGNOSTICS DTC B1788 - SUPPLEMENTAL RESTRAINT SYSTEM 05IWY-01 OCCUPANT CLASSIFICATION SENSOR REAR RH COLLISION DETECTION CIRCUIT DESCRIPTION DTC B1788 is output when the occupant classification ECU receives a collision detection signal sent by the occupant classification sensor rear RH if an accident occurs. DTC B1788 is also output when the seat adjuster frame assy is subjected to a strong impact, even if an actual accident does not occur. However, when the occupant classification ECU outputs a collision detection signal, even if the vehicle is not in a collision, DTC B1788 can be cleared by ”Zero point calibration” and ”Sensitivity check”. Therefore, if DTC B1788 is output, first perform ”Zero point calibration” and ”Sensitivity check”. DTC No. B1788 DTC Detecting Condition Trouble Area
Seat adjuster frame assy malfunction
Occupant classification ECU malfunction
Occupant classification sensor rear RH sensed large load
Occupant classification ECU
Seat adjuster frame assy (Occupant classification sensor rear RH) HINT:
When DTC B1150/23 is detected as a result of troubleshooting for the supplemental restraint system, perform troubleshooting for DTC B1788 of the classification system. Use the hand-held tester to check the DTC of the occupant classification ECU, otherwise the DTC cannot be read.
WIRING DIAGRAM see page 05-1474 . INSPECTION PROCEDURE 1 (a) PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. NG Go to step 4 OK 2 (a) PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 4 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1680 05-1491 DIAGNOSTICS 3 (a) (b) (c) (d) (e) - SUPPLEMENTAL RESTRAINT SYSTEM CHECK DTC Turn the ignition switch to the ON position. Clear the DTCs stored in airbag sensor assy center memory (see page 05-1215 ). Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position. Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1788 is not output. HINT: Codes other than code B1788 may be output at this time, but they are not related to this check. NG Go to step 4 OK END 4 REPLACE SEAT ADJUSTER FRAME ASSY (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Replace the seat adjuster frame assy (see page 72-1 1, 72-19 ). HINT: Perform the inspection using parts from a normal vehicle when possible. 5 (a) PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. NG Go to step 8 OK 6 (a) PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 8 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1681 05-1492 DIAGNOSTICS 7 (a) (b) (c) (d) HINT:
- SUPPLEMENTAL RESTRAINT SYSTEM CHECK DTC Connect the connectors to the occupant classification ECU and the occupant classification sensor rear RH. Connect the negative (-) terminal cable to the battery. Turn the ignition switch to the ON position. Clear the DTCs stored in memory (see page 05-1215 ). First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory. Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position. Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1788 is not output.
(e) (f) (g) HINT: Codes other than code B1788 may be output at this time, but they are not related to this check. NG Go to step 8 OK END 8 (a) (b) (c) REPLACE OCCUPANT CLASSIFICATION ECU Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Replace the occupant classification ECU (see page 60-64 ). 9 (a) PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. 10 (a) PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1682 05-1493 DIAGNOSTICS DTC B1790 - SUPPLEMENTAL RESTRAINT SYSTEM 05IX3-02 AIRBAG SENSOR ASSY CENTER COMMUNICATION CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION The airbag sensor assy center communication circuit consists of the occupant classification ECU and the airbag sensor assy center. DTC B1790 is recorded when a malfunction is detected in the airbag sensor assy center communication circuit. DTC No. DTC Detecting Condition B1790
When the occupant classification ECU receives a line short signal, open signal, short to ground signal or B+ short signal in the airbag sensor assy center communication circuit for 2 seconds.
Airbag sensor assy center malfunction
Occupant classification ECU malfunction Trouble Area
Occupant classification ECU
Airbag sensor assy center
Floor wire
Front seat wire RH HINT:

When DTC B1150/23 is detected as a result of troubleshooting for the supplemental restraint system, perform troubleshooting for DTC B1790 of the occupant classification system. Use the hand-held tester to check the DTC of the occupant classification ECU, otherwise the DTC cannot be read. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1683 05-1494 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM WIRING DIAGRAM Occupant Classification ECU 8 FSR+ O6 Airbag Sensor Assy Center W 1 BL1 W 3 1 A18 A18 FSR+ (*2) (*1) FSR- 4 O6 B 4 BL1 B 2 10 A18 A18 FSR(*2) (*1) *1: w/ Curtain Shield Airbag *2: w/o Curtain Shield Airbag H43055 H44108 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1684 05-1495 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE HINT:
If troubleshooting (wire harness inspection) is difficult to perform, remove the front RH seat assy installation bolts to see the under surface of seat cushion. In the above case, hold the seat so that it does not fall down. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat only as necessary.
1 CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in memory (see page 05-1215 ). HINT:
First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory.
Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position. (e) Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1790 is not output. HINT: Codes other than code B1790 may be output at this time, but they are not related to this check. NG Go to step 2 OK USE SIMULATION METHOD TO CHECK (SEE PAGE 05-1207 ) 2 (a) (b) (c) CHECK CONNECTION OF CONNECTORS Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Check that the connectors are properly connected to the occupant classification ECU and the airbag sensor assy center. OK: The connectors are connected. NG CONNECT CONNECTORS, THEN GO TO STEP 1 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1685 05-1496 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM PREPARE FOR INSPECTION CAUTION: Be sure to perform the following procedures before troubleshooting to avoid unexpected airbag deployment. (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Disconnect the connectors from the airbag sensor assy center. (d) Disconnect the connectors from the horn button assy. (e) Disconnect the connectors from the front passenger airbag assy. (f) Disconnect the connector from the front seat airbag assy LH (g) Disconnect the connector from the front seat airbag assy RH. (h) Disconnect the connector from the curtain shield airbag assy LH. (i) Disconnect the connector from the curtain shield airbag assy RH (j) Disconnect the connector from the front seat outer belt assy LH. (k) Disconnect the connector from the front seat outer belt assy RH. 4 CHECK WIRE HARNESS (TO B+) (a) Occupant Classification ECU Airbag Sensor Assy A Center F E FSR- DC w/o Side and Curtain Shield Airbag H41715 H44130 FSRFSR+ FSR+ A18 B A18 w/ Side and Curtain Shield Airbag H44536 Disconnect the connector from the occupant classification ECU. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch to the ON position. (d) Measure the voltage according to the value(s) in the table below. Standard: w/ Side and curtain shield airbag: Tester connection Condition Specified condition A18-3 (FSR+) Body ground Ignition switch ON Below 1 V A18-10 (FSR-) Body ground Ignition switch ON Below 1 V w/o Side and curtain shield airbag: Tester connection Condition Specified condition A18-1 (FSR+) Body ground Ignition switch ON Below 1 V A18-2 (FSR-) Body ground Ignition switch ON Below 1 V NG Go to step 13 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1686 05-1497 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK WIRE HARNESS (OPEN) (a) (b) Occupant Classification ECU Airbag Sensor Assy A Center F E DC B FSR- FSR+ FSR+ FSRO6 FSR+ FSRA18 (*2) A18 (*1) Service Wire H44130 H44536 H41715 H43694 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Using a service wire, connect the O6-8 (FSR+) and O6-4 (FSR-) of connector ”E”. NOTICE: Do not forcibly insert a service wire into the terminal of the connector when connecting. (d) Measure the resistance according to the value(s) in the table below. Standard: w/ Side and curtain shield airbag: Tester connection Condition Specified condition A18-3 (FSR+) A18-10 (FSR-) Always Below 1 Ω w/o Side and curtain shield airbag: *1: w/ Side and Curtain Shield Airbag *2: w/o Side and Curtain Shield Airbag H44681 Tester connection Condition Specified condition A18-1 (FSR+) A18-2 (FSR-) Always Below 1 Ω NG Go to step 14 OK 6 CHECK WIRE HARNESS (SHORT) Occupant Classification ECU Airbag Sensor Assy A Center F E FSR- DC FSRFSR+ FSR+ A18 w/o Side and Curtain Shield Airbag H41715 H44130 B A18 w/ Side and Curtain Shield Airbag H44536 (a) (b) Disconnect the service wire from connector ”E”. Measure the resistance according to the value(s) in the table below. w/ Side and curtain shield airbag: Tester connection Condition Specified condition A18-3 (FSR+) A18-10 (FSR-) Always 1 MΩ or Higher w/o Side and curtain shield airbag: Tester connection Condition Specified condition A18-1 (FSR+) A18-2 (FSR-) Always 1 MΩ or Higher NG Go to step 15 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1687 05-1498 DIAGNOSTICS 7 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK WIRE HARNESS (TO GROUND) (a) Occupant Classification ECU Airbag Sensor Assy A Center F E DC B FSRFSR+ FSR+ FSR- A18 w/ Side and Curtain Shield Airbag H41715 H44130 Tester connection Condition Specified condition A18-3 (FSR+) Body ground Always 1 MΩ or Higher A18-10 (FSR-) Body ground Always 1 MΩ or Higher w/o Side and curtain shield airbag: A18 w/o Side and Curtain Shield Airbag Measure the resistance according to the value(s) in the table below. Standard: w/ Side and curtain shield airbag: H44536 Tester connection Condition Specified condition A18-1 (FSR+) Body ground Always 1 MΩ or Higher A18-2 (FSR-) Body ground Always 1 MΩ or Higher NG Go to step 16 OK 8 RECHECK DTC (a) Connect the connectors to the occupant classification ECU and the airbag sensor assy center. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch to the ON position. (d) Clear the DTCs stored in memory (see page 05-1215 ). HINT:
First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory.
Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position. (g) Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1790 is not output. HINT: Codes other than code B1790 may be output at this time, but they are not related to this check. NG Go to step 9 OK USE SIMULATION METHOD TO CHECK (SEE PAGE 05-1207 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1688 05-1499 DIAGNOSTICS 9 - SUPPLEMENTAL RESTRAINT SYSTEM REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Replace the occupant classification ECU (see page 60-64 ). HINT: Perform the inspection using parts from a normal vehicle when possible. 10 (a) PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. 11 (a) PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) 12 RECHECK DTC (a) Connect the connector to the occupant classification ECU. (b) Connect the negative (-) terminal cable to the battery. (c) Turn the ignition switch to the ON position. (d) Clear the DTCs stored in memory (see page 05-1215 ). HINT:
First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory.
Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. (e) Turn the ignition switch to the LOCK position. (f) Turn the ignition switch to the ON position. (g) Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1790 is not output. HINT: Codes other than code B1790 may be output at this time, but they are not related to this check. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1689 05-1500 DIAGNOSTICS 13 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT WIRE RH (TO B+) Occupant Floor Wire Classification Front Seat Airbag Wire RH ECU Sensor Assy F A Center E D C B (a) (b) (c) (d) (e) (f) BL1 FSR+ FSRH03354 H43116 H43129 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from battery, and wait for at least 90 seconds. Disconnect the front seat wire RH connector from the floor wire. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition BL1-1 (FSR+) Body ground Ignition switch ON Below 1 V BL1-4 (FSR-) Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK REPAIR OR REPLACE FLOOR WIRE 14 CHECK FRONT SEAT WIRE RH (OPEN) Occupant Floor Wire Classification Front Seat ECU Wire RH F E D C Airbag Sensor Assy A Center B BL1 O6 FSR+ (a) FSR- Disconnect the front seat wire RH connector from the floor wire. HINT: Connector ”E” has already been inserted into the service wire. (b) Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition BL1-1 (FSR+) BL1-4 (FSR-) Always Below 1 Ω FSR+ FSRH43129 H03354 H43116 Service Wire H44538 NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK REPAIR OR REPLACE FLOOR WIRE 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1690 05-1501 DIAGNOSTICS 15 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT WIRE RH (SHORT) Occupant Floor Wire Classification Front Seat Airbag Wire RH ECU Sensor Assy F A Center E D C B (a) (b) Disconnect the front seat wire RH connector from the floor wire. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition BL1-1 (FSR+) BL1-4 (FSR-) Always 1 MΩ or Higher BL1 FSR+ FSRH03354 H43116 H43129 NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK REPAIR OR REPLACE FLOOR WIRE 16 CHECK FRONT SEAT WIRE RH (TO GROUND) Occupant Floor Wire Classification Front Seat Airbag Wire RH ECU Sensor Assy F A Center E D C B BL1 FSR+ (a) (b) Disconnect the front seat wire RH connector from the floor wire. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition BL1-1 (FSR+) Body ground Always 1 MΩ or Higher BL1-4 (FSR-) Body ground Always 1 MΩ or Higher FSRH03354 H43116 H43129 NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK REPAIR OR REPLACE FLOOR WIRE 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1691 05-1502 DIAGNOSTICS DTC B1793 - SUPPLEMENTAL RESTRAINT SYSTEM 05IWZ-02 OCCUPANT CLASSIFICATION SENSOR POWER SUPPLY CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION The occupant classification sensor power supply circuit consists of the occupant classification ECU and the occupant classification sensors. DTC B1793 is recorded when a malfunction is detected in the occupant classification sensor power supply circuit. DTC No. B1793 DTC Detecting Condition
When the occupant classification ECU receives a line short signal, an open signal, short to ground signal or B+ short signal in the occupant classification sensor power supply circuit for 2 seconds.
Open circuit in occupant classification sensors wire harness
Occupant classification ECU malfunction Trouble Area
Seat adjuster frame assy (Occupant classification sensors)
Front seat wire RH
Occupant classification ECU HINT:

When DTC B1150/23 is detected as a result of troubleshooting for the supplemental restraint system, perform troubleshooting for DTC B1793 of the occupant classification sensor. Use the hand-held tester to check the DTC of the occupant classification ECU, otherwise the DTC cannot be read. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1692 05-1503 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM WIRING DIAGRAM O11 Occupant Classification Sensor Rear RH SVC4 Occupant Classification ECU V 6 O7 SVC4 W 12 O7 SVC2 GR 5 O7 SVC3 R 11 O7 SVC1 1 O9 Occupant Classification Sensor Front RH SVC2 1 O10 Occupant Classification Sensor Rear LH SVC3 1 O8 Occupant Classification Sensor Front LH SVC1 1 H43061 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1693 05-1504 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE HINT:
If troubleshooting (wire harness inspection) is difficult to perform, remove the front RH seat assy installation bolts to see the under surface of seat cushion. In the above case, hold the seat so that it does not fall down. Holding the seat for a long period of time may cause a problem, such as seat rail deformation. Hold the seat only as necessary.
1 CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in memory (see page 05-1215 ). HINT:
First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory.
Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. (c) Turn the ignition switch to the LOCK position. (d) Turn the ignition switch to the ON position. (e) Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1793 is not output. HINT: Codes other than code B1793 may be output at this time, but they are not related to this check. NG Go to step 2 OK USE SIMULATION METHOD TO CHECK (SEE PAGE 05-1207 ) 2 (a) (b) (c) CHECK CONNECTION OF CONNECTORS Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Check that the connectors are properly connected to the occupant classification ECU and the occupant classification sensors. OK: The connectors are connected. NG CONNECT CONNECTORS, THEN GO TO STEP 1 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1694 05-1505 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT WIRE RH (TO B+) (a) O7 SVC3 (b) (c) (d) SVC4 SVC2 SVC1 H43111 Disconnect the occupant classification ECU connector and the 4 occupant classification sensor connectors. Connect the negative (-) terminal cable to the battery. Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition O7-5 (SVC3) Body ground Ignition switch ON Below 1 V O7-6 (SVC4) Body ground Ignition switch ON Below 1 V O7-1 1 (SVC1) Body ground Ignition switch ON Below 1 V O7-12 (SVC2) Body ground Ignition switch ON Below 1 V NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 4 CHECK FRONT SEAT WIRE RH (TO GROUND) O7 (a) (b) SVC3 (c) SVC4 SVC2 SVC1 H43111 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition O7-5 (SVC3) Body ground Always 1 MΩ or Higher O7-6 (SVC4) Body ground Always 1 MΩ or Higher O7-1 1 (SVC1) Body ground Always 1 MΩ or Higher O7-12 (SVC2) Body ground Always 1 MΩ or Higher NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1695 05-1506 DIAGNOSTICS 5 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK FRONT SEAT WIRE RH (OPEN) (a) O7 SVC3 Measure the resistance according to the value(s) in the table below. Standard: SVC4 Tester connection Condition Specified condition SVC2 O7-5 (SVC3) O10-1 (SVC3) Always Below 1 Ω O7-6 (SVC4) O11-1 (SVC4) Always Below 1 Ω O7-1 1 (SVC1) O8-1 (SVC1) Always Below 1 Ω O7-12 (SVC2) O9-1 (SVC2) Always Below 1 Ω SVC1 H43111 NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 6 CHECK FRONT SEAT WIRE RH (SHORT) (a) O7 SVC3 Measure the resistance according to the value(s) in the table below. Standard: SVC4 Tester connection Condition Specified condition SVC2 O7-5 (SVC3) O7-6 (SVC4) Always 1 MΩ or Higher O7-6 (SVC4) O7-1 1 (SVC1) Always 1 MΩ or Higher O7-1 1 (SVC1) O7-12 (SVC2) Always 1 MΩ or Higher O7-12 (SVC2) O7-5 (SVC3) Always 1 MΩ or Higher O7-12 (SVC2) O7-6 (SVC4) Always 1 MΩ or Higher O7-1 1 (SVC1) O7-5 (SVC3) Always 1 MΩ or Higher SVC1 H43111 NG REPAIR OR REPLACE FRONT SEAT WIRE RH OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1696 05-1507 DIAGNOSTICS 7 (a) (b) (c) (d) HINT:
- SUPPLEMENTAL RESTRAINT SYSTEM RECHECK DTC Connect the occupant classification ECU connector and the 4 occupant classification sensor connectors. Connect the negative (-) terminal cable to the battery. Turn the ignition switch to the ON position. Clear the DTCs stored in memory (see page 05-1215 ). First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory. Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. Turn the ignition switch to the LOCK position. Turn the ignition switch to the ON position. Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1793 is not output.
(e) (f) (g) HINT: Codes other than code B1793 may be output at this time, but they are not related to this check. NG Go to step 8 OK USE SIMULATION METHOD TO CHECK (SEE PAGE 05-1207 ) 8 REPLACE OCCUPANT CLASSIFICATION ECU (a) Turn the ignition switch to the LOCK position. (b) Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. (c) Replace the occupant classification ECU (see page 60-64 ). HINT: Perform the inspection using parts from a normal vehicle when possible. 9 (a) PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. NG Go to step 12 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1697 05-1508 DIAGNOSTICS 10 (a) - SUPPLEMENTAL RESTRAINT SYSTEM PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) NG Go to step 12 OK 11 RECHECK DTC (a) Connect the negative (-) terminal cable to the battery. (b) Turn the ignition switch to the ON position. (c) Clear the DTCs stored in memory (see page 05-1215 ). HINT:
First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory.
Use the hand-held tester to clear the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. (d) Turn the ignition switch to the LOCK position. (e) Turn the ignition switch to the ON position. (f) Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1793 is not output. HINT: Codes other than code B1793 may be output at this time, but they are related to this check. NG Go to step 12 OK END 12 (a) (b) (c) 13 (a) REPLACE SEAT ADJUSTER FRAME ASSY Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Replace the seat adjuster frame assy (see page 72-1 1, 72-19 ). CHECK PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1698 05-1509 DIAGNOSTICS 14 (a) - SUPPLEMENTAL RESTRAINT SYSTEM CHECK PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1699 05-1510 DIAGNOSTICS DTC B1795 - SUPPLEMENTAL RESTRAINT SYSTEM 05IX0-03 OCCUPANT CLASSIFICATION ECU MALFUNCTION CIRCUIT DESCRIPTION DTC B1795 is recorded when a malfunction is detected in the occupant classification ECU. Troubleshoot DTC B1771 first when the DTC B1771 and B1795 are output simultaneously. DTC No. DTC Detecting Condition B1795
Occupant classification ECU circuit malfunction
Occupant classification ECU malfunction
When the occupant classification ECU receives a short to ground signal in the passenger side buckle switch circuit for 2 seconds.
The occupant classification ECU receives the ignition switch LOCK to ON signal 50 times in a row when a malfunction occurs in the power circuit for the occupant classification ECU (LOCK to ON to LOCK should be counted as once). Trouble Area
Occupant classification ECU
Front seat wire RH
ECU-B Fuse
Front seat inner belt assy RH (Buckle switch RH) HINT:

When DTC B1150/23 is detected as a result of troubleshooting for the supplemental restraint system, perform troubleshooting for DTC B1795 of the occupant classification sensor. Use the hand-held tester to check the DTC of the occupant classification ECU, otherwise the DTC cannot be read. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1700 05-151 1 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 (a) (b) CHECK DTC Turn the ignition switch to the ON position, and wait for at least 10 seconds. Using the hand-held tester, check the DTCs (see page 05-1215 ). Result: A: DTC B1771 and B1795 are output. B: DTC B1795 is output. HINT: Codes other than code B1771 and B1795 may be output at this time, but they are not related to this check. A GO TO DTC B1771 (SEE PAGE 05-1446 ) B 2 (a) CHECK FUSE Check the ECU-B fuse. Standard: Below 1 Ω NG REPLACE FUSE OK 3 CHECK WIRE HARNESS(SOURCE VOLTAGE) (a) (b) O6 +B GND (c) (d) (e) (f) H43112 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the ”O6” connector from the occupant classification ECU. Connect the negative (-) terminal cable to the battery. Turn the ignition switch to the ON position. Measure the voltage and resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition O6-1 (+B) - Body ground Ignition switch ON 10 to 14 V O6-3 (GND) Body ground Always Below 1 Ω NG REPAIR OR REPLACE WIRE HARNESS OR BATTERY OK CHECK USE SIMULATION METHOD TO CHECK (SEE PAGE 05-1207 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1701 05-1512 DIAGNOSTICS 4 (a) (b) (c) SUPPLEMENTAL RESTRAINT SYSTEM REPLACE OCCUPANT CLASSIFICATION ECU Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Replace the occupant classification ECU (see page 60-64 ). 5 (a) PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. 6 (a) - PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1702 05-1513 DIAGNOSTICS DTC B1796 - SUPPLEMENTAL RESTRAINT SYSTEM 05IX1-01 SLEEP OPERATION FAILURE OF OCCUPANT CLASSIFICATION ECU CIRCUIT DESCRIPTION During sleep mode, the occupant classification ECU reads the condition of each sensor while the ignition switch is off. In this mode, if occupant classification ECU detects an internal malfunction, DTC B1796 is output. DTC No. B1796 DTC Detecting Condition Trouble Area
Occupant classification ECU malfunction
Occupant classification ECU HINT:
When DTC B1150/23 is detected as a result of troubleshooting for the supplemental restraint system, perform troubleshooting for the DTC B1796 of the occupant classification ECU. Use the hand-held tester to check the DTC of the occupant classification ECU, otherwise the DTC cannot be read.
INSPECTION PROCEDURE 1 CHECK DTC (a) Turn the ignition switch to the ON position. (b) Clear the DTCs stored in memory (see page 05-1215 ). HINT:
First clear DTCs stored in the occupant classification ECU memory and then in the airbag sensor assy center memory.
Use the hand-held tester to check the DTC of the occupant classification ECU, otherwise the DTC cannot be cleared. (c) Turn the ignition switch to the LOCK position, and wait for at least 10 seconds. (d) Turn the ignition switch to the ON position. (e) Using the hand-held tester, check the DTCs (see page 05-1215 ). OK: DTC B1796 is not output. HINT: Codes other than code B1796 may be output at this time, but they are not related to this check. NG Go to step 2 OK USE SIMULATION METHOD TO CHECK (SEE PAGE 05-1207 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1703 05-1514 DIAGNOSTICS 2 (a) (b) (c) SUPPLEMENTAL RESTRAINT SYSTEM REPLACE OCCUPANT CLASSIFICATION ECU Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Replace the occupant classification ECU (see page 60-64 ). 3 (a) PERFORM ZERO POINT CALIBRATION Using the hand-held tester, perform ”Zero point calibration” (see page 05-1203 ). OK: The ”COMPLETED” is displayed. 4 (a) - PERFORM SENSITIVITY CHECK Using the hand-held tester, perform ”Sensitivity check” (see page 05-1203 ). Standard value: 27 to 33 kg (59.52 to 72.75 lb) END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1704 05-1218 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM 05MOH-01 CHECK MODE PROCEDURE Hand-held Tester 1. (a) (b) (c) DLC3 SIGNAL CHECK (CHECK MODE) (USING HAND-HELD TESTER) Connect the hand-held tester to the DLC3. Turn the ignition switch to the ON position. Select the ”SIGNAL CHECK”, and proceed checking with the hand-held tester. A80020 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1408 05-1207 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM 05IV5-02 DIAGNOSIS SYSTEM 1. (a) CHECK DLC3 The vehicle’s ECM conforms to ISO 9141-2 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and meets the ISO 9141-2 format. H40173 Terminal No. Connection/Voltage or Resistance Condition 7 Bus  Line/Pulse generation During Transmission 4 Chassis Ground  Body Ground/ Below 1 Ω Always 16 Battery Positive  Body Ground/10 to 14 V Always HINT: If the display shows UNABLE TO CONNECT TO VEHICLE when you connect the cable of the hand-held tester to the DLC3, turn the ignition switch to the ON position and operate the hand-held tester, there is a problem on the vehicle side or tool side.
If communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle.
If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself. Consult the Service Department listed in the tool’s instruction manual. 2. FUNCTION OF SRS WARNING LIGHT (a) Primary check. (1) Turn the ignition switch to the LOCK position. Wait for at least 2 seconds, then turn the ignition switch to the ON position. The SRS warning light comes on for approximately 6 seconds and the airbag system diagnosis (including the seat belt protensioner and occupant classification system) is performed. HINT: If trouble is detected during the primary check, the SRS warning light remains on or blinks even after the primary check period (for approximately 6 seconds) has elapsed. (b) Constant check. (1) After the primary check, the airbag sensor assy center constantly monitors the SRS airbag system for trouble. HINT: If trouble is detected during the constant check, the airbag sensor assy center functions as follows:
The SRS warning light comes on or blinks.
The SRS warning light goes off, and then comes on. This blinking pattern indicates the source voltage drop. The SRS warning light goes off 10 seconds after the source voltage returns to normal. (c) Review. (1) When the airbag system is normal: The SRS warning light comes on only during the primary check period (for approximately 6 seconds after the ignition switch is turned to the ON position). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1397 05-1208 DIAGNOSTICS (2)


- SUPPLEMENTAL RESTRAINT SYSTEM When the airbag system has trouble: The SRS warning light remains on or blinks even after the primary check period has elapsed. The SRS warning light goes off after the primary check, but comes on or blinks again during the constant check. The SRS warning light does not come on when turning the ignition switch from the LOCK to ON position. HINT: The airbag sensor assy center keeps the SRS waning light on if the airbag has been deployed. 3. FUNCTION OF PASSENGER AIRBAG ON/OFF INDICATOR (a) Initial check. (1) Turn the ignition switch to the ON position. (2) The passenger airbag ON/OFF indicator (”ON” and ”OFF”) comes on for approximately 4 seconds, then goes off for approximately 2 seconds. (3) Approximately 6 seconds after the ignition switch is turned to the ON position, the passenger airbag ON/OFF indicator will be ON/OFF depending on the conditions listed below. Condition ”ON” indicator ”OFF” indicator Vacant OFF OFF Adult is seated. ON OFF Child is seated. OFF ON Child restraint system is set. OFF ON Front passenger occupant classification system failure OFF ON HINT:
The passenger airbag ON/OFF indicator is based on the timing chart below in order to check the indicator light circuit ON Ignition Switch OFF 4 sec. 2 sec. 4 sec. 2 sec. ON Passenger Airbag ON/OFF Indicator (”ON”) OFF ON Passenger Airbag ON/OFF Indicator (”OFF”) OFF ON/OFF condition depends on the front passenger detection results. H43700
When the occupant classification system has trouble, both the SRS warning light and the passenger airbag OFF indicator come on. In this case, check the DTCs in the supplemental restraint system first. Then troubleshoot the occupant classification system if DTC B1150/23 is indicated and troubleshoot the passenger airbag ON/OFF indicator (supplemental restraint system) if DTC B1152/28 is detected. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1398 05-1209 DIAGNOSTICS 4. (a) (b) C93955 H44095 - SUPPLEMENTAL RESTRAINT SYSTEM SRS WARNING LIGHT CHECK Turn the ignition switch to the ON position, and check that the SRS warning light comes on for approximately 6 seconds (primary check). Check that the SRS warning light goes off approximately 6 seconds after the ignition switch is turned to the ON position (constant check). HINT: When any of the following symptoms occur, refer to the ”Problem Symptoms Table” (see page 05-1227 ).
The SRS warning light comes on occasionally, even after the primary check period has elapsed.
The SRS warning light comes on, but a DTC is not output.
The ignition switch is turned from the LOCK to ON position, both the SRS warning light does not come on. 5. PASSENGER AIRBAG ON/OFF INDICATOR CHECK (a) Turn the ignition switch to the ON position. (b) Check that the passenger airbag ON/OFF indicator (”ON” and ”OFF”) come on for approximately 4 seconds, then goes off for approximately 2 seconds. HINT: Refer to the table in step 3 regarding the passenger airbag ON/ OFF indicator when the ignition switch is turned to the ON position and approximately 6 seconds pass. 6. (a) RELEASE METHOD OF ACTIVATION PREVENTION MECHANISM The activation prevention mechanism is built into the connector for the squib circuit of the SRS. As explained in the troubleshooting section, insert a piece of paper that is the same thickness as the male terminal between the terminal and the short spring to release it (Refer to the illustrations on the next 5 pages). CAUTION: Never release the activation prevention mechanism on the squib connector even when inspecting with the squib disconnected. NOTICE:
Never release the activation prevention mechanism unless specially directed by the troubleshooting procedure.
To prevent the terminal and the short spring from being damaged, always use a piece of paper that is the same thickness as the male terminal. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1399 05-1210 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM w/ Side and Curtain Shield Airbag: To Occupant Classification ECU 35 36 9 Front Seat Outer Belt Assy RH (Squib) 31 Airbag Sensor Rear RH 10 27 7 32 (*1) (*1) 28 Side Airbag Sensor Assy RH Curtain Shield Airbag Assy RH (Squib) 29 (*2) 8 30 5 25 Airbag Sensor Front RH Front Seat Airbag Assy RH (Squib) 6 26 3 23 4 24 Front Passenger Airbag Assy (Squib) 1 19 Airbag Sensor Assy Center 2 3 13 21 Integration Switch Assy 20 22 14 16 17 4 5 Horn Button Assy (Squib) 15 18 Spiral Cable Sub-assy 25 Airbag Sensor Rear LH 6 Front Seat Airbag Assy LH (Squib) 26 7 29 Side Airbag Sensor Assy LH 8 Curtain Shield Airbag Assy LH (Squib) 30 9 31 Airbag Sensor Front LH 10 Front Seat Outer Belt Assy LH (Squib) 32 11 Seat Position Airbag Sensor 12 *1: w/ Rear Seat Entertainment System *2: w/o Rear Seat Entertainment System H44135 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1400 05-121 1 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM w/o Side and Curtain Shield Airbag: 9 Airbag Sensor Rear RH 10 7 To Occupant Classification ECU 29 Side Airbag Sensor Assy RH 30 8 5 26 Front Seat Outer Belt Assy RH (Squib) Airbag Sensor Front RH 6 25 3 24 Front Passenger Airbag Assy (Squib) 23 4 1 22 Airbag Sensor Assy Center 19 13 2 Telltale Lamp Assy 20 14 21 3 18 16 Horn Button Assy (Squib) 15 4 5 17 Spiral Cable Sub-assy 26 Airbag Sensor Rear LH 25 6 Front Seat Outer Belt Assy LH (Squib) 7 Side Airbag Sensor Assy LH 8 9 Airbag Sensor Front LH 10 11 Seat Position Airbag Sensor 12 H44087 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1401 05-1212 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM Occupant Classification ECU: Front Seat Inner Belt Assy RH (Buckle Switch RH) 5 From Airbag Sensor Assy Center 6 Occupant Classification Sensor Front LH 7 8 1 Occupant Classification Sensor Front RH 7 Occupant Classification ECU 2 8 3 Occupant Classification Sensor Rear LH 7 4 8 Occupant Classification Sensor Rear RH 7 8 H43077 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1402 05-1213 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM w/ Side and Curtain Shield Airbag: Airbag Sensor Assy Center Side Connector 4 2 Short Spring Short Spring 4 Short Spring Short Spring Before Release After Release Paper Paper Short Spring Connector Short Spring 16 Before Release After Release Paper Short Spring Connector 25 Paper Short Spring Before Release Short Spring Paper After Release Short Spring Paper Short Spring H44086 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1403 05-1214 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM w/o Side and Curtain Shield Airbag: Airbag Sensor Assy Center Side Connector 4 Short Spring 4 2 Short Spring Short Spring After Release Before Release Paper Paper Short Spring Connector Short Spring 16 Before Release Short Spring Paper After Release Paper Short Spring Short Spring H44088 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1404 05-1219 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM 05IV8-02 DATA LIST/ACTIVE TEST HINT: By accessing the DATA LIST displayed by the hand-held tester, you can perform such functions as reading the values of switches and sensors without removing any parts. Reading the DATA LIST is the first step of troubleshooting and is one method to shorten labor time. (d) Connect the hand-held tester to the DLC3. (e) Turn the ignition switch to the ON position. (f) Following the display on the tester screen, read the ”DATA LIST”. 1. DATA LIST FOR AIRBAG SENSOR ASSY CENTER Item D SEAT POSITION PASSENGER CLASS D BUCKLE SW P BUCKLE SW #CODES Measurement Item/ Normal Condition Range (Display) Seat position (Driver side)/ FORWARD: Seat position is forward FORWARD/BKWARD BKWARD: Seat position is rearward FAIL: A failure is detected Passenger classification/ NG: A date is not determined NONE: Vacant CHILD: Child (less than 36 kg (79.37 lb)) is seated NG/NONE/CHILD/SMALL/ SMALL: Adult (36 to 54 kg REGULAR (79.37 to 119.05 lb)) is seated REGULAR: Adult (more than 54 kg (119.05 lb)) is seated FAIL: A failure is detected Buckle switch (Driver side)/ ON: The seat belt is fastened OFF: The seat belt is not ON/OFF fastened NG: A data is not determined Buckle switch (Passenger side)/ ON: The seat belt is fastened ON/OFF OFF: The seat belt is not fastened NG: A data is not determined Number of past DTC recorded/ 0 Min.: 0, Max.: 255 Diagnostic Note - - - - - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1409 05-1220 DIAGNOSTICS 2. - SUPPLEMENTAL RESTRAINT SYSTEM DATA LIST FOR OCCUPANT CLASSIFICATION ECU Item IG SW P BUCKLE SW PASSENGER CLASS SENS RANGE INF FL SENS RANGE FR SENS RANGE RL SENS RANGE Measurement Item/ Range (Display) Ignition switch condition/ ON: Ignition switch ON OFF: Ignition switch OFF Buckle switch (Passenger side)/ OFF: Unfasten the passenger side seat belt ON: Fasten the passenger side seat belt NG: Passenger side seat belt has trouble Passenger classification/ AF05: Adult (36 to 54 kg (79.37 to 119.05 lb)) is seated AM50: Adult (more than 54 kg (119.05 lb)) is seated CHILD: Child (less than 36 kg (79.37 lb) is seated CRS: Child restraint system (less than 7 kg (15.43 lb)) and passenger side buckle switch is ON, then 7 to 36 kg (15.43 to 79.37 lb)) is set OFF: Vacant Sensor range information/ OK: The value of a sensor is within the range NG: The value of a sensor is over the range Front left sensor range information/ OK: Sensor range is -17 to 27 kg (-37.48 to 59.52 lb) Min.: Less than -17 kg (-37.48 lb) Max.: More than 27 kg (59.52 lb) Front right sensor range information/ OK: Sensor range is -17 to 27 kg (-37.48 to 59.52 lb) Min.: Less than -17 kg (-37.48 lb) Max.: More than 27 kg (59.52 lb) Rear left sensor range information/ OK: Sensor range is -17 to 37 kg (-37.48 to 81.57 lb) Min.: Less than -17 kg (-37.48 lb) Max.: More than 37 kg (81.57 lb) Normal Condition Diagnostic Note ON/OFF - OFF/ON - AF05/AM50/CHILD/CRS/ OFF - OK - OK - OK - OK - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1410 05-1221 DIAGNOSTICS Item RR SENS RANGE FL SENS VOL FR SENS VOL RL SENS VOL RR SENS VOL FL SENS WEIGHT FR SENS WEIGHT RL SENS WEIGHT RR SENS WEIGHT TOTAL WEIGHT #CODES Measurement Item/ Range (Display) Rear right sensor range information/ OK: Sensor range is -17 to 37 kg (-37.48 to 81.57 lb) Min.: Less than -17 kg (-37.48 lb) Max.: More than 37 kg (81.57 lb) Front left sensor voltage/ Min.: 0 V Max.: 19.8 V Front right sensor voltage/ Min.: 0 V Max.: 19.8 V Rear left sensor voltage/ Min.: 0 V Max.: 19.8 V Rear right sensor voltage/ Min.: 0 V Max.: 19.8 V Front left sensor weight information/ Min.: -17 kg (-37.48 lb) Max.: 27 kg (59.52 lb) Front right sensor weight information/ Min.: -17 kg (-37.48 lb) Max.: 27 kg (59.52 lb) Rear left sensor weight information/ Min.: -17 kg (-37.48 lb) Max.: 37 kg (81.57 lb) Rear right sensor weight information/ Min.: -17 kg (-37.48 lb) Max.: 37 kg (81.57 lb) Total weight information/ Min.: -68 kg (-88.18 lb) Max.: 128 kg (220.46 lb) Number of DTC recorded/ Min.: 0, Max.: 255 - SUPPLEMENTAL RESTRAINT SYSTEM Normal Condition Diagnostic Note OK - 0 to 4.7 V - 0 to 4.7 V - 0 to 4.7 V - 0 to 4.7 V - -17 to 27 kg (-37.48 to 59.52 lb) - -17 to 27 kg (-37.48 to 59.52 lb) - -17 to 37 kg (-37.48 to 81.57 lb) - -17 to 37 kg (-37.48 to 81.57 lb) - -68 to 128 kg (-149.91 to 282.19 lb) - 0 - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1411 05-1215 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM 05MOG-01 DTC CHECK/CLEAR 1. H40173 Normal System Code (w/o Past Trouble Code) 0.25 ON OFF 0.25 Normal System Code (w/ Past Trouble Code) 0.75 ON OFF 0.25 Trouble Code (Example Code 11 and 31) 0.5 2.5 4.0 1.5 DTC 11 0.5 Repeat DTC 31 H13050 SUPPLEMENTAL RESTRAINT SYSTEM DTC CHECK (USING SST CHECK WIRE) (a) Check the DTCs (Present trouble code). (1) Turn the ignition switch to the ON position, and wait for approximately 60 seconds. (2) Using SST, connect terminals TC and CG of the DTC3. SST 09843-18040 NOTICE: Connect the terminals to the correct positions to avoid a malfunction. (b) Check the DTCs (Past trouble code). (1) Using SST, connect terminals TC and CG of the DTC3. SST 09843-18040 NOTICE: Connect the terminals to the correct positions to avoid a malfunction. (2) Turn the ignition switch to the ON position, and wait for approximately 60 seconds. (c) Read the DTCs. (1) Read the blinking patterns of the DTCs. Examples, the blinking patterns for the normal system code and trouble codes 11 and 31 are shown in the illustration to the left.
Normal system code indication (w/o past trouble code) The light blinks twice per second.
Normal system code indication (w/ past trouble code) When the past trouble code is stored in the airbag sensor assy center, the light blinks only ones per second.
Trouble code indication The first blinking indicates the first DTC. The second blinking occurs after a 1.5-second pause. If there are more than 1 code, there will be a 2.5-second pause between each code. After all the codes are shown, there will be a 4.0-second pause, and they will all be repeated. HINT:
If 2 or more malfunctions are found, the indication begins will the smallest numbered code.
If DTCs are inspection without connecting the terminals, proceed to the ”Tc terminal circuit” on page 05-1522 . 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1405 05-1216 DIAGNOSTICS 2. (a) - SUPPLEMENTAL RESTRAINT SYSTEM DTC CLEAR (USING SST CHECK WIRE) Clear the DTCs. (1) When the ignition switch is turned off, the DTCs are cleared. HINT: Depending on the DTC, the code may not be cleared by turning off the ignition switch. In this case, proceed to the next procedure. (2) Using SST, connect terminals TC and CG of the DLC3, and then turn the ignition switch to the ON position. SST 09843-18040 (3) Disconnect terminal TC of the DLC3 within 3 to 10 seconds after the DTCs are output, and check if the SRS warning light comes on after 3 seconds. (4) Within 2 to 4 seconds after the SRS warning light comes on, connect terminals TC and CG of the DLC3. (5) The SRS warning light should go off within 2 to 4 seconds after connecting the terminals TC and CG of the DLC3. Then, disconnect terminal TC within 2 to 4 seconds after the SRS warning light goes off. (6) The SRS warning light comes on again within 2 to 4 seconds after disconnecting terminal TC. Then, reconnect terminals TC and CG within 2 to 4 seconds after the SRS warning light comes on, connect terminals TC and CG of the DLC3. (7) Check if the SRS warning light goes off 2 to 4 seconds after connecting terminals TC and CG of the DLC3. Also check if and the normal system code is output within 1 second after the SRS warning light goes off. If DTCs are to cleared, repeat this above procedure until the codes are cleared. IG S/W ON OFF DTC3 Open TC Short 0.5 sec. 0.5 sec. 0.25 sec. 0.25 sec. CG ON SRS Warning Light (*) OFF 1.5 sec. T1: 0 to ∞ sec. T2: approx. 6 sec. T3: 3 to 5 sec. T4: 3 to 10 sec. T5: 2 to 4 sec. T6: 1 to 5 sec. T7: within 1 sec. T1 T2 T3 T4 T5 T6 T5 T6 T5 T6 T5 T7 *: The past trouble code in the illustration shows DTC 21 as an example. H44132 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1406 05-1217 DIAGNOSTICS Hand-held Tester 3. (a) DLC3 A80020 Hand-held Tester - SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM DTC CHECK (USING HAND-HELD TESTER) Check the DTCs. (1) Connect the hand-held tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) Check the DTCs by following the prompts on the tester screen. HINT: Refer to the hand-held tester operator’s manual for further details. (b) Clear the DTCs. (1) Connect the hand-held tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) Clear the DTCs by following the prompts on the tester screen. HINT: Refer to the hand-held tester operator’s manual for further details. 4. OCCUPANT CLASSIFICATION SYSTEM DTC CHECK (USING HAND-HELD TESTER) HINT:

DLC3 A80020 (a) When DTC B1150/23 is detected as a result of troubleshooting the supplemental restraint system, perform troubleshooting for the occupant classification system. Since the DTCs for the occupant classification system can only be output by the hand-held tester, use the handheld tester to output the DTCs. Check the DTCs. (1) Connect the hand-held tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) Check the DTCs by following the prompts on the tester screen. HINT: Refer to the hand-held tester operator’s manual for further details. (b) Clear the DTCs. (1) Connect the hand-held tester to the DLC3. (2) Turn the ignition switch to the ON position. (3) Clear the DTCs by following the prompts on the tester screen. HINT: Refer to the hand-held tester operator’s manual for further details. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1407 05-1203 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM 05MOF-01 INITIALIZATION Hand-held Tester DLC3 A80020 1. ZERO POINT CALIBRATION AND SENSITIVITY CHECK NOTICE: Make sure that the seat is not occupied before performing the operation. HINT: Perform the zero point calibration and sensitivity check if any of the following conditions occur.
The occupant classification ECU is replaced.
Accessories (seatback tray and seat cover, etc.) are installed.
The passenger seat is removed from the vehicle.
The passenger airbag ON/OFF indicator (”OFF”) comes on when the passenger seat is not occupied.
The vehicle is brought to the workshop for repair due to an accident or a collision. (a) Zero point calibration and sensitivity check procedures. HINT: Make sure that zero point calibration has finished normally, and then perform the sensitivity check. (1) Adjust the seat position according to the table below. Adjustment Component Position (2) (3) (4) Slide Direction Rearmost position Reclining Angle Upright position Headrest Height Lowest position Lifter Height Lowest position Connect the hand-held tester to the DLC3. Turn the ignition switch to the ON position. Perform the zero point calibration by following the prompts on the tester screen shown in 2 pages later. HINT: Refer to the hand-held tester operator’s manual for further details. OK: ”COMPLETE” is displayed. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1393 05-1204 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM (5) Perform the sensitivity check by following the prompts on the tester screen shown in 2 pages later. (6) Confirm that the beginning sensor reading is within the standard value. Standard value: -3.2 to 3.2 kg (-7 to 7 lb) (7) Place a 30 kg (66.14 lb) weight (eg. a 30 kg (66.14 lb) of lead mass) onto the passenger seat. (8) Confirm that the sensitivity is within the standard value. Standard value: 27 to 33 kg (59.52 to 72.75 lb) HINT:


When performing the sensitivity check, use a solid metal weight (the check result may not appear properly if the weight made from liquid is used). When the sensitivity deviates from the standard value, retighten the bolts of the passenger seat taking care not to deform the seat rail. After performing this procedure, if the sensitivity is not within the standard value, replace the front RH seat assy. When zero point calibration has not finished normally, replace the front RH seat assy. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1394 05-1205 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM ZERO POINT CALIBRATION PROCEDURE ”1: DIAGNOSIS” - ”1: OBD/MOBD” - ”MODEL YEAR” - ”MODEL SELECTION = HIGH LANDER” Select the option parts - ”9: OCCUPANT DETECT” - Refer to the following screen flow. DIAGNOSTIC MENU OCCUPANT DETECT 1: DATA LIST 2: DTC INFO 4: SNAPSHOT 5: ZERO CALIBRATION 6: SENSITIVITY CHK NOTICE NOTICE Please confirm seat position. Confirm that nothing is placed on the passenger seat. Slide: Max rear Recline: Max upright Headrest: Max down Lifter: Max down PRESS [ENTER] or [EXIT] PRESS [ENTER] or [EXIT] NOTICE Do you wish to start ”ZERO CALIBRATION”? ZERO CALIBRATION COMPLETED Perform sensitivity check. Next, perform the SENSITIVITY CHECK. PRESS [YES] or [NO] PRESS [ENTER] ZERO CALIBRATION ZERO CALIBRATION FAILED FAILED Failed to SECURITY ACCESS. Perform DTC check and repair. EEPROM writing error Please check DTCs Try again PRESS [ENTER] PRESS [ENTER] ZERO CALIBRATION FAILED Sensor range over malfunction Front Left ----[ Front Right ----[ Rear Left ----[ Rear Right ----[ ] ] ] ] Sensor information is expressed as OK, MAX or MIN in [ ]. If MAX or MIN is displayed, replace the front RH seat assy. PRESS [ENTER] 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1395 05-1206 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM SENSITIVITY CHECK PROCEDURE ”1: DIAGNOSIS” - ”1: OBD/MOBD” - ”MODEL YEAR” - ”MODEL SELECTION = HIGH LANDER” Select the option parts - ”9: OCCUPANT DETECT” - Refer to the following screen flow. DIAGNOSTIC MENU OCCUPANT DETECT 1: DATA LIST 2: DTC INFO 4: SNAPSHOT 5: ZERO CALIBRATION 6: SENSITIVITY CHK SENSITIVITY CHECK NOTICE Beginning sensor reading should be -3.2 to 3.2 kg. (-7 to 7 lbs) Please confirm that nothing is placed on the passenger seat. Sensor reading 0.00 kg PRESS [ENTER] or [EXIT] PRESS [ENTER] SENSITIVITY CHECK Place 30 kg (66 lbs) weight on passenger seat. Sensor reading should be 27 to 33 kg. (59 to 73 lbs) Sensor reading (*1) 0.00 kg PRESS [ENTER] *1: kg ⇔ lb Unit can be changed based on unit conversion setting. [System Selection Screen] ”1: DIAGNOSIS” - ”9: SETUP” - ”4: UNIT CONVERSION” - ”WEIGHT” (kg ⇔ lbs) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1396 05-1515 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM 05267-05 SOURCE VOLTAGE DROP CIRCUIT DESCRIPTION The SRS is equipped with a voltage-increase circuit (DC-DC converter) in the airbag sensor assy center in case the source voltage drops. When the battery voltage drops, the voltage-increase circuit (DC-DC converter) functions to increase the voltage of the SRS to normal voltage. A malfunction in this circuit is displayed differently from other codes. The source voltage drop is indicated when the SRS warning light comes on without showing any DTCs. A malfunction in this circuit is not recorded in the airbag sensor assy center. The SRS warning light automatically goes off when the source voltage returns to normal. DTC No. Diagnosis (Normal) Source voltage drop WIRING DIAGRAM I15 Ignition SW AM2 Y Instrument Panel J/B IG2 1 1C GR 6 7 Airbag Sensor Assy Center IGN 6 1L B 5 A17 IG2 F7 FL Block 1 IC1 L-Y 10 AM2 W 1 W Instrument Panel J/B W-B 14 1D 1 1L 9 1L W-B W-B 28 A17 E2 27 A17 E1 FL MAIN Battery IA H45941 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1705 05-1516 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 CHECK SOURCE VOLTAGE (a) (b) (c) IG2 A17 (d) E2 E1 H40065 (e) (f) Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connector of the airbag sensor assy center. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the voltage and resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A17-5 (IG2) Body ground Ignition switch ON 10 to 14 V A17-27 (E1) Body ground Always Below 1 Ω A17-28 (E2) Body ground Always Below 1 Ω NG REPAIR OR REPLACE WIRE HARNESS (BATTERY - AIRBAG SENSOR ASSY CENTER), CHARGING SYSTEM AND BATTERY OK 2 (a) (b) (c) (d) (e) (f) CHECK SRS WARNING LIGHT Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Connect the airbag sensor assy center connectors. Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Operate all components of the electrical system (defogger, wiper, headlight, heater blower, etc.) and check the SRS warning light operation. OK: SRS warning light does not come on. NG REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) OK END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1706 05-1517 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM 05IX2-02 SRS WARNING LIGHT CIRCUIT MALFUNCTION (ALWAYS LIGHT UP, WHEN DTC IS NOT OUTPUT.) CIRCUIT DESCRIPTION The SRS warning light is located on the combination meter. When the SRS is normal, the SRS warning light lights up for approx. 6 seconds after the ignition switch is turned from the LOCK position to ON position, and then turns off automatically. If there is a malfunction in the SRS, the SRS warning light lights up to inform the driver of the abnormality. When terminals Tc and CG of the DLC3 are connected, the DTC is displayed by blinking the SRS warning light. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1707 05-1518 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM WIRING DIAGRAM A/C Control Assembly G 9 2 MPX+ MPD1 4 G V 11 A10 MPXA11 (*1) MPD2 (*1) P5 Power Window Master SW with ECU GR 8 Airbag Sensor Assy Center G5 Gate Way ECU MPX1 7 V MPX2 12 IL2 Short Connector 1 1 BR R S31 S30 24 A17 MPX1 G (*2) IB2 Passenger Side J/B 7 5 BR SB 4F 4A 2 S31 2 S30 22 A17 MPX2 BR *1: w/ Navigation System *2: w/o Navigation System *3: w/ Theft Deterrent System E6 Engine Control Module Body ECU 1 IB2 GR Y 5 3H 12 3J O 10 6 MPX2 29 W 18 MPX1 B9 MPX2 B10 MPX1 Y Combination Meter B SB V 31 MPX1 (*3) 1 3E 12 3A 1 IL2 T4 Theft Deterrent ECU Center J/B G 5 IF3 1 3C P 1 C11 21 C11 Y 9 C12 SB Center J/B B 11 C11 Instrument Panel J/B HEATER 13 7 1K IC F7 FL Block FL MAIN ALT 2 B W 1 12 3B R 2 3K BR G Instrument Panel J/B AM1 1 6 1 2 1A 1C I15 Ignition SW W 2 4 AM1 Battery IG1 IB H45942 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1708 05-1519 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 (a) (b) (c) CHECK CONNECTOR Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Check that the connectors are properly connected to the airbag sensor assy center and the combination meter assy. OK: The connectors are connected. NG CONNECT CONNECTORS OK 2 CHECK WIRE HARNESS (a) (b) Airbag Sensor Assy Center: (c) (d) A17 MPX1 MPX2 Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connector from the airbag sensor assy center. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A17-24 (MPX1) - C11-21 Always Below 1 Ω A17-24 (MPX1) A17-22 (MPX2) Always 1 MΩ or Higher Combination Meter Assy: C11-21 H40452 NG REPAIR OR REPLACE WIRE HARNESS (AIRBAG SENSOR ASSY CENTER COMBINATION METER ASSY) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1709 05-1520 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK COMBINATION METER ASSY (a) Disconnect the connector from the combination meter assy. (b) Connect the negative (-) terminal cable to the battery, and wait for at least 2 seconds. (c) (d) Turn the ignition switch to the ON position. Measure the voltage according to the value(s) in the table below. Standard: C82952 Tester connection Condition Specified condition C11-21 - Body ground Ignition switch ON 8 to 14 V NG REPLACE COMBINATION METER ASSY (SEE PAGE 71-10 ) OK REPLACE AIR BAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1710 05-1521 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM 05269-04 SRS WARNING LIGHT CIRCUIT MALFUNCTION (DOES NOT LIGHT UP, WHEN IGNITION SWITCH IS TURNED TO ON) CIRCUIT DESCRIPTION The SRS warning light is located on the combination meter. When the SRS is normal, the SRS warning light lights up for approx. 6 seconds after the ignition switch is turned from the LOCK position to ON position, and then turns off automatically. If there is a malfunction is the SRS, the SRS warning light lights up to inform the driver of the abnormality. When terminals Tc and CG of the DLC3 are connected, the DTC is displayed by blinking the SRS warning light. WIRING DIAGRAM see page 05-1517 . INSPECTION PROCEDURE 1 (a) CHECK BATTERY Measure the voltage of the battery. Standard: 11 to 14 V NG REPLACE BATTERY OK 2 (a) (b) (c) (d) (e) (f) CHECK WIRE HARNESS Turn the ignition switch to the LOCK position. Disconnect the negative (-) terminal cable from the battery, and wait for at least 90 seconds. Disconnect the connector from the airbag sensor assy center. Connect the negative (-) terminal cable from the battery, and wait for at least 2 seconds. Turn the ignition switch to the ON position. Measure the resistance according to the value(s) in the table below. OK: The SRS warning light comes on. NG REPAIR OR REPLACE WIRE HARNESS (COMBINATION METER - BATTERY) OK REPLACE COMBINATION METER ASSEMBLY (SEE PAGE 71-10 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1711 05-1 197 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM 05MOE-01 SYSTEM DESCRIPTION 1. (a) (b) (c) 2. (a) DESCRIPTION OF SUPPLEMENTAL RESTRAINT SYSTEM General description. (1) In this system, the airbag sensor assy center installed on the floor under the A/C unit determines whether or not to activate the SRS airbags (driver airbag, passenger airbag, front seat airbags and curtain shield airbags) and seat belt pretensioners by receiving the collision signal from each sensor (excluding the airbag sensor assy center). When there is trouble in the system, the airbag sensor assy center turns on the SRS warning light on the combination meter assy to inform the driver. Description of the dual stage control. (1) The airbag sensor assy center controls the dual stage deployment of the driver airbag in the horn button assy and the passenger airbag on the instrument panel. The airbag sensor assy center controls the dual stage deployment of the driver airbag according to the collision impact, seat position and seat belt ON/OFF state. It also controls the dual stage deployment of the passenger airbag according to the collision impact and seat belt ON/OFF state. Description of check mode (signal check). (1) This airbag sensor assy center is operable using the check mode of the hand-held tester function. Check mode can detect and output DTC by using a hand-held tester to switch the airbag sensor assy center to the check mode. A simulation method is used, if the malfunction cannot be reproduced during troubleshooting (the malfunction is temporarily solved, etc.). In this case, joggling each connector, or driving on a city or rough road with the airbag sensor assy center in check mode makes it possible to obtain a more accurate malfunction condition. IGNITION JUDGEMENT AND CONDITIONS Operation in case of front collision. (1) When the vehicle collides in the hatched area (Fig.1) and shock is larger than a predetermined level, the airbags (driver and front passenger) are activated automatically. The deceleration sensor of the airbag sensor assy center determines the need for ignition in response to collisions within the hatched area based on the signal from the deceleration sensor of the front airbag sensor. (2) Safing sensor of the airbag sensor assy center is designed to activate at a smaller deceleration rate than the deceleration sensor. As illustrated in Fig.2 below, when both the safing sensor and deceleration sensor go on simultaneously, current flows to the squib and ignition occurs. Airbag Sensor Assy Center Safing Sensor ON AND Airbag Inflating Deceleration Sensor ON Fig.2 Fig.1 H44048 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1387 05-1 198 DIAGNOSTICS (b) - SUPPLEMENTAL RESTRAINT SYSTEM w/ Side and curtain shield airbag: Operation in case of front side collision. (1) Electronic safing sensor of the side airbag sensor assy is designed to activate at a smaller deceleration rate than the deceleration sensor of the side airbag sensor assy. As illustrated below, when both the safing sensor and deceleration sensor go on simultaneously, current flows to the squib and ignition occurs. Airbag Sensor Assy Center Electronic Safing Sensor ON AND Airbag Inflating Deceleration Sensor ON Side Airbag Sensor Assy H44049 (c) w/ Side and curtain shield airbag: Operation in case of rear side collision. (1) Electronic safing sensor of the airbag sensor assy center is designed to activate at a smaller deceleration rate than the deceleration sensor of the airbag sensor rear. As illustrated below, when both the safing sensor and deceleration sensor go on simultaneously, current flows to the squib and ignition occurs. Airbag Sensor Assy Center Front Seat Airbag Assy Deployment Airbag Sensor Assy Center Electronic Safing Sensor ON OR Airbag Sensor Rear Airbag Inflating AND Deceleration Sensor ON H44901 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1388 05-1 199 DIAGNOSTICS 3. (a) (b) - SUPPLEMENTAL RESTRAINT SYSTEM DESCRIPTION OF PASSENGER OCCUPANT CLASSIFICATION SYSTEM GENERAL DESCRIPTION. (1) In the passenger occupant classification system, the occupant classification ECU calculates the weight of the occupant based on a signal from the occupant classification sensor. This system recognizes the occupant to be a child if it detects a weight of less than 36 kg (79.37 lb), and disables the front and side airbags. (2) This system is mainly comprised of 4 occupant classification sensors that detect the load on the front passenger seat. The occupant classification ECU controls the system, and the passenger airbag ON/OFF indicator indicates the ON/OFF condition of the front passenger airbag assy and front passenger seat airbag assy. OCCUPANT CLASSIFICATION SENSOR. (1) The occupant classification sensors are installed on 4 brackets connecting the seat rail and seat frame. Accordingly, when load is applied to the passenger seat by an occupant sitting in it, the occupant classification sensors register a distortion. Occupant Classification Sensor Occupant Classification Sensor Occupant Classification ECU Occupant Load A Occupant Classification Sensor A A - A Cross Section H44065 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1389 05-1 196 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM SYSTEM DIAGRAM *1: w/ Side and Curtain Shield Airbag Airbag Sensor Front LH 05IV1-02 Airbag Sensor Front RH Side Airbag Sensor Assy LH (*1) Side Airbag Sensor Assy RH (*1) Airbag Sensor Rear LH (*1) Airbag Sensor Rear RH (*1) Seat Position Airbag Sensor Front Seat Inner Belt Assy LH (Buckle Switch LH) Airbag Sensor Assy Center Horn Button Assy (D Squib) Front Passenger Airbag Assy (P Squib) Front Seat Airbag Assy LH (Side Squib LH) (*1) Front Seat Airbag Assy RH (Side Squib RH) (*1) Curtain Shield Airbag Assy LH (Curtain Shield Squib LH) (*1) Curtain Shield Airbag Assy RH (Curtain Shield Squib RH) (*1) Front Seat Outer Belt Assy LH (P/T Squib LH) Front Seat Outer Belt Assy RH (P/T Squib RH) Combination Meter Assy (SRS Warning Light) Telltale Lamp Assy (Passenger Airbag ON/OFF Indicator) ECM DLC3 Occupant Classification ECU Front Seat Inner Belt Assy RH (Buckle Switch RH) Occupant Classification Sensors (Front left, Front right, Rear left, Rear right) H43622 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1386 05-1522 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM 0526A-05 TC TERMINAL CIRCUIT CIRCUIT DESCRIPTION The DTCs output mode is set by connecting terminals TC and CG of the DLC3. The DTCs are displayed by blinking the SRS warning light. HINT:
Make sure that DTC B1281 has not been output. If DTC B1281 has been output, refer to the multiplex communication system.
When each warning light stays blinking, a ground short in the wiring of terminal TC of the DLC3 or an internal ground short in each ECU is suspected.
The DTC output mode signal is transmitted through BEAN to each ECU including the airbag sensor assy center, except for the skid control ECU with actuator. Thus when all systems except the ABS system do not enter DTC output mode, it can be suspected that there is an ECM malfunction. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1712 05-1523 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM WIRING DIAGRAM A/C Control Assembly 2 9 MPX+ V 11 MPD1 4 G A10 MPXA11 MPD2 (*1) (*1) G 8 8 IB2 MPX1 7 V MPX2 12 IL2 G (*2) P5 Power Window Master SW with ECU GR Airbag Sensor Short Connector Assy Center 1 1 24 R BR A17 S31 S30 G5 Gateway ECU Passenger Side J/B 7 5 BR 4F 4A SB 2 S31 22 2 BR S30 A17 Engine Control Module Body ECU GR 1 IB2 10 5 6 O MPX1 IF3 B10 B9 MPX2 T4 Theft Deterrent ECU Y Center J/B 5 3H V (*3) 31 W 18 E6 GR 29 E6 MPX1 Combination Meter 1 3E 12 3J G Y 21 9 MPX+ C11 MPXC12 SB 1 IL2 J16 J/C D3 DLC3 O TC D D 20 E5 O M3 Multi-Display D CG 4 W-B Passenger Side J/B 6 1 4C 4N O 3 IF3 P 7 TC *1: w/ Navigation System *2: w/o Navigation System *3: w/ Theft Deterrent System W-B IC H45940 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1713 05-1524 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 DLC3: CHECK WIRE HARNESS(DLC3 - ECM) (a) (b) (c) TC Turn the ignition switch to the LOCK position. Disconnect the airbag sensor assy center connector. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition DLC3 (TC) E5-20 (TC) Always Below 1 Ω ECM: E5 TC H40173 A67445 H44085 NG REPAIR OR REPLACE WIRE HARNESS(TC of DLC3 - TC of ECM) OK 2 CHECK WIRE HARNESS(CG of DLC3 - BODY GROUND) (a) DLC3 CG H40173 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition DLC3 (CG) Body ground Always Below 1 Ω NG REPAIR OR REPLACE WIRE HARNESS(CG of DLC3 - BODY GROUND) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1714 05-1525 DIAGNOSTICS 3 - SUPPLEMENTAL RESTRAINT SYSTEM CHECK WIRE HARNESS(TC of ECM - BODY GROUND) (a) ECM: E5 TC A67445 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition E5-20 (TC) Body ground Always 1MΩ or Higher NG REPAIR OR REPLACE WIRE HARNESS AND EACH ECU OK 4 (a) REPLACE ECM Check that the ECM. Result: A: Normal system code is output. B: DTC is output. C: ECM does not set the DTC output mode. A END B GO TO INSPECTION PROCEDURE OF DTC OUTPUT C REPLACE AIRBAG SENSOR ASSY CENTER (SEE PAGE 60-53 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1715 05-1202 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM 05IV3-02 CUSTOMER PROBLEM ANALYSIS CHECK Inspector’s Name Supplemental Restraint System Check Sheet VIN Customer’s Name Production Date / / Licence Plate No. km Miles Odometer Reading Date Vehicle Brought In Date Problem Occurred Cloudy Fine Weather Temperature Snowy Rainy Other Approx. Starting Driving Vehicle Operation Idling [ Constant speed Acceleration Deceleration ] Other Road Condition Details of Problem Vehicle Inspection, and Repair History Prior to Occurrence of Malfunction (Including Supplemental Restraint System) Diagnostic System Inspection SRS Warning Light Inspection Passenger Airbag ON/OFF Indicator Inspection 1st Time Remains ON Sometimes comes on Does not come on 2nd Time Remains ON Sometimes comes on Does not come on 1st Time Remains ON Does not come on 2nd Time Remains ON Does not come on 1st Time Normal System Code Trouble Code [ Code. ] 2nd Time Normal System Code Trouble Code [ Code. ] DTC Inspection 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1392 05-1228 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM 05259-22 DIAGNOSTIC TROUBLE CODE CHART 1. DTCS FOR SUPPLEMENTAL RESTRAINT SYSTEM If a trouble code is displayed during the DTC check, check the circuit listed for the code in the table below (Proceed to the page listed for that circuit.). HINT:
When the SRS warning light remains on and the DTC output is the normal system code, a voltage source drop is likely to occur. This malfunction is not stored in memory by the airbag sensor assy center. If the power source voltage returns to normal, the SRS warning light will automatically go off.
When 2 or more codes are indicated, the code with the lower number appears first.
If a code is not listed on the display chart, the airbag sensor assy center may have failed.
In the case of any malfunction concerning an open circuit, short to ground, or short to B+ due to an squib, other trouble codes may not detected. In this case, repair the malfunction currently indicated and then perform malfunction diagnosis again.
Mark in the check mode column: ””: DTC is corresponding to the check mode. ””: DTC is not corresponding to the check mode.
When DTC B1150/23 is detected as a result of troubleshooting for the Supplemental Restraint System, perform troubleshooting for the occupant classification system as shown in the chart below. Check Mode SRS Warning Light Short in D squib circuit
Horn button assy (squib)
Spiral cable sub-assy
Airbag sensor assy center
Cowl wire  ON B0101/14 (05-1238 ) Open in D squib circuit
Horn button assy (squib)
Spiral cable sub-assy
Airbag sensor assy center
Cowl wire  ON B0102/11 (05-1242 ) Short in D squib circuit (to ground)
Horn button assy (squib)
Spiral cable sub-assy
Airbag sensor assy center
Cowl wire  ON B0103/12 (05-1246 ) Short in D squib circuit (to B+)
Horn button assy (squib)
Spiral cable sub-assy
Airbag sensor assy center
Cowl wire  ON B0105/53 (05-1251 ) Short in P squib circuit
Front passenger airbag assy (squib)
Airbag sensor assy center
Cowl wire  ON B0106/54 (05-1254 ) Open in P squib circuit
Front passenger airbag assy (squib)
Airbag sensor assy center
Cowl wire  ON B0107/51 (05-1257 ) Short in P squib circuit (to ground)
Front passenger airbag assy (squib)
Airbag sensor assy center
Cowl wire  ON B0108/52 (05-1260 ) Short in P squib circuit (to B+)
Front passenger airbag assy (squib)
Airbag sensor assy center
Cowl wire  ON B0110/43 (*1) (05-1263 ) Short in side squib (RH) circuit
Separate type front seat back assy (squib)
Airbag sensor assy center
Floor wire  Blink B0111/44 (*1) (05-1266 ) Open in side squib (RH) circuit
Separate type front seat back assy (squib)
Airbag sensor assy center
Floor wire  Blink DTC No. (See Page) B0100/13 (05-1233 ) Detection Item Trouble Area 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1418 05-1229 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM B0112/41 (*1) (05-1269 ) Short in side squib (RH) circuit (to ground)
Separate type front seat back assy (squib)
Airbag sensor assy center
Floor wire  Blink B0113/42 (*1) (05-1272 ) Short in side squib (RH) circuit (to B+)
Separate type front seat back assy (squib)
Airbag sensor assy center
Floor wire  Blink B0115/47 (*1) (05-1275 ) Short in side squib (LH) circuit
Separate type front seat back assy (squib)
Airbag sensor assy center
Floor wire No.2  Blink B0116/48 (*1) (05-1278 ) Open in side squib (LH) circuit
Separate type front seat back assy (squib)
Airbag sensor assy center
Floor wire No.2  Blink B0117/45 (*1) (05-1281 ) Short in side squib (LH) circuit (to ground)
Separate type front seat back assy (squib)
Airbag sensor assy center
Floor wire No.2  Blink B0118/46 (*1) (05-1284 ) Short in side squib (LH) circuit (to B+)
Separate type front seat back assy (squib)
Airbag sensor assy center
Floor wire No.2  Blink B0126/27 (05-1287 ) Seat belt buckle switch (LH) malfunction
Front seat inner belt assy LH
Airbag sensor assy center
Floor wire No.2  ON B0130/63 (05-1293 ) Short in P/T squib (RH) circuit
Front seat outer belt assy RH (squib)
Airbag sensor assy center
Floor wire  Blink B0131/64 (05-1297 ) Open in P/T squib (RH) circuit
Front seat outer belt assy RH (squib)
Airbag sensor assy center
Floor wire  Blink B0132/61 (05-1300 ) Short in P/T squib (RH) circuit (to ground)
Front seat outer belt assy RH (squib)
Airbag sensor assy center
Floor wire  Blink B0133/62 (05-1303 ) Short in P/T squib (RH) circuit (to B+)
Front seat outer belt assy RH (squib)
Airbag sensor assy center
Floor wire  Blink B0135/73 (05-1306 ) Short in P/T squib (LH) circuit
Front seat outer belt assy LH (squib)
Airbag sensor assy center
Floor wire No.2  Blink B0136/74 (05-1310 ) Open in P/T squib (LH) circuit
Front seat outer belt assy LH (squib)
Airbag sensor assy center
Floor wire No.2  Blink B0137/71 (05-1313 ) Short in P/T squib (LH) circuit (to ground)
Front seat outer belt assy LH (squib)
Airbag sensor assy center
Floor wire No.2  Blink B0138/72 (05-1316 ) Short in P/T squib (LH) circuit (to B+)
Front seat outer belt assy LH (squib)
Airbag sensor assy center
Floor wire No.2  Blink B1100/31 (05-1319 ) Airbag sensor assy center malfunction
Airbag sensor assy center  ON B1135/24 (05-1320 ) Half connection in airbag sensor assy center connctors
Electrical connection check mechanism
Airbag sensor assy center  ON B1140/32 (*1) (05-1322 ) Side airbag sensor assy (RH) malfunction
Side airbag sensor assy RH
Floor wire
Airbag sensor assy center  Blink B1141/33 (*1) (05-1327 ) Side airbag sensor assy (LH) malfunction
Side airbag sensor assy LH
Airbag sensor assy center
Floor wire No.2  Blink B1148/36 (05-1332 ) Front airbag sensor (RH) malfunction
Airbag front RH sensor
Airbag sensor assy center
Engine room main wire
Cowl wire  ON 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1419 05-1230 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM B1149/37 (05-1339 ) Front airbag sensor (LH) malfunction
Airbag front sensor LH
Airbag sensor assy center
Engine room main wire
Cowl wire  ON B1150/23 (05-1346 ) Occupant classification system malfunction
Occupant classification ECU
Airbag sensor assy center
Floor wire
Front seat wire RH  ON B1152/28 (05-1352 ) Passenger airbag ON/OFF indicator circuit malfunction
Telltale lamp assy
Airbag sensor assy center
Cowl wire  ON B1153/25 (05-1360 ) Seat position airbag sensor assy malfunction
Seat position airbag sensor
Airbag sensor assy center
Floor wire No.2  ON B1154/38 (05-1366 ) Airbag sensor rear (RH) malfunction
Airbag sensor rear RH
Airbag sensor assy center
Floor wire  Blink B1155/39 (05-1371 ) Airbag sensor rear (LH) malfunction
Airbag sensor rear LH
Airbag sensor assy center
Floor wire No.2  Blink B1160/83 (*1) (05-1376 ) Short in curtain shield squib (RH) circuit
Curtain shield airbag assy RH (squib)
Airbag sensor assy center
Floor wire
Roof wire No.2  Blink B1161/84 (*1) (05-1384 ) Open in curtain shield squib (RH) circuit
Curtain shield airbag assy RH (squib)
Airbag sensor assy center
Floor wire
Roof wire No.2  Blink B1162/81 (*1) (05-1390 ) Short in curtain shield squib (RH) circuit (to ground)
Curtain shield airbag assy RH (squib)
Airbag sensor assy center
Floor wire
Roof wire No.2  Blink B1163/82 (*1) (05-1396 ) Short in curtain shield squib (RH) circuit (to B+)
Curtain shield airbag assy RH (squib)
Airbag sensor assy center
Floor wire
Roof wire No.2  Blink B1165/87 (*1) (05-1403 ) Short in curtain shield squib (LH) circuit
Curtain shield airbag assy LH (squib)
Airbag sensor assy center
Floor wire No.2  Blink B1166/88 (*1) (05-1407 ) Open in curtain shield squib (LH) circuit
Curtain shield airbag assy LH (squib)
Airbag sensor assy center
Floor wire No.2  Blink B1167/85 (*1) (05-1410 ) Short in curtain shield squib (LH) circuit (to ground)
Curtain shield airbag assy LH (squib)
Airbag sensor assy center
Floor wire No.2  Blink B1168/86 (*1) (05-1413 ) Short in curtain shield squib (LH) circuit (to B+)
Curtain shield airbag assy LH (squib)
Airbag sensor assy center
Floor wire No.2  Blink B1180/17 (05-1416 ) Short in D squib (Dual stage 2nd step) circuit
Horn button assy (squib, Dual stage - 2nd step)
Spiral cable sub-assy
Airbag sensor assy center
Cowl wire  ON B1181/18 (05-1421 ) Open in D squib (Dual stage 2nd step) circuit
Horn button assy (squib, Dual stage - 2nd step)
Spiral cable sub-assy
Airbag sensor assy center
Cowl wire  ON B1182/19 (05-1425 ) Short in D squib (Dual stage 2nd step) circuit (to ground)
Horn button assy (squib, Dual stage - 2nd step)
Spiral cable sub-assy
Airbag sensor assy center
Cowl wire  ON 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1420 05-1231 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM B1183/22 (05-1429 ) Short in D squib (Dual stage 2nd step) circuit (to B+)
Horn button assy (squib, Dual stage - 2nd step)
Spiral cable sub-assy
Airbag sensor assy center
Cowl wire  ON B1185/57 (05-1434 ) Short in P squib (Dual stage 2nd step) circuit
Front passenger airbag assy (squib, Dual stage - 2nd step)
Airbag sensor assy center
Cowl wire  ON B1186/58 (05-1437 ) Open in P squib (Dual stage 2nd step) circuit
Front passenger airbag assy (squib, Dual stage - 2nd step)
Airbag sensor assy center
Cowl wire  ON B1187/55 (05-1440 ) Short in P squib (Dual stage 2nd step) circuit (to ground)
Front passenger airbag assy (squib, Dual stage - 2nd step)
Airbag sensor assy center
Cowl wire  ON B1188/56 (05-1443 ) Short in P squib (Dual stage 2nd step) circuit (to B+)
Front passenger airbag assy (squib, Dual stage - 2nd step)
Airbag sensor assy center
Cowl wire  ON  OFF  ON Normal (05-1515 ) System normal Voltage source drop
Battery
Airbag sensor assy center *1: w/ Side and curtain shield airbag 2. DTCS FOR FRONT PASSENGER OCCUPANT CLASSIFICATION SYSTEM HINT: When DTC B1150/23 is detected as a result of troubleshooting for the Supplemental Restraint System, perform troubleshooting for the occupation classification system as shown in the chart below. DTC No. (See page) B1771 (05-1446 ) B1780 (05-1453 ) B1781 (05-1460 ) B1782 (05-1467 ) B1783 (05-1474 ) B1785 (05-1481 ) B1786 (05-1484 ) B1787 (05-1487 ) B1788 (05-1490 ) B1790 (05-1493 ) Detection Item Passenger Airbag OFF Indicator Trouble Area
Passenger side buckle switch circuit malfunction
Front seat inner belt assy RH
Occupant classification ECU
Front seat wire RH ON
Occupant classification sensor front LH circuit malfunction
Occupant classification sensor front LH
Occupant classification ECU
Front seat wire RH ON
Occupant classification sensor front RH circuit malfunction
Occupant classification sensor front RH
Occupant classification ECU
Front seat wire RH ON
Occupant classification sensor rear LH circuit malfunction
Occupant classification sensor rear LH
Occupant classification ECU
Front seat wire RH ON
Occupant classification sensor rear RH circuit malfunction
Occupant classification sensor rear RH
Occupant classification ECU
Front seat wire RH ON
Occupant classification sensor front LH collision detection
Occupant classification ECU
Front RH seat assy (seat frame)
Occupant classification sensor front LH ON
Occupant classification sensor front RH collision detection
Occupant classification ECU
Front RH seat assy (seat frame)
Occupant classification sensor front RH ON
Occupant classification sensor rear LH collision detection
Occupant classification ECU
Front RH seat assy (seat frame)
Occupant classification sensor rear LH ON
Occupant classification sensor rear RH collision detection
Occupant classification ECU
Front RH seat assy (seat frame)
Occupant classification sensor rear RH ON
Airbag sensor assy center communication circuit malfunction
Occupant classification ECU
Airbag sensor assy center
Floor wire
Front seat wire RH ON 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1421 05-1232 DIAGNOSTICS B1793 (05-1502 ) B1795 (05-1510 ) B1796 (05-1513 ) - SUPPLEMENTAL RESTRAINT SYSTEM
Occupant classification sensor power supply circuit malfunction
Seat adjuster frame assy (Occupant classification sensors)
Front seat wire RH
Occupant classification ECU ON
Occupant classification ECU malfunction
Occupant classification ECU
Front seat wire RH
ECU-B Fuse
Front seat inner belt assy RH (Buckle switch RH) ON
Sleep operation failure of occupant classification ECU
Occupant classification ECU ON 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1422 05-1200 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM 05256-33 HOW TO PROCEED WITH TROUBLESHOOTING The hand-held tester can be used in step 3, 4, 6, 9 and 10. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (SEE PAGE 05-1202 ) NEXT 3 CHECK MULTIPLEX COMMUNICATION SYSTEM (SEE PAGE 05-2044 ) DTC IS OUTPUT: CHECK MULTIPLEX COMMUNICATION CIRCUIT (SEE PAGE 05-2044 ) DTC IS NOT OUTPUT: Go to step 4 4 CHECK DTC (Present and Past DTC) (SEE PAGE 05-1215 ) DTC IS OUTPUT: Go to step 5 DTC IS NOT OUTPUT: PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1227 ) DTC B1150/23 IS OUTPUT: Go to step 5 5 DTC CHART (SEE PAGE 05-1228 ) NEXT 6 CIRCUIT INSPECTION (SEE PAGE 05-1233 TO 05-1521 ) MALFUNCTION CODE IS OUTPUT: Go to step 7 NORMAL CODE IS OUTPUT: Go to step 12 7 IDENTIFICATION OF PROBLEM NEXT 8 REPAIR NEXT 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1390 05-1201 DIAGNOSTICS 9 - SUPPLEMENTAL RESTRAINT SYSTEM CLEAR DTC (Present and Past DTC’s) (SEE PAGE 05-1215 ) NEXT 10 CHECK DTC (SEE PAGE 05-1215 ) DTC CODE IS NOT OUTPUT: Go to step 11 DTC CODE IS OUTPUT: Go to step 5 11 SYMPTOM SIMULATION (SEE PAGE 01-36 ) WARNING LIGHT REMAINS OFF: Go to step 12 WARNING LIGHT IS ON: Go to step 5 12 CONFIRMATION TEST NEXT END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1391 05-1 195 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM 0525A-30 LOCATION Combination Meter Assy: Telltale Lamp Assy: SRS Warning Light Front Passenger Airbag Sensor Airbag Assy Front RH Airbag Sensor Curtain Shield Airbag Assy LH (*1) Assy Center Passenger Airbag ON/OFF Indicator Curtain Shield Airbag Assy RH (*1) Occupant Classification ECU Airbag Sensor Front LH Front Seat Airbag Assy RH (*1) Spiral Cable Sub-assy DLC3 Horn Button Assy Seat Position Airbag Sensor Side Airbag Sensor Assy LH (*1) Front Seat Outer Belt Assy LH Airbag Sensor Rear RH (*1) Side Airbag Sensor Assy RH (*1) Front Seat Outer Belt Assy RH Front Seat Inner Belt Assy RH Front Seat Airbag Assy LH (*1) Front Seat Inner Belt Assy LH Airbag Sensor Rear LH (*1) *1: w/ Side and Curtain Shield Airbag H44115 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1385 05-1 194 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM 05IV0-02 PRECAUTION 1. HANDLING PRECAUTIONS AIRBAG SENSOR HINT: In this section, the airbag sensor assy center, airbag sensor front LH, airbag sensor front RH, side airbag sensor assy LH, side airbag sensor assy RH, airbag sensor rear LH, airbag sensor rear RH and seat position airbag sensor are collectively referred to as the airbag sensor. (a) Before starting the following operations, wait at least 90 seconds after disconnection the negative (-) terminal of the battery: (1) Replacement of the airbag sensor. (2) Adjustment of the front/rear door of the vehicle equipped with the side airbag and curtain shield airbag (fitting adjustment). (b) When connecting or disconnecting the airbag sensor connector, ensure that all of the sensor are installed in the vehicle. (c) Do not use an airbag sensor which has been dropped during the operation or transportation. (d) Do not disassemble the airbag sensor. 2. INSPECTION PROCEDURE FOR VEHICLE INVOLVED IN ACCIDENT (a) When the airbag has not deployed, confirm the DTC by checking the SRS warning light. If there is any malfunction in the SRS airbag system, perform troubleshooting. (b) When any of the airbags have deployed, replace the airbag sensor and check the installation condition. (c) Perform the zero point calibration and sensitivity check if any of the following conditions occur.
The occupant classification ECU is replaced.
Accessories (seatback tray and seat cover, etc.) are installed.
The passenger seat is removed from the vehicle.
The passenger airbag ON/OFF indicator (”OFF”) comes on when the passenger seat is not occupied.
The vehicle is brought to the workshop for repair due to an accident or collision. NOTICE: When an accident vehicle is brought into the workshop for repair, check the flatness of the body side that is equipped with the passenger seat. If the flatness is not within
3.0 mm (0.118 in.), adjust it to the specified range. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1384 05-1227 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM 0525C-21 PROBLEM SYMPTOMS TABLE HINT: Proceed with troubleshooting of each circuit in the table below. Symptom Suspect Area See Page When the ignition switch is in the ON position, the SRS warning light sometimes comes on after approximately 6 seconds. SRS warning light circuit malfunction (Always lights up, when DTC is not output). 05-1517 SRS warning light always comes on even when DTC is not position. SRS warning light circuit malfunction (Always lights up, when DTC is not output). 05-1517 With the ignition switch in the ON position, the SRS warning light does not come on. SRS warning light circuit malfunction (Does not light up, when ignition switch is turned to the ON position). 05-1521 Although a SRS warning light oprates normal, DTC or a normal system code is not displayed. TC Terminal Circuit 05-1522 Although terminals TC and CG are not connected, DTC or a normal system code is displayed. TC Terminal Circuit 05-1522 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1417 05-1222 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM 05IV9-02 TERMINALS OF ECU 1. AIRBAG SENSOR ASSY CENTER (w/ Side and curtain shield airbag) A16 A17 A18 H40533 No. Symbol A - Electrical Connector Check Mechanism Destination B - Electrical Connector Check Mechanism A16-1 CSL- Airbag Sensor Rear LH A16-2 LBE- Front Seat Inner Belt Assy LH (Buckle SW) A16-3 LSP- Seat Position Airbag Sensor A16-4 LSP+ Seat Position Airbag Sensor A16-7 PL- Front Seat Outer Belt Assy LH (P/T Squib LH) A16-8 PL+ Front Seat Outer Belt Assy LH (P/T Squib LH) A16-9 ICL+ Curtain Shield Airbag Assy LH (Curtain Shield Squib LH) A16-10 ICL- Curtain Shield Airbag Assy LH (Curtain Shield Squib LH) A16-11 SFL- Front Seat Airbag Assy LH (Side Squib LH) A16-12 SFL+ Front Seat Airbag Assy LH (Side Squib LH) A16-13 ESCL Airbag Sensor Rear LH A16-14 VUCL Airbag Sensor Rear LH A16-15 CSL+ Airbag Sensor Rear LH A16-16 VUPL Side Airbag Sensor Assy LH A16-17 SSL+ Side Airbag Sensor Assy LH A16-18 ESL Side Airbag Sensor Assy LH A16-19 LBE+ Front Seat Inner Belt Assy LH (Buckle SW) A16-20 SSL- Side Airbag Sensor Assy LH A17-1 P-AB Passenger Airbag ON/OFF Indicator A17-5 IG2 IGN Fuse A17-7 P2- Front Passenger Airbag Assy (P Squib, Dual stage - 2nd step) A17-8 P2+ Front Passenger Airbag Assy (P Squib, Dual stage - 2nd step) A17-9 +SR Airbag Sensor Front RH A17-10 P+ Front Passenger Airbag Assy (P Squib) A17-11 P- Front Passenger Airbag Assy (P Squib) A17-12 SIL Diagnosis A17-13 D- Horn Button Assy (D Squib) A17-14 D+ Horn Button Assy (D Squib) A17-15 +SL Airbag Sensor Front LH 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1412 05-1223 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM No. Symbol Destination A17-16 D2+ Horn Button Assy (D Squib, Dual stage - 2nd step) A17-17 D2- Horn Button Assy (D Squib, Dual stage - 2nd step) A17-20 -SR Airbag Sensor Front RH A17-22 MPX2 Combination Meter Assy A17-24 MPX1 Combination Meter Assy A17-25 PAON Passenger Airbag ON/OFF Indicator A17-26 -SL Airbag Sensor Front LH A17-27 E1 Ground A17-28 E2 Ground A18-1 FSR+ Occupant Classification ECU A18-2 FSR- Occupant Classification ECU A18-4 CSR- Airbag Sensor Rear RH A18-5 SFR+ Front Seat Airbag Assy RH (Side Squib RH) A18-6 SFR- Front Seat Airbag Assy RH (Side Squib RH) A18-7 ICR- Curtain Shield Airbag Assy RH (Curtain Shield Squib RH) A18-8 ICR+ Curtain Shield Airbag Assy RH (Curtain Shield Squib RH) A18-9 PR+ Front Seat Outer Belt Assy RH (P/T Squib RH) A18-10 PR- Front Seat Outer Belt Assy RH (P/T Squib RH) A18-13 SSR- Side Airbag Sensor Assy RH A18-15 ESR Side Airbag Sensor Assy RH A18-16 SSR+ Side Airbag Sensor Assy RH A18-17 VUPR Side Airbag Sensor Assy RH A18-18 CSR+ Airbag Sensor Rear RH A18-19 VUCR Airbag Sensor Rear RH A18-20 ESCR Airbag Sensor Rear RH 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1413 05-1224 DIAGNOSTICS 2. - SUPPLEMENTAL RESTRAINT SYSTEM AIRBAG SENSOR ASSY CENTER (w/o Side and curtain shield airbag) A16 A18 A17 H40028 No. Symbol A - Electrical Connector Check Mechanism Destination Electrical Connector Check Mechanism B - A16-1 PL- Front Seat Outer Belt Assy LH (P/T Squib LH) A16-2 PL+ Front Seat Outer Belt Assy LH (P/T Squib LH) A16-3 LSP+ Seat Position Airbag Sensor A16-6 LBE- Front Seat Inner Belt Assy LH (Buckle SW) A16-8 LSP- Seat Position Airbag Sensor A16-11 LBE+ Front Seat Inner Belt Assy LH (Buckle SW) A17-1 P-AB Passenger Airbag ON/OFF Indicator A17-5 IG2 IGN Fuse A17-7 P2- Front Passenger Airbag Assy (P Squib, Dual stage - 2nd step) A17-8 P2+ Front Passenger Airbag Assy (P Squib, Dual stage - 2nd step) Airbag Sensor Front RH A17-9 +SR A17-10 P+ Front Passenger Airbag Assy (P Squib) A17-11 P- Front Passenger Airbag Assy (P Squib) A17-12 SIL Diagnosis A17-13 D- Horn Button Assy (D Squib) A17-14 D+ Horn Button Assy (D Squib) A17-15 +SL Airbag Sensor Front LH A17-16 D2+ Horn Button Assy (D Squib, Dual stage - 2nd step) A17-17 D2- Horn Button Assy (D Squib, Dual stage - 2nd step) A17-20 -SR Airbag Sensor Front RH A17-22 MPX2 Combination Meter Assy A17-24 MPX1 Combination Meter Assy A17-25 PAON Passenger Airbag ON/OFF Indicator A17-26 -SL Airbag Sensor Front LH A17-27 E1 Ground 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1414 05-1225 DIAGNOSTICS No. 3. - SUPPLEMENTAL RESTRAINT SYSTEM Symbol Destination A17-28 E2 A18-3 FSR+ Ground A18-5 PR+ Front Seat Outer Belt Assy RH (P/T Squib RH) A18-6 PR- Front Seat Outer Belt Assy RH (P/T Squib RH) A18-10 FSR- Occupant Classification ECU Occupant Classification ECU OCCUPANT CLASSIFICATION ECU O6 O7 6 5 4 3 21 121110 9 8 7 6 5 4 3 21 121110 9 8 7 H43128 Symbols (Terminal No.) Wiring Color Terminal Description Condition Specification +B (O6-1) - GND (O6-3) R - W-B Power Source IG switch ON 10 to 14 V DIA (O6-2) GND (O6-3) V - W-B Diagnosis (DLC3) IG switch ON Pulse generation GND (O6-3) Body ground W-B - Body ground Ground Always Below 1 Ω FSR- (O6-4) GND (O6-3) B - W-B Airbag sensor assy center communication line (-) Always Below 1 Ω BGND (O6-5) GND (O6-3) GR - W-B Passenger side buckle switch ground line Always Below 1 Ω IG (O6-7) - GND (O6-3) BR - W-B Power Source IG switch ON 10 to 14 V IG switch ON Pulse generation FSR+ (O6-8) FSR- (O6-4) W-B Airbag sensor assy center communication line BSW (O6-9) BGND (O6-5) L - GR Passenger side buckle switch line Buckle switch ON Buckle switch OFF 10 to 14 V Below 1 V SGD1 (O7-1) GND (O6-3) G - W-B Passenger side buckle switch circuit Always Below 1 Ω SGD2 (O7-2) GND (O6-3) O - W-B Occupant classification sensor front RH ground line Always Below 1 Ω SGD3 (O7-3) GND (O6-3) W - W-B Occupant classification sensor rear LH ground line Always Below 1 Ω SGD4 (O7-4) GND (O6-3) BR - W-B Occupant classification sensor rear RH ground line Always Below 1 Ω SVC3 (O7-5) SGD3 (O7-3) GR - W Occupant classification sensor rear LH power supply line IG switch ON, a load is applied to occupant classification sensor rear LH 4.5 to 5.1 V SVC4 (O7-6) SGD4 (O7-4) V - BR Occupant classification sensor rear RH power supply line IG switch ON, a load is applied to occupant classification sensor rear RH 4.5 to 5.1 V SIG1 (O7-7) SGD1 (O7-1) SB - G Occupant classification sensor front LH signal line IG switch ON, a load is applied to occupant classification sensor front LH 0.2 to 4.9 V SIG2 (O7-8) SGD2 (O7-2) L-O Occupant classification sensor rear RH signal line IG switch ON, a load is applied to occupant classification sensor front RH 0.2 to 4.9 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1415 05-1226 DIAGNOSTICS Symbols (Terminal No.) Wiring Color SIG3 (O7-9) SGD3 (O7-3) Y-W SIG4 (O7-10) SGD4 (O7-4) - SUPPLEMENTAL RESTRAINT SYSTEM Terminal Description Condition Specification Occupant classification sensor rear LH signal line IG switch ON, a load is applied to occupant classification sensor rear LH 0.2 to 4.9 V B - BR Occupant classification sensor front RH signal line IG switch ON, a load is applied to occupant classification sensor rear RH 0.2 to 4.9 V SVC1 (O7-11) SGD4 (O7-4) R - BR Occupant classification sensor rear LH power supply line IG switch ON, a load is applied to occupant classification sensor front LH 4.5 to 5.1 V SVC2 (O7-12) SGD2 (O7-2) W-O Occupant classification sensor rear LH power supply line IG switch ON, a load is applied to occupant classification sensor front RH 4.5 to 5.1 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1416 05-1548 DIAGNOSTICS DTC B1241 - LIGHTING SYSTEM 05IQ7-01 BODY ECU SWITCH CIRCUIT DIAGNOSIS CIRCUIT DESCRIPTION The following explains when this DTC is output: This DTC is not output when the switches are operated but fail to make contact. It is only output when the switches are stuck or held on. For example, this code is output when checking the DTC while the switches are on: System is normal: (a) DTC is output during DTC check with the switches on. (b) DTC is not output during DTC check with the switches off. Inspect the switches and replace if necessary. If there is no problem with the switches, inspect the wire harness. DTC No. B1241 DTC Detecting Condition Trouble Area
Headlamp dimmer switch assy
Wire harness or connector
Multiplex network body ECU Switch is stuck WIRING DIAGRAM Body ECU 18 V B10 TAIL 17 B10 HEAD LG C13 Combination Switch 14 T Light Control Switch 13 H EL OFF Tail Head 16 W-B IA E74075 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1738 05-1549 DIAGNOSTICS - LIGHTING SYSTEM INSPECTION PROCEDURE 1 READ VALUE OF HAND-HELD TESTER (a) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the hand-held tester main switch on. (c) Select the item below in the DATA LIST and read the display on hand-held tester. BODY NO.1 (MULTIPLEX NETWORK BODY ECU): Item Measurement Item/ Display (Range) HEAD LIGHT SW Headlight control SW signal/ ON or OFF TAIL LIGHT SW Tail light SW signal/ ON or OFF Normal Condition Diagnostic Note ON: Light control switch is in HEAD position OFF: Light control switch is in except HEAD position - ON: Light control switch is in TAIL position OFF: Light control switch is in except TAIL position - OK: Condition sign can be displayed. NG Go to step 2 OK REPLACE MULTIPLEX NETWORK BODY ECU 2 INSPECT HEADLAMP DIMMER SWITCH ASSY (a) Connector Front View: C13 E11948 Inspect light control switch. (1) Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 14 - 16 TAIL Below 1 Ω 13 - 16 14 - 16 HEAD Below 1 Ω NG REPLACE HEADLAMP DIMMER SWITCH ASSY (SEE PAGE 65-25 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1739 05-1550 DIAGNOSTICS 3 - LIGHTING SYSTEM CHECK HARNESS AND CONNECTOR(HEADLAMP DIMMER SWITCH ASSY MULTIPLEX NETWORK BODY ECU) Headlamp Dimmer Switch Connector Front View: C13 (a) (b) E11948 Disconnect the headlamp dimmer switch assy connector and B10 connector from the multiplex network body ECU. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition C13-13 - B10-17 Always Below 1 Ω C13-14 - B10-18 Always Below 1 Ω B10-17 - Body ground Always 10 kΩ or higher B10-18 - Body ground Always 10 kΩ or higher C13-16 - Body ground Always Below 1 Ω Multiplex Network Body ECU Connector Front View: B10 B10-18 B10-17 E74263 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE MULTIPLEX NETWORK BODY ECU 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1740 05-1551 DIAGNOSTICS DTC B1244 - LIGHTING SYSTEM 05IQ8-01 LIGHT SENSOR CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION This DTC is output when a failure in the automatic light control sensor circuit is detected. DTC No. B1244 DTC Detecting Condition Trouble Area
Automatic light control sensor
Wire Wi h harness or connector t
Multiplex network body ECU
Malfunction of automatic light control sensor
Open or short in automatic light control sensor circuit WIRING DIAGRAM A23 Automatic Light Control Sensor CLTS CLTE CLTB Body ECU R 21 B9 CLTS W 20 B9 CLTE G 12 B9 CLTB 4 3 1 E68822 E70389 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1741 05-1552 DIAGNOSTICS - LIGHTING SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(AUTOMATIC LIGHT CONTROL SENSOR POWER SOURCE CIRCUIT) (a) (b) Wire Harness View: A23 Automatic Light Control Sensor 3 Disconnect the automatic light control sensor connector. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A23-1 - A23-3 Ignition switch ON 10 to 14 V 1 I39976 NG Go to step 4 OK 2 CHECK HARNESS AND CONNECTOR(MULTIPLEX NETWORK BODY ECU AUTOMATIC LIGHT CONTROL SENSOR) (a) Wire Harness View: A23 Automatic Light Control Sensor (b) 4 Disconnect the B9 connector from the multiplex network body ECU. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A23-4 - B9-21 Always Below 1 Ω I39976 Multiplex Network Body ECU Connector Front View: B9 B9-21 E74263 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1742 05-1553 DIAGNOSTICS 3 - LIGHTING SYSTEM REPLACE AUTOMATIC LIGHT CONTROL SENSOR OK: Return to normal condition. NG REPLACE MULTIPLEX NETWORK BODY ECU OK END 4 CHECK HARNESS AND CONNECTOR(MULTIPLEX NETWORK BODY ECU AUTOMATIC LIGHT CONTROL SENSOR) (a) Wire Harness View: A23 Automatic Light Control Sensor Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A23-1 - Body ground Ignition switch ON 10 to 14 V 1 I39976 NG Go to step 6 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1743 05-1554 DIAGNOSTICS 5 - LIGHTING SYSTEM CHECK HARNESS AND CONNECTOR(MULTIPLEX NETWORK BODY ECU AUTOMATIC LIGHT CONTROL SENSOR) (a) Wire Harness View: A23 Automatic Light Control Sensor (b) 3 Disconnect the B9 connector from the multiplex network body ECU. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A23-3 - B9-20 Always Below 1 Ω I39976 Multiplex Network Body ECU Connector Front View: B9 B9-20 E74263 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE MULTIPLEX NETWORK BODY ECU 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1744 05-1555 DIAGNOSTICS 6 - LIGHTING SYSTEM CHECK HARNESS AND CONNECTOR(MULTIPLEX NETWORK BODY ECU AUTOMATIC LIGHT CONTROL SENSOR) (a) Wire Harness View: A23 Automatic Light Control Sensor (b) 1 Disconnect the B9 connector from the multiplex network body ECU. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A23-1 - B9-12 Always Below 1 Ω I39976 Multiplex Network Body ECU Connector Front View: B9 B9-12 E74263 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE MULTIPLEX NETWORK BODY ECU 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1745 05-1604 DIAGNOSTICS - LIGHTING SYSTEM 05IQF-02 DOOR LOCK POSITION CIRCUIT CIRCUIT DESCRIPTION This circuit detects the state of the door lock detection sensor and sends it to the multiplex network body ECU. WIRING DIAGRAM Multiplex Communication System Body ECU 6 B10 MPX1 Power Window Master SW with ECU 7 P5 MPX1 D12 Door Key Lock and Unlock SW Front LH 16 Door Lock Motor Front LH P5 Door Unlock Detection SW 3 Front LH P5 BR LSSR 1 E MPX2 8 P5 LSW J12 J/C A B A B A A 8 BG3 GR 4 LSSR S Instrument Panel J/B 14 1D 7 BC1 4 E E 2 D14 5 D13 Door Key Lock and Unlock Door Lock Motor Rear LH Door Unlock Detection SW SW Front RH Door Lock Motor Front RH Rear LH Door Unlock Detection W-B Passenger Side J/B SW Front RH 2 10 6 W-B W-B W-B IN1 4L 4M W-B BR V 1 LSSR 4 1E 17 B12 LSWA B 15 BH1 B GR 6 LSSR 10 B9 MPX2 O 11 B10 LSWP 3 IA1 B 6 BB1 5 IF3 BR LG BR Y LSWE 2 2 IN2 IA 1 IB2 GR E E 3 B15 3 D15 Back Door Lock Motor Door Lock Motor Back Door Unlock Rear RH Detection SW Door Unlock Detection W-B SW Rear RH W-B 11 BB1 W-B A J14 J/C BA 13 BC1 W-B BE BB E74082 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1794 05-1605 DIAGNOSTICS - LIGHTING SYSTEM INSPECTION PROCEDURE HINT: Inspect if the door lock system is normal before performing this procedure. 1 CHECK HARNESS AND CONNECTOR(FRONT DOOR LOCK POSITION CIRCUIT) (a) Power Window Master SW with ECU Connector Front View: P5 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition P5-3 - P5-16 Driver side door is locked. 10 to 14 V P5-3 - P5-16 Driver side door is unlocked. Below 1 V NG E74383 GO TO POWER DOOR LOCK CONTROL SYSTEM (SEE PAGE 05-1935 ) OK 2 (a) CHECK HARNESS AND CONNECTOR(PASSENGER AND REAR DOOR LOCK POSITION CIRCUIT) Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition B10-11 - Body ground Passenger side door is locked. Passenger side door is unlocked. 10 to 14 V Below 1 V B12-17 - Body ground Rear doors and back door are locked. One of the rear doors or back door is unlocked. 10 to 14 V Below 1 V Multiplex Network Body ECU Connector Front View: B10 B12 B10-1 1 B12-17 E74263 NG GO TO POWER DOOR LOCK CONTROL SYSTEM (SEE PAGE 05-1935 ) OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1538 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1795 05-1562 DIAGNOSTICS - LIGHTING SYSTEM 05ETR-02 DRL RELAY CIRCUIT CIRCUIT DESCRIPTION The multiplex network body ECU controls DRL No.2, No.3 and No.4 relays. The headlamp (High) is connected in serial when the daytime running light system operates. When Daytime Running Light System is Operated: DRL No.2 Relay To Multiplex Network Body ECU DRL No.3 Relay Headlamp RH (Hi) DRL No.4 Relay Headlamp LH (Hi) To HEAD Relay I40822 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1752 05-1563 DIAGNOSTICS - LIGHTING SYSTEM The headlamp (High) is connected in parallel when the HI BEAM or FLASH operates. When HI Beam or Flash is Operated: DRL No.2 Relay To Multiplex Network Body ECU DRL No.3 Relay Headlamp RH (Hi) DRL No.4 Relay Headlamp LH (Hi) To HEAD Relay I40823 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1753 05-1564 DIAGNOSTICS - LIGHTING SYSTEM WIRING DIAGRAM Engine Room R/B No.3 DRL No.2 Relay R-B R-B 3 R-B 3 Body ECU 1 3 L-W 3 L-Y 3 3 B11 HRLY R 2 3 B 3 5 2 1 DRL No.3 Relay 1 2 5 3 Engine Room R/B H-LP LH LWR DRL L-W 4 IK3 L-R 3 B 3 1 2 H-LP RH LWR B 2 W-B 1 2 2 2 3 H4 Headlamp RH (Low Beam) R-Y 1 2 H2 Headlamp LH (Low Beam) 3 4 3 R-W H3 Headlamp RH (High Beam) R-L R-W 1 2 1 2 W-B W-B W-B R-W Engine Room R/B No.3 DRL No.4 Relay H1 Headlamp LH (High Beam) R R-W 1 2 3 H-LP LH UPR 2 3 MAIN 2 Battery 1 5 3 3 W-B 2F 4 HEAD LAMP Relay 2G 1 2 4 2 3 Engine Room J/B 5 H-LP RH UPR 2F 3 1 1 2B 1 2I F7 FL Block FL MAIN W 1 16 IK3 P A 2 B11 DRL A J1 J/C J3 J/C EB B EA EG W 3 E74077 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1754 05-1565 DIAGNOSTICS - LIGHTING SYSTEM INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST USING HAND-HELD TESTER (a) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the hand-held tester main switch on. (c) Select the item below in the ACTIVE TEST and then check the relay operation. BODY NO.1 (MULTIPLEX NETWORK BODY ECU): Item Test Details Diagnostic Note HEAD LIGHT Headlamp relay ON/OFF - OK: Headlamp (low) comes on. BODY NO.1 (MULTIPLEX NETWORK BODY ECU): Item Test Details Diagnostic Note DIMMER SIG DRL No.2 relay ON/OFF - OK: Headlamp (high) comes on. NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1538 ) 2 (a) (b) INSPECT MULTIPLEX NETWORK BODY ECU Disconnect the B11 connector from the multiplex network body ECU. Using a service wire, connect B11-3 of the wire harness side and body ground. OK: Headlamp (low) comes on. Multiplex Network Body ECU Connector Front View: B11 B11-3 E74263 NG Go to step 5 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1755 05-1566 DIAGNOSTICS 3 (a) - LIGHTING SYSTEM INSPECT MULTIPLEX NETWORK BODY ECU Using a service wire, connect B11-2 of the wire harness side and body ground. OK: Headlamp (high) comes on (decrease mode). Multiplex Network Body ECU Connector Front View: B11 B11-2 E74263 NG Go to step 7 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1756 05-1567 DIAGNOSTICS 4 (a) (b) - LIGHTING SYSTEM INSPECT MULTIPLEX NETWORK BODY ECU Using a service wire, connect B11-3 of the wire harness side and body ground. Using a service wire, connect B11-2 of the wire harness side and body ground. OK: Headlamp (high) comes on. Multiplex Network Body ECU Connector Front View: B11 B11-3 B11-2 E74263 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1538 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1757 05-1568 DIAGNOSTICS 5 (a) - LIGHTING SYSTEM INSPECT ENGINE ROOM J/B Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 2G-4 - Body ground Always 10 to 14 V Engine Room J/B Connector Front View: 2G 2G-4 E72985 NG Go to step 6 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (ENGINE ROOM J/B - MULTIPLEX NETWORK BODY ECU) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1758 05-1569 DIAGNOSTICS 6 (a) (b) - LIGHTING SYSTEM CHECK HARNESS AND CONNECTOR(POWER SOURCE CIRCUIT) Disconnect the 2I connector from the engine room J/B. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 2I-1 - Body ground Always 10 to 14 V Engine Room J/B Connector Front View: 2I 2I-1 E72985 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE ENGINE ROOM J/B 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1759 05-1570 DIAGNOSTICS 7 (a) (b) - LIGHTING SYSTEM INSPECT ENGINE ROOM J/B Disconnect the 2B connector from the engine room J/B. Using a service wire, connect 2B-1 of the engine room J/B side and body ground. OK: Headlamp (high) comes on (decrease mode). Engine Room J/B Connector Front View: 2B-1 2B E72985 NG Go to step 8 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (ENGINE ROOM J/B - MULTIPLEX NETWORK BODY ECU) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1760 05-1571 DIAGNOSTICS 8 (a) - LIGHTING SYSTEM INSPECT ENGINE ROOM J/B Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 2F-2 - Body ground Connect 2B-1 and body ground 10 to 14 V 2F-5 - Body ground Connect 2B-1 and body ground 10 to 14 V Engine Room J/B Connector Front View: 2F 2F-2 2F-5 E72985 NG Go to step 9 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (EACH OF HEADLAMP CIRCUIT) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1761 05-1572 DIAGNOSTICS 9 (a) - LIGHTING SYSTEM INSPECT ENGINE ROOM J/B Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 2B-1 - Body ground Always 10 to 14 V Engine Room J/B Connector Front View: 2B-1 2B E72985 NG Go to step 10 OK REPLACE ENGINE ROOM J/B 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1762 05-1573 DIAGNOSTICS 10 (a) (b) - LIGHTING SYSTEM CHECK HARNESS AND CONNECTOR(POWER SOURCE CIRCUIT) Disconnect the 2I connector from the engine room J/B. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 2I-1 - Body ground Always 10 to 14 V Engine Room J/B Connector Front View: 2I 2I-1 E72985 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE ENGINE ROOM J/B 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1763 05-1596 DIAGNOSTICS - LIGHTING SYSTEM 05CS6-03 GENERATOR SIGNAL CIRCUIT CIRCUIT DESCRIPTION The multiplex network body ECU receives an engine condition signal via a generator. WIRING DIAGRAM ECM 21 W-G E9 RL Generator L 4 G1 E74084 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1786 05-1597 DIAGNOSTICS - LIGHTING SYSTEM INSPECTION PROCEDURE 1 CHECK ECM ECM Connector Front View: (a) E9 Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition E9-21 - Body ground Engine running 10 to 14 V E9-21 E74382 NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1538 ) 2 (a) INSPECT GENERATOR ASSY Inspect generator assy (see page 19-17 or 19-42 ). NG CHECK AND REPLACE GENERATOR ASSY OK REPAIR OR REPLACE HARNESS OR CONNECTOR (GENERATOR ASSY - ECM) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1787 05-1598 DIAGNOSTICS - LIGHTING SYSTEM 05ETU-02 PARKING BRAKE SWITCH CIRCUIT CIRCUIT DESCRIPTION The multiplex network body ECU receives the parking brake switch signal. WIRING DIAGRAM Passenger Side J/B B 9 4M Body ECU 3 4H R 14 B12 PKB 1 P3 Parking Brake SW E74085 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1788 05-1599 DIAGNOSTICS - LIGHTING SYSTEM INSPECTION PROCEDURE 1 (a) (b) CHECK HARNESS AND CONNECTOR(PARKING BRAKE SWITCH CIRCUIT) Disconnect the B12 connector from the multiplex network body ECU. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition B12-14 - Body ground Shaft of parking brake switch is pressed B12-14 - Body ground Shaft of parking brake switch is not pressed 10 kΩ or higher Below 1 Ω Multiplex Network Body ECU Connector Front View: B12 B12-14 E74263 NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1538 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1789 05-1600 DIAGNOSTICS 2 - LIGHTING SYSTEM INSPECT PARKING BRAKE SWITCH ASSY (a) (b) ON OFF Remove the parking brake switch. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 1 - Switch body OFF (When shaft is pressed) 10 kΩ or higher 1 - Switch body ON (When shaft is not pressed) Below 1 Ω E71372 NG REPLACE PARKING BRAKE SWITCH ASSY OK REPAIR OR REPLACE HARNESS OR CONNECTOR (PARKING BRAKE SWITCH CIRCUIT) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1790 05-1574 DIAGNOSTICS - LIGHTING SYSTEM 05IQA-01 TAIL RELAY CIRCUIT CIRCUIT DESCRIPTION The multiplex network body ECU controls the TAIL relay when a signal is received from the headlamp dimmer switch assy. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1764 05-1575 DIAGNOSTICS - LIGHTING SYSTEM WIRING DIAGRAM Instrument Panel J/B Body ECU TAILLIGHT Relay 1 1 1A B 4 1J 2 TAIL 4 1B 3 5 4 1H W 11 1B 8 IA1 J12 J/C W-B BR E TRLY F3 Front Parking Lamp LH G W-B 1 2 F4 Front Parking Lamp RH G W-B 1 2 R8 Taillamp RH (Rear Combination Lamp RH) J13 J/C 7 B9 SB 4 B 6 R7 Taillamp LH (Rear Combination Lamp LH) BR W-B BR E E 4 6 B B B W 2 BG2 BR E E E R15 Rear Side Marker Lamp RH BR W-B 1 2 R14 Rear Side Marker Lamp LH BR W-B 2 1 W-B L1 License Plate Lamp 1 W-B F7 FL Block 2 A 2 Battery ALT FL MAIN 1 A J14 J/C J3 J/C BE BC A J1 J/C EA EG W E74078 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1765 05-1576 DIAGNOSTICS - LIGHTING SYSTEM INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST USING HAND-HELD TESTER (a) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the hand-held tester main switch on. (c) Select the item below in the ACTIVE TEST and then check the relay operation. BODY NO.1 (MULTIPLEX NETWORK BODY ECU): Item Test Details Diagnostic Note TAIL LIGHT Taillamp relay ON/OFF - OK: Taillamp comes on. NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1538 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1766 05-1577 DIAGNOSTICS 2 (a) (b) - LIGHTING SYSTEM INSPECT MULTIPLEX NETWORK BODY ECU Disconnect the B9 connector from the multiplex network body ECU. Using a service wire, connect B9-7 of the wire harness side and body ground. OK: Taillamp comes on. Multiplex Network Body ECU Connector Front View: B9 B9-7 E74263 NG Go to step 3 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1538 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1767 05-1578 DIAGNOSTICS 3 - LIGHTING SYSTEM INSPECT INSTRUMENT PANEL JUNCTION BLOCK ASSY (a) Instrument Panel Junction Block Front Side View: (b) Disconnect the 1J connector from the instrument panel junction block assy. Using a service wire, connect 1J-4 of the instrument panel junction block side and body ground. OK: Taillamp comes on. 1J 1J-4 E72975 NG Go to step 4 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (INSTRUMENT PANEL JUNCTION BLOCK ASSY - MULTIPLEX NETWORK BODY ECU) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1768 05-1579 DIAGNOSTICS 4 LIGHTING SYSTEM INSPECT INSTRUMENT PANEL JUNCTION BLOCK ASSY (a) Instrument Panel Junction Block Back Side View: 1B 1B-4 - Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 1B-4 - Body ground Connect 1J-4 and body ground 10 to 14 V 1B-1 1 - Body ground Connect 1J-4 and body ground 10 to 14 V 1H-4 - Body ground Connect 1J-4 and body ground 10 to 14 V 1H 1H-4 1B-1 1 E72976 NG Go to step 5 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (EACH OF TAILLAMP CIRCUIT) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1769 05-1580 DIAGNOSTICS 5 - LIGHTING SYSTEM INSPECT INSTRUMENT PANEL JUNCTION BLOCK ASSY (a) Instrument panel Junction Block Front Side View: Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 1J-4 - Body ground Always 10 to 14 V 1J 1J-4 NG Go to step 6 E72975 OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1770 05-1581 DIAGNOSTICS 6 - LIGHTING SYSTEM CHECK HARNESS AND CONNECTOR(POWER SOURCE CIRCUIT) (a) Instrument Panel Junction Block Back Side View: (b) Disconnect the 1A connector from the instrument panel junction block assy. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 1A-1 - Body ground Always 10 to 14 V 1A 1A-1 E72976 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1771 05-1537 DIAGNOSTICS - LIGHTING SYSTEM 05IQ2-01 CUSTOMIZE PARAMETERS HINT: The followings are the possible items to be customized. NOTICE:
After confirming whether the items of the customer’s request are applicable or not for the customized items, perform the customize operation.
Be sure to record the current value before customizing.
In case of performing the troubleshooting, pay attention as there is a possibility that the function is OFF by customizing. (Example: In case of the symptom in which ”The wireless operation does not function”, check that the wireless operation is not OFF by customizing, then perform the troubleshooting.) ILLUMINATED ENTRY DISPLAY(ITEM) DEFAULT CONTENTS SETTING I/L ON / UNLOCK (Interior lamp ON w/ door key unlock) ON Function to light up the interior lamp*, ignition lamp and step lamp when unlocking with the door key cylinder. *: Interior lamp comes on when the interior lamp switch is at the DOOR position. LIGHTING TIME (Lighting Time) 15 s To change the lighting time after closing the door. (It will quickly fade out in case of turning the ignition ON.) ON / OFF 7.5 s / 15 s / 30 s LIGHT CONTROL HINT: Sensitivity adjustment can hardly be confirmed. Please check by customer’s actual driving. DISPLAY(ITEM) DEFAULT SENSITIVITY (Turn ON luminous intensity) NORMAL LIGHT CTRL TYPE (Control Type) CURRENT CONTENTS SETTING DARK2 / DARK1 / NORMAL / LIGHT1 / LIGHT2 To adjust the sensitivity of the lighting illumination. Refer to the *1 illustration. To change the control logic when the light control switch is in the AUTO position. Refer to the *2 illustration. CURRENT / OLD Illustration of *1 Dark Lighting brightness DARK2 Setting Bright DARK1 NORMAL LIGHT1 LIGHT2 Illustration of *2 Brightness of the surrounding when lighting OLD CURRENT Lighting delay Delay of turning light off Old logic 6 sec. 6 sec. 3 sec. New logic **1 (’97/8-) 15 sec. 15 sec. 15 sec. **2 **1: The new one has the logic to light up two times brighter than the old logic. **2: Delay time until the headlamp is turned on when it suddenly gets dark. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1727 05-1544 DIAGNOSTICS - LIGHTING SYSTEM 05IQ4-01 DIAGNOSIS SYSTEM D3 BAT SIL SG 1. (a) DLC3 CG CHECK DLC3 The vehicle’s ECU uses BEAN conforming to ISO 9141-2 for communication. The terminal arrangement of DLC3 complies with SAE J1962 and matches the ISO 9141-2 format. C52361 Standard: Symbols (Terminals No.) Terminal Description Condition Specified condition SIL (7) - SG (5) Bus ”+” line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V HINT: If the screen displays UNABLE TO CONNECT TO VEHICLE after you have connected the cable of the hand-held tester to the DLC3, turned the ignition switch ON and used the hand-held tester, there is a problem on the vehicle side or tester side.
If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle.
If communication is still impossible when the tester is connected to another vehicle, the problem is probably in the tester itself, so consult the Service Department listed in the tester’s manual. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1734 05-1546 DIAGNOSTICS - LIGHTING SYSTEM 05IQ6-01 DATA LIST/ACTIVE TEST 1. DATA LIST HINT: Using the DATA LIST displayed on the hand-held tester, you can read the value of the switch, sensor, actuator, etc. without removing any parts. Reading the DATA LIST as the first step of troubleshooting is one of the methods to shorten labor time. (a) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) According to the display on the tester, read the ”DATA LIST”. BODY NO.1 (MULTIPLEX NETWORK BODY ECU): Item Measurement Item/ Display (Range) I/L ON/UNLOCK Interior light ON w/unlock/ON or OFF Customized value will be displayed - LIGHTING TIME Lighting time/ 7.5s or 15s or 30s Customized value will be displayed - SENSITIVITY Turn on luminous intensity/ DARK2 or DARK1 or NO Customized value will be displayed - LIGHT CTRL TYPE Light control system/ CURRENT or OLD Customized value will be displayed - PARKING BRAKE SW Parking brake SW signal/ON or OFF ON: Parking brake switch is ON OFF: Parking brake switch is released - LUGG COURTSY SW Luggage door courtesy switch/ ON or OFF ON: Luggage door is open OFF: Luggage door is closed - F FOG LIGHT SW Front fog light SW signal/ON or OFF ON: Front fog light switch is in ON position OFF: Front fog light switch is in OFF position - AUTO LIGHT SW Auto light SW signal/ ON or OFF ON: Light control switch is in AUTO position OFF: Light control switch is in except AUTO position - HEAD LIGHT SW Headlight control SW signal/ON or OFF ON: Light control switch is in HEAD position OFF: Light control switch is in except HEAD position - TAIL LIGHT SW Tail light SW signal/ ON or OFF ON: Light control switch is in TAIL or HEAD position OFF: Light control switch is in OFF position - ILLUMINATE RATE Illumination rate information Condition value will be displayed - Normal Condition Diagnostic Note 2. ACTIVE TEST HINT: Performing the ACTIVE TEST using the hand-held tester allows the relay, VSV, actuator, etc. to operate without removing any parts. Performing the ACTIVE TEST as the first step of troubleshooting is one of the methods to shorten labor time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) According to the display on the tester, perform the ”ACTIVE TEST”. BODY NO.1 (MULTIPLEX NETWORK BODY ECU): Item HEAD LIGHT Test Details Diagnostic Note Turn Headlight relay ON/OFF - TAIL LIGHT Turn Tail light relay ON/OFF - DIMMER SIG Turn Dimmer relay ON/OFF - (Test Details) Turn Interior light and Key illumination ON/OFF (Vehicle Condition) Interior light SW is in DOOR position and all doors are closed - ILLUMI OUTPUT 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1736 05-1601 DIAGNOSTICS - LIGHTING SYSTEM 05CS4-05 DOOR COURTESY SWITCH CIRCUIT CIRCUIT DESCRIPTION The multiplex network body ECU detects the condition of the door courtesy switch assy. WIRING DIAGRAM Body ECU J13 J/C W 14 IA1 LG 15 B12 RCTY V 17 IO2 SB 16 B12 PCTY B 9 IA1 B 11 B11 DCTY W B B B W 6 BH1 G 1 1 D9 Door Courtesy SW Rear LH 1 D10 Door Courtesy SW Rear RH 1 D8 Door Courtesy SW Front RH D7 Door Courtesy SW Front LH E74081 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1791 05-1602 DIAGNOSTICS - LIGHTING SYSTEM INSPECTION PROCEDURE 1 (a) (b) CHECK HARNESS AND CONNECTOR(COURTESY LAMP SWITCH - MULTIPLEX NETWORK BODY ECU) Disconnect the B11 and B12 connectors from the multiplex network body ECU. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition B11-1 1 - Body ground Driver side door is open. Driver side door is closed. Below 1 Ω 10 kΩ or higher B12-16 - Body ground Front passenger side door is open. Front passenger side door is closed. Below 1 Ω 10 kΩ or higher B12-15 - Body ground One of the rear side doors is open. Both rear side doors are closed. Below 1 Ω 10 kΩ or higher Multiplex Network Body ECU Connector Front View: B12 B12-16 B12-15 B11 B11-1 1 E74263 NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1538 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1792 05-1603 DIAGNOSTICS 2 - LIGHTING SYSTEM INSPECT COURTESY LAMP SWITCH ON OFF (a) (b) Remove the courtesy lamp switch. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 1 - Body ground OFF (When shaft is pressed) 10 kΩ or higher 1 - Body ground ON (When shaft is not pressed) Below 1 Ω E71371 NG REPLACE COURTESY LAMP SWITCH OK REPAIR OR REPLACE HARNESS OR CONNECTOR (EACH OF COURTESY SWITCH CIRCUIT) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1793 05-1545 DIAGNOSTICS - LIGHTING SYSTEM 05IQ5-01 DTC CHECK/CLEAR 1. DTC CHECK (a) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch to the ON position. (c) Read DTCs by following the prompts on the tester screen. HINT: Please refer to the hand-held tester operator’s manual for further details. 2. DTC CLEAR (a) DTC can be erased by operating the hand-held tester. HINT: Please refer to the hand-held tester operator’s manual for further details. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1735 05-1606 DIAGNOSTICS - LIGHTING SYSTEM 05IQG-02 ILLUMINATION CIRCUIT CIRCUIT DESCRIPTION The multiplex network body ECU controls the following. (1) Key cylinder lamp (2) Interior lamp (3) Personal lamp (overhead J/B) (4) Door courtesy lamp 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1796 05-1607 DIAGNOSTICS - LIGHTING SYSTEM WIRING DIAGRAM D6 Door Courtesy Lamp Front RH 3 IN1 BR G 1 8 IL1 Y 3 IB1 V I14 Ignition Key Cylinder Illumination Y (*2) 10 IN2 Y (*1) 1 OFF ON G 1 4H W-B 8 IE1 W-B 5 4D W 1 IE1 3 W O5 Overhead J/B 7 CTY +B1 5 4J 5 IE1 R R 2 DOOR 2 4F BR 11 B12 ILE 7 4L 1 4N 13 4D 12 4D B W W-B W-B 6 4H V Engine Room J/B D.C.C DOME 3 2A Instrument Panel J/B 12 1D 19 B11 DCYL 12 1 2I 6 1K L Passenger Side J/B G (*1) 6 2 R I16 Interior Lamp Y O 2 D5 Door Courtesy Lamp Front LH 10 G O IB2 1 2 G (*2) 1 T7 Ignition Key Cylinder Illumination (Transponder Key Amplifier) 2 Body ECU 12 B12 PCYL P FR DOOR 12 IK3 R F7 FL Block W 3 D FR DOOR Battery 1 1A FL MAIN ALT B 2 1 IC W *1: w/ Engine Immobilizer System *2: w/o Engine Immobilizer System E74086 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1797 05-1608 DIAGNOSTICS - LIGHTING SYSTEM INSPECTION PROCEDURE 1 (a) (b) CHECK HARNESS AND CONNECTOR(ILLUMINATION CIRCUIT) Disconnect the B11 and B12 connectors from the multiplex network body ECU. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition B11-19 - Body ground Always 10 to 14 V B12-11 - Body ground Always 10 to 14 V B12-12 - Body ground Always 10 to 14 V Multiplex Network Body ECU Connector Front View: B11 B12 B12-12 B12-1 1 B11-19 E74263 NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1538 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1798 05-1609 DIAGNOSTICS 2 - LIGHTING SYSTEM INSPECT INTERIOR LIGHT (a) Connector Front View: I16 Inspect room lamp assy No.1 (interior light). (1) Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified resistance 1-2 Switch is OFF Below 1 Ω 1-3 Switch is OFF Below 1 Ω (2) Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2, then check that the lamp comes on when the switch is in the DOOR position. OK: Lamp comes on. (3) Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 3, then check that the lamp comes on when the switch is in the ON position. OK: Lamp comes on. E69434 E50228 (b) Connector Front View: T7 Inspect key cylinder illumination. (1) w/ Theft deterrent system: Connect the positive (+) lead from the battery to terminal 2 and negative (-) lead to terminal 6, then check that the lamp comes on. OK: Illumination comes on. E74066 (2) w/o Theft deterrent system: Connect the positive (+) lead from the battery to terminal 2 and negative (-) lead to terminal 1, then check that the lamp comes on. OK: Illumination comes on. Connector Front View: I14 E69342 (c) Connector Front View: O5 Inspect personal lamp (overhead J/B). (1) Connect the positive (+) lead from the battery to terminal 12 and negative (-) lead to terminal 7, then check that the lamp comes on when switch is in the DOOR position. OK: Lamp comes on. E72986 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1799 05-1610 DIAGNOSTICS (d) Connector Front View: D5 D6 - LIGHTING SYSTEM Inspect courtesy lamp. (1) Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2, then check that the lamp comes on. OK: Lamp comes on. NG REPLACE INTERIOR LIGHT (EACH OF ILLUMINATION LAMP) E69342 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (EACH OF ILLUMINATION CIRCUIT) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1800 05-1594 DIAGNOSTICS - LIGHTING SYSTEM 05IQE-01 IGNITION SWITCH CIRCUIT CIRCUIT DESCRIPTION This circuit detects the state of the ignition switch and sends it to the multiplex network body ECU. WIRING DIAGRAM Instrument Panel J/B I15 Ignition SW 2 L 1C ACC 3 IG1 10 1K 1C IG1 4 AM1 6 1C W 6 1J 7 G 2 AM1 RAD No.2 Body ECU Center J/B 6 W 8 3A 3C GR 10 3A 5 3B B BR 17 B9 ACC 5 B9 IG 1 1A 2 1 F7 FL Block W B 1 ALT 2 FL MAIN Battery E74083 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1784 05-1595 DIAGNOSTICS - LIGHTING SYSTEM INSPECTION PROCEDURE HINT: Inspect if another system (engine, wiper and so on) is normal before performing this procedure. 1 (a) (b) CHECK HARNESS AND CONNECTOR(IGNITION SWITCH CIRCUIT) Disconnect the B9 connector from multiplex network body ECU. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition B9-5 - Body ground Ignition switch is ON Ignition switch is OFF 10 to 14 V Below 1 V B9-17 - Body ground Ignition switch is ACC Ignition switch is OFF 10 to 14 V Below 1 V Multiplex Network Body ECU Connector Front View: B9 B9-5 B9-17 E74263 NG REPAIR OR REPLACE HARNESS OR CONNECTOR (IGNITION SWITCH - MULTIPLEX NETWORK BODY ECU) OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1538 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1785 05-1586 DIAGNOSTICS - LIGHTING SYSTEM 05IQC-01 LIGHT CONTROL SWITCH CIRCUIT CIRCUIT DESCRIPTION This circuit detects the state of the headlamp dimmer switch. WIRING DIAGRAM Body ECU 10 B10 FFOG BR Passenger Side J/B 2 4N Y 6 4F 14 B10 HU 15 Y O B10 18 B10 17 B10 16 B10 V LG P C13 Combination Switch 11 7 LFG BFG HU Fog Light SW 14 13 8 HL HF T H HF TAIL HEAD A 12 EL A OFF ON OFF TAIL Light Control SW HEAD AUTO LOW Dimmer SW HIGH FLASH 17 10 16 W-B L IA E74080 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1776 05-1587 DIAGNOSTICS - LIGHTING SYSTEM INSPECTION PROCEDURE 1 (a) (b) INSPECT MULTIPLEX NETWORK BODY ECU Disconnect the B10 connector from the multiplex network body ECU. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition B10-10 - Body ground Front fog light switch OFF → ON 10 kΩ or higher → Below 1 Ω B10-14 - Body ground Headlamp Dimmer switch LOW → HIGH 10 kΩ or higher → Below 1 Ω B10-15 - Body ground Headlamp Dimmer switch LOW → FLASH 10 kΩ or higher → Below 1 Ω B10-16 - Body ground Light control switch OFF → AUTO 10 kΩ or higher → Below 1 Ω B10-17 - Body ground Light control switch OFF → HEAD 10 kΩ or higher → Below 1 Ω B10-18 - Body ground Light control switch OFF → TAIL 10 kΩ or higher → Below 1 Ω Multiplex Network Body ECU Connector Front View: B10 B10-10 B10-14 B10-18 B10-15 B10-17 B10-16 NG E74263 Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1538 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1777 05-1588 DIAGNOSTICS 2 - LIGHTING SYSTEM INSPECT HEADLAMP DIMMER SWITCH ASSY (a) Connector Front View: C13 Inspect light control switch (when headlamp is malfunctioning). (1) Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 12 - 16 13 - 16 14 - 16 OFF 10 kΩ or higher 14 - 16 TAIL Below 1 Ω 13 - 16 14 - 16 HEAD Below 1 Ω 12 - 16 AUTO Below 1 Ω E11948 (b) Inspect headlamp dimmer switch (when headlamp is malfunctioning). (1) Measure the resistance according to the value(s) in the table below. Standard: Tester connection (c) Condition Specified condition 16 - 17 LOW Below 1 Ω 7 - 16 HIGH Below 1 Ω 7 - 16 8 - 16 FLASH Below 1 Ω Inspect front fog light switch (when fog lamp is malfunctioning). (1) Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 10 - 11 OFF 10 kΩ or higher 10 - 11 ON Below 1 Ω NG REPLACE HEADLAMP DIMMER SWITCH ASSY (SEE PAGE 65-25 ) OK REPAIR OR REPLACE HARNESS OR CONNECTOR 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1778 05-1556 DIAGNOSTICS - LIGHTING SYSTEM 05IQ9-01 HEADLIGHT RELAY CIRCUIT CIRCUIT DESCRIPTION The multiplex network body ECU controls the HEAD relay when a signal is received from the headlamp dimmer switch assy. WIRING DIAGRAM Engine Room J/B 1 2I MAIN 1 Body ECU HEAD LAMP Relay 1 2B 2 4 3 1 2G 1 2 4 IK3 L-R R 3 B11 HRLY R-B Engine Room R/B H-LP RH LWR 2 2 2 1 H-LP LH LWR 2 2 1 R-W H2 Headlamp LH (Low) 2 W-B 1 H4 Headlamp RH (Low) R-Y W-B 2 1 F7 FL Block W W 3 FL MAIN Battery 1 A J3 J/C A EA E74076 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1746 05-1557 DIAGNOSTICS - LIGHTING SYSTEM INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST USING HAND-HELD TESTER (a) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch to the ON position and turn the hand-held tester main switch on. (c) Select the item below in the ACTIVE TEST and then check the relay operation. BODY NO.1 (MULTIPLEX NETWORK BODY ECU): Item Test Details Diagnostic Note HEAD LIGHT Headlamp relay ON/OFF - OK: Headlamp comes on. NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1538 ) 2 (a) (b) INSPECT MULTIPLEX NETWORK BODY ECU Disconnect the B11 connector from the multiplex network body ECU. Using a service wire, connect B11-3 of the wire harness side and body ground. OK: Headlamp comes on. Multiplex Network Body ECU Connector Front View: B11 B11-3 E74263 NG Go to step 3 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1538 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1747 05-1558 DIAGNOSTICS 3 (a) (b) - LIGHTING SYSTEM INSPECT ENGINE ROOM J/B Disconnect the 2B connector from the engine room J/B. Using a service wire, connect 2B-1 of the engine room J/B side and body ground. OK: Headlamp comes on. Engine Room J/B Connector Front View: 2B-1 2B E72974 NG Go to step 4 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (ENGINE ROOM J/B - MULTIPLEX NETWORK BODY ECU) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1748 05-1559 DIAGNOSTICS 4 (a) - LIGHTING SYSTEM INSPECT ENGINE ROOM J/B Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 2G-1 - Body ground Connect 2B-1 and body ground 10 to 14 V Engine Room J/B Connector Front View: 2G 2G-1 E72974 NG Go to step 5 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (EACH OF HEADLAMP CIRCUIT) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1749 05-1560 DIAGNOSTICS 5 (a) - LIGHTING SYSTEM INSPECT ENGINE ROOM J/B Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 2B-1 - Body ground Always 10 to 14 V Engine Room J/B Connector Front View: 2B-1 2B E72974 NG Go to step 6 OK REPLACE ENGINE ROOM J/B 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1750 05-1561 DIAGNOSTICS 6 (a) (b) - LIGHTING SYSTEM CHECK HARNESS AND CONNECTOR(POWER SOURCE CIRCUIT) Disconnect the 2I connector from the engine room J/B. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 2I-1 - Body ground Always 10 to 14 V Engine Room J/B Connector Front View: 2I 2I-1 E72974 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE ENGINE ROOM J/B 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1751 05-1582 DIAGNOSTICS - LIGHTING SYSTEM 05IQB-01 FRONT FOG LIGHT CIRCUIT CIRCUIT DESCRIPTION The multiplex network body ECU controls the FOG relay when a signal is received from the headlamp dimmer switch assy. WIRING DIAGRAM Instrument Panel J/B Body ECU TAILLIGHT Relay 1 B 1 1A 2 TAIL 5 4 1J 3 FOG LIGHT Relay 2 1 FR FOG 2 3 5 1J 7 SB 7 B9 TRLY V 6 B9 FFGO R-W 1B F2 Front Fog Lamp RH R-W 1 2 W-B F1 Front Fog Lamp LH W-B R-W 1 2 F7 FL Block W 2 ALT 1 FL MAIN A J1 J/C Battery A J3 J/C EG EA E74079 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1772 05-1583 DIAGNOSTICS - LIGHTING SYSTEM INSPECTION PROCEDURE HINT: Inspect if the taillamp system is normal before performing this procedure. 1 (a) (b) INSPECT MULTIPLEX NETWORK BODY ECU Disconnect the B9 connector from the multiplex network body ECU. Using a service wire, connect B9-6 and B9-7 of the wire harness side and body ground. OK: Front fog lamp comes on. Multiplex Network Body ECU Connector Front View: B9 B9-7 B9-6 E74263 NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1538 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1773 05-1584 DIAGNOSTICS 2 - LIGHTING SYSTEM INSPECT INSTRUMENT PANEL JUNCTION BLOCK ASSY (a) Instrument Panel Junction Block Front Side View: (b) Disconnect the 1J connector from the instrument panel junction block. Using a service wire, connect 1J-2, 1J-4 of the instrument panel junction block side and body ground. OK: Front fog lamp comes on. 1J 1J-2 1J-4 E72975 NG Go to step 3 OK REPAIR OR REPLACE HARNESS OR CONNECTOR (INSTRUMENT PANEL JUNCTION BLOCK ASSY - MULTIPLEX NETWORK BODY ECU) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1774 05-1585 DIAGNOSTICS 3 - LIGHTING SYSTEM INSPECT INSTRUMENT PANEL JUNCTION BLOCK ASSY (a) Instrument Panel Junction Block Back Side View: Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 1B-7 - Body ground Connect 1J-2, 1J-4 and body ground 10 to 14 V 1B 1B-7 E72977 NG REPLACE INSTRUMENT PANEL JUNCTION BLOCK ASSY OK REPAIR OR REPLACE HARNESS OR CONNECTOR (EACH OF FOG LAMP CIRCUIT) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1775 05-1589 DIAGNOSTICS - LIGHTING SYSTEM 05IQD-01 AUTOMATIC LIGHT CONTROL SENSOR CIRCUIT CIRCUIT DESCRIPTION The multiplex network body ECU receives a signal from the automatic light control sensor. HINT: A DTC code is output when the automatic light control sensor is malfunctioning or there is an open or short circuit in the automatic light control sensor (see page 05-1551 ). WIRING DIAGRAM A23 Automatic Light Control Sensor CLTS CLTE Body ECU R 21 B9 CLTS W 20 B9 CLTE 4 3 12 CLTB G B9 1 CLTB E68822 E70389 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1779 05-1590 DIAGNOSTICS - LIGHTING SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(AUTOMATIC LIGHT CONTROL SENSOR POWER SOURCE CIRCUIT) (a) (b) Wire Harness View: A23 Automatic Light Control Sensor 3 Disconnect the automatic light control sensor connector. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A23-1 - A23-3 Ignition switch ON 10 to 14 V 1 I39976 NG Go to step 4 OK 2 CHECK HARNESS AND CONNECTOR(MULTIPLEX NETWORK BODY ECU AUTOMATIC LIGHT CONTROL SENSOR) (a) Wire Harness View: A23 Automatic Light Control Sensor (b) 4 Disconnect the B9 connector from the multiplex network body ECU. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A23-4 - B9-21 Always Below 1 Ω I39976 Multiplex Network Body ECU Connector Front View: B9 B9-21 E74263 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1780 05-1591 DIAGNOSTICS 3 - LIGHTING SYSTEM REPLACE AUTOMATIC LIGHT CONTROL SENSOR OK: Return to normal condition. NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1538 ) OK END 4 CHECK HARNESS AND CONNECTOR(MULTIPLEX NETWORK BODY ECU AUTOMATIC LIGHT CONTROL SENSOR) (a) Wire Harness View: A23 Automatic Light Control Sensor Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A23-1 - Body ground Ignition switch ON 10 to 14 V 1 I39976 NG Go to step 6 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1781 05-1592 DIAGNOSTICS 5 - LIGHTING SYSTEM CHECK HARNESS AND CONNECTOR(MULTIPLEX NETWORK BODY ECU AUTOMATIC LIGHT CONTROL SENSOR) (a) Wire Harness View: A23 Automatic Light Control Sensor (b) 3 Disconnect the B9 connector from the multiplex network body ECU. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A23-3 - B9-20 Always Below 1 Ω I39976 Multiplex Network Body ECU Connector Front View: B9 B9-20 E74263 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1538 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1782 05-1593 DIAGNOSTICS 6 - LIGHTING SYSTEM CHECK HARNESS AND CONNECTOR(MULTIPLEX NETWORK BODY ECU AUTOMATIC LIGHT CONTROL SENSOR) (a) Wire Harness View: A23 Automatic Light Control Sensor (b) 1 Disconnect the B9 connector from the multiplex network body ECU. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A23-1 - B9-12 Always Below 1 Ω I39976 Multiplex Network Body ECU Connector Front View: B9 B9-12 E74263 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1538 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1783 05-1536 DIAGNOSTICS - LIGHTING SYSTEM 05ETG-02 OPERATION CHECK 1. (a) (b) (c) (d) (e) (f) (g) 2. (a) (b) (c) (d) ILLUMINATED ENTRY SYSTEM OPERATION CHECK Illuminated entry system controls the following lamps:
Ignition key cylinder lamp
Interior lamp (Room lamp assy No.1)
Personal lamp (Overhead J/B) Check that the lamps come on after: (1) Unlocking any door that was closed and locked with the ignition switch off. Check that the lamps fade out after: (1) Leaving the doors unlocked for 15 seconds (2) Turning the ignition switch to the ACC or ON position (3) Locking all the doors Check that the lamps stay ON for at least 15 seconds after opening any of the doors, then fade out again after 15 seconds. Check that the lamps fade out after: (1) Leaving the doors unlocked for 15 seconds (2) Locking all the doors Check that the lamps stay ON for at least 15 seconds after opening any of the doors, then fade out again in 15 seconds after closing all the doors. Check that the lamps come on when opening any of the doors or turning the ignition switch off from the ACC or ON position. LIGHT AUTO TURN OFF OPERATION CHECK Turn the ignition switch to the ON position, and switch the headlamps into the TAIL or HEAD position. Turn the ignition switch off and open the driver’s door, and check that the headlamps go off immediately. Turn the ignition switch to the ON position, and switch the headlamps into the AUTO position. Turn the ignition switch off and open the driver’s door when operating the automatic light control system, and check that the headlamps go off immediately. AUTOMATIC LIGHT CONTROL OPERATION CHECK 3. HINT: Perform the operation check at a location with bright surroundings. (a) Turn the ignition switch to the ON position. (b) Turn the headlamp dimmer switch to the AUTO position. (c) Cover the automatic light control sensor and check that the taillamp and headlamp in order. (d) Uncover the automatic light control sensor and check that the headlamp and taillamp go off in order. 4. DAYTIME RUNNING LIGHT OPERATION CHECK (a) Check that the high beams come on when the headlamp switch is off with the engine running and parking brake released. (b) Check that the high beams go off when turning the headlamp dimmer switch into the TAIL or HEAD (LOW) position under the condition as shown in (a). (c) Check that the high beams go off when turning the ignition switch off under the condition as shown in (a). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1726 05-1531 DIAGNOSTICS - LIGHTING SYSTEM 05ETF-02 SYSTEM DESCRIPTION 1. (a) (b) (c) LIGHTING SYSTEM Illumination control system (Illuminated entry system): When a door is unlocked through a key or transmitter operation, or if a door is opened or closed, the illuminated entry system turns on the interior lamp and the ignition key illumination. (1) The multiplex network body ECU receives the following.
Door courtesy switch signal
Door detection switch signal
Ignition switch signal (2) The multiplex network body ECU controls the following based on the signals listed in (1).
Illumination operation signal (3) The multiplex network body ECU controls the on/off and fade-in/fade-out operation of the following.
Room lamp assy No.1
Ignition key cylinder lamp
Personal lamp (Overhead J/B) Manual light control system: This system functions if lights such as the headlamps and taillamps come on by manual operation of the light control switch. (1) The multiplex network body ECU receives the following.
Light control switch signal
Fog lamp switch signal (2) The multiplex network body ECU controls the following based on the signals listed in (1).
HEAD relay operation signal
TAIL relay operation signal
FOG relay operation signal
DRL relay No.2
DRL relay No.3
DRL relay No.4 (3) The multiplex network body ECU controls the on/off operation of the following signals based on the signals listed in (2).
Headlamp (Low)
Clearance lamp
Taillamp
License plate lamp
Fog lamp Light auto turn off system: When the headlamps and taillamps are on through the operation of the automatic light control system or through the light control switch, if the ignition switch is turned off and driver side door is opened, this system will turn the headlamps and taillamps off immediately. (1) The multiplex network body ECU receives the following.
Door courtesy switch signal
Ignition switch signal (2) The multiplex network body ECU controls the following based on the signals listed in (1).
HEAD relay operation signal
TAIL relay operation signal 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1721 05-1532 DIAGNOSTICS - LIGHTING SYSTEM (3) (d) (e) The multiplex network body ECU controls the illuminating period based on the signals listed in (2).
Headlamp (Low)
Headlamp (Hi)
Clearance lamp
Taillamp
License plate lamp
Fog lamp Automatic light control system: When the light control switch is in the AUTO position, the automatic light control sensor detects ambient light and automatically turns the headlamps and taillamps on or off accordingly. (1) The multiplex network body ECU receives the following.
Light control switch signal
Automatic light control sensor signal (2) The multiplex network body ECU controls the following based on the signals listed in (1).
HEAD relay operation signal
TAIL relay operation signal (3) The multiplex network body ECU controls the on/off operation of the following.
Headlamp (Low)
Clearance lamp
Taillamp
License plate lamp Daytime running light system: This system is directly connected to the high-beam headlamps and is designed to automatically activate the daytime running light in order to remain highly visible to other vehicles. (1) The multiplex network body ECU receives the following.
Ignition switch signal
Generator signal
Parking brake switch signal
Light control switch signal (2) The multiplex network body ECU controls the following based on the signals listed in (1).
DRL relay operation signal (3) The multiplex network body ECU controls the on/off operation of the following.
Headlamp (Hi) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1722 05-1530 DIAGNOSTICS - LIGHTING SYSTEM 05ETD-02 SYSTEM DIAGRAM Ignition Switch Multiplex Network Body ECU  Alternator L Signal  Driver Side Door Detection Signal Headlamp Dimmer Switch Courtesy Lamp Switch Door Unlock Detection Switch Parking Brake Switch Automatic Light Control Sensor Headlamp (Low) HEAD Relay Taillamp TAIL Relay Headlamp (Hi) DRL Relay Fog Lamp FOG Relay Door Courtesy Lamp Illumination Ignition Key Cylinder Lamp Interior Lamp Generator ECM  Alternator L Signal Power Window Master Switch  Driver Side Door Detection Signal BEAN BEAN DLC3 : Input Signal : Output Signal E70394 E74056 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1720 05-1535 DIAGNOSTICS - LIGHTING SYSTEM 05CTX-05 CUSTOMER PROBLEM ANALYSIS CHECK LIGHTING SYSTEM Check Sheet Inspector’s name: VIN Customer’s Name Production Date Licence Plate No. Date Vehicle Brought in / / Date Problem First Occurred Frequency Problem Occurs Weather Conditions Weather When Problem Occurred Outdoor Temperature km mile Odometer Reading / Always Once only / Sometimes ( Fine Cloudy Various/ Others Rainy times per day, month) Snowy Hot Warm Cool Cold (Approx. °F ( °C))
Headlamp system
Taillight system
Automatic light control system Malfunctioning System:
Light auto turn off system
Daytime running light system
Fog light system
Turn signal and hazard warning system
Stop light system
Back-up light system
Illuminated entry system
Others



I34763 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1725 05-1547 DIAGNOSTICS - LIGHTING SYSTEM 05CTZ-05 DIAGNOSTIC TROUBLE CODE CHART 1. DTC CHECK If a trouble code is displayed during the DTC check, check the suspected area listed for that code in the table below, and proceed to the appropriate page. DTC No. (See Page) Symptom Suspected Area B1241 (05-1548 ) Body ECU switch circuit diagnosis
Headlamp dimmer switch assy
Wire harness or connector
Multiplex network body ECU B1244 (05-1551 ) Light sensor circuit malfunction
Automatic light control sensor
Wire harness or connector
Multiplex network body ECU 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1737 05-1533 DIAGNOSTICS - LIGHTING SYSTEM 05CUG-05 HOW TO PROCEED WITH TROUBLESHOOTING The hand-held tester can be used at steps 4, 5, 6 and 13. 1 VEHICLE BROUGHT TO WORK SHOP 2 CUSTOMER PROBLEM ANALYSIS (SEE PAGE 05-1535 ) (a) Confirm problem symptoms. 3 PROBLEM SYMPTOM CONFIRMATION SYMPTOM DOES NOT OCCUR (GO TO STEP 4) SYMPTOM OCCURS (GO TO STEP 5) 4 SYMPTOM SIMULATION 5 CHECK BODY MULTIPLEX COMMUNICATION SYSTEM (SEE PAGE 05-2040 ) (a) Check for the DTC output. MULTIPLEX DTC OUTPUT (PROCEED TO ”BODY MULTIPLEX COMMUNICATION SYSTEM”) NO MULTIPLEX DTC (GO TO STEP 6) 6 DTC CHECK (SEE PAGE 05-1545 ) MALFUNCTION CODE (GO TO STEP 7) NORMAL SYSTEM CODE (GO TO STEP 8) 7 DTC CHART (SEE PAGE 05-1547 ) GO TO STEP 10 8 PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1538 ) 9 TERMINALS OF ECU (SEE PAGE 05-1541 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1723 05-1534 DIAGNOSTICS - LIGHTING SYSTEM 10 CIRCUIT INSPECTION (SEE PAGE 05-1548 TO 05-1606 ) 11 IDENTIFICATION OF PROBLEM 12 REPAIR OR REPLACE 13 CONFIRMATION TEST END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1724 05-1527 DIAGNOSTICS - LIGHTING SYSTEM 05ETC-02 LOCATION Engine Room R/B No.3
DRL Fuse
DRL No.2 Relay
DRL No.3 Relay
DRL No.4 Relay Headlamp Assy RH
Headlamp (Low)
Headlamp (High)
Parking Lamp
Turn Signal Lamp Generator Assy Engine Room J/B
H-LP LH UPR Fuse
H-LP RH UPR Fuse
HAZARD Fuse
TOWING Fuse
DOME Fuse
HEAD LAMP Relay Engine Room R/B
H-LP LH LWR Fuse
H-LP RH LWR Fuse Front Fog Lamp RH Front Fog Lamp LH Headlamp Assy LH
Headlamp (Low)
Headlamp (High)
Parking Lamp
Turn Signal Lamp I40003 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1717 05-1528 DIAGNOSTICS - LIGHTING SYSTEM Front Door w/ Motor Lock Assy LH (Door Unlock Detection Switch LH) Vanity Lamp Assy LH Overhead J/B (Personal Lamp) Vanity Lamp Assy RH Room Lamp Assy No.1 (Interior Lamp) Front Door w/ Motor Lock Assy RH (Door Unlock Detection Switch RH) Power Window Master Switch with ECU Front Door Courtesy Lamp Switch Front Door Courtesy Lamp Switch Assy Room Lamp Assy No.2 (Rear Interior Lamp) High Mounted Stop Lamp Rear Door w/ Motor Lock Assy RH (Door Unlock Detection Switch RH) Rear Door Courtesy Lamp Switch Assy Front Door Courtesy Lamp Assy Rear Door w/ Motor Lock Assy LH (Door Unlock Detection Switch LH) Rear Door Courtesy Lamp Switch Assy License Plate Lamp Front Door Courtesy Lamp Assy Back Door Lock Assy (Back Door Courtesy Lamp Switch) Rear Combination Lamp LH
Stop Lamp
Taillamp
Turn Signal Lamp
Back-up Lamp
Rear Side Marker Lamp Rear Combination Lamp RH
Stop Lamp
Taillamp
Turn Signal Lamp
Back-up Lamp
Rear Side Marker Lamp I40005 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1718 05-1529 DIAGNOSTICS - LIGHTING SYSTEM Automatic Light Control Sensor Combination Meter Assy
High Beam Indicator Lamp Hazard Warning Switch Assy Multiplex Network Body ECU Parking Brake Switch ECM Glove Box Lamp Key Cylinder Lamp Headlamp Dimmer Switch Assy
Light Control Switch
Headlamp Dimmer Switch
Turn Signal Lamp Switch
Front Fog Lamp Switch Instrument Panel Junction Block
FR FOG Fuse
STOP Fuse
TAIL Fuse
TAIL LIGHT Relay
FOG LIGHT Relay Stop Lamp Switch DLC3 Turn Signal Flasher Relay I40007 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1719 05-1526 DIAGNOSTICS - LIGHTING SYSTEM LIGHTING SYSTEM 05CTV-05 PRECAUTION 1. (a) (b) (c) (d) (e) PRECAUTION OF HEADLAMP BULB REPLACEMENT If even a thin film of oil is left on the surface of the halogen lamp, the bulb may be damaged because the lamp will burn at a higher temperature. Handle any halogen lamp with great care. Dropping, hitting or damaging the bulb, in any way, may result in it exploding and shattering because the internal pressure is high. Always prepare a new bulb for immediate replacement. While replacing the bulb, the lens may attract dust and moisture if removed from the vehicle for too long. Always use a bulb of the same wattage for replacement. Firmly reinstall the socket after bulb replacement. The lens may become cloudy or the light cavity may fill with water through the gaps around the socket. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1716 05-1538 DIAGNOSTICS - LIGHTING SYSTEM 05CU2-05 PROBLEM SYMPTOMS TABLE If a normal system code is displayed during the DTC check but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. HINT: Inspect the fuse and relay before confirming the suspected area as shown in the charts below. Inspect each malfunction circuit in numerical order for the corresponding symptom. If the malfunction still exists even after checking and confirming that all the circuits are normal, replace the ECU. 1. HEADLAMP AND TAIL LAMP SYSTEM Symptom Suspected Area ”Low beam” does not come on (One side). 3. Bulb 4. Wire harness or connector ”Low beam” does not come on (Both sides). 1. 2. 3. 4. 5. ”High beam” does not come on (One side). 1. Bulb 2. Wire harness or connector ”High beam” does not come on (Both sides). (Low beam is normal) 1. 1. 2. 3. ”Flash” does not come on. (Low beam and High beam are normal) 1. Light control switch circuit 2. Multiplex network body ECU Headlamp is dark. 1. Bulb 2. Wire harness or connector Tail lamp does not come on (All). 1. 2. 3. 4. 5. Only one tail lamp comes on. 1. Bulb 2. Wire harness or connector Daytime running light system does not operate. 1. 2. 3. 4. 5. 6. Light control switch circuit Generator signal circuit Parking brake switch circuit Ignition switch circuit DRL relay circuit Multiplex network body ECU 1. 2. 3. 4. Light control switch circuit Ignition switch circuit Automatic light control sensor circuit Multiplex network body ECU 2. See page - Bulb Light control switch circuit Headlight relay circuit (w/o Daytime running light) DRL relay circuit (w/ Daytime running light) Multiplex network body ECU 05-1586 05-1556 05-1562 - Bulb Light control switch circuit DRL relay circuit (w/ Daytime running light) Multiplex network body ECU 05-1586 05-1562 05-1586 - Light control switch circuit TAIL relay circuit Ignition switch circuit Door courtesy switch circuit Multiplex network body ECU 05-1586 05-1574 05-1594 05-1601 05-1586 05-1596 05-1598 05-1594 05-1562 - AUTOMATIC LIGHT CONTROL SYSTEM Symptom Automatic light control system does not operate. Suspected Area See page 05-1586 05-1594 05-1589 - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1728 05-1539 DIAGNOSTICS 3. - LIGHTING SYSTEM LIGHT AUTO TURN OFF SYSTEM Symptom Light auto turn off system does not operate. 4. Suspected Area 1. 2. 3. 4. 05-1586 05-1594 05-1601 - FOG LAMP SYSTEM Symptom Suspected Area Front fog lamp does not come on with light control switch in the TAIL or HEAD position. 1. Light control switch circuit 2. Front fog light circuit 3. Multiplex network body ECU Only one front fog lamp does not come on. 1. Bulb 2. Wire harness or connector 5. See page Light control switch circuit Ignition switch circuit Door courtesy switch circuit Multiplex network body ECU See page 05-1586 05-1582 - TURN SIGNAL AND HAZARD WARNING SYSTEM Symptom Suspected Area See page ”Hazard” and ”Turn” do not come on. 1. Ignition switch 2. Turn signal flasher relay 3. Wire harness or connector 65-2 - Hazard warning light does not come on. (Turn is normal) 1. Hazard warning switch 2. Wire harness or connector 65-4 - Turn signal does not come on. (Hazard is normal) 1. Headlamp dimmer switch (turn signal switch) 2. Wire harness or connector 65-4 - Turn signal does not come on in one direction. 1. Headlamp dimmer switch (turn signal switch) 2. Wire harness or connector 65-4 - Only one bulb does not come on. 1. Bulb 2. Wire harness or connector 6. - STOP LIGHT SYSTEM Symptom Suspected Area See page Stop light does not operate (All). 1. Stop light switch 2. Wire harness or connector 65-4 - Only one stop light does not operate. 1. Bulb 2. Wire harness or connector - 7. ILLUMINATED ENTRY SYSTEM Symptom Illuminated entry of multiplex network body ECU control does not operate (All). Suspected Area 1. 2. 3. 4. 5. See page Ignition switch circuit Door lock position circuit Door courtesy switch circuit Illumination circuit Multiplex network body ECU 05-1594 05-1604 05-1601 05-1606 - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1729 05-1540 DIAGNOSTICS 8. - LIGHTING SYSTEM OTHERS Symptom Suspected Area See page 1. Park/neutral position switch 2. Wire harness or connector 05-922 or 05-1036 - Vanity light does not operate. 1. Bulb 2. Wire harness or connector - Door courtesy lamp does not come on. 1. 2. 3. 4. Luggage compartment light does not come on. (When back door is opened) 1. Rear interior light 2. Back door courtesy switch 3. Wire harness or connector Luggage compartment light does not come on. (When rear door is opened) 1. 2. 3. 4. Back up lamp does not come on (All). Bulb Door courtesy switch circuit Wire harness or connector Multiplex network body ECU 05-1601 65-4 65-4 - Rear interior light Door courtesy switch circuit Wire harness or connector Multiplex network body ECU 65-4 05-1601 - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1730 05-1541 DIAGNOSTICS - LIGHTING SYSTEM 05IQ3-01 TERMINALS OF ECU 1. MULTIPLEX NETWORK BODY ECU B12 B11 B10 B9 E74263 Symbols (Terminals No.) Wiring Color Terminal Description GND2 (B9-2) - Body ground W-B - Body ground Body ground BR - W-B Ignition switch signal Condition Specified Condition Always Below 1 V
Ignition switch is OFF
Ignition switch is in the ON position
Below 1 V
10 to 14 V V - W-B Front fog relay (Front fog circuit)
Front fog lamp is in the OFF position
Front fog lamp is in the ON position
10 to 14 V
Below 1 V TRLY (B9-7) - GND1 (B12-7) SB - W-B TAIL Relay (TAIL signal)
Light control switch is in the TAIL position
Light control switch is in the OFF position
10 to 14 V
Below 1 V MPX2 (B9-10) GND1 (B12-7) O - W-B Multiplex communication circuit Ignition switch is in the ON position Signal waveform CLTB (B9-12) - GND1 (B12-7) G - W-B Automatic light control sensor (Power source circuit)
Ignition switch is OFF
Ignition switch is in the ON position
Below 1 V
10 to 14 V ACC (B9-17) - GND1 (B12-7) B - W-B Ignition switch signal
Ignition switch is OFF
Ignition switch is in the ACC position
Below 1 V
10 to 14 V CLTE (B9-20) - GND1 (B12-7) W - W-B Automatic light control sensor (Ground circuit) Always Below 1 V CLTS (B9-21) - GND1 (B12-7) R - W-B Automatic light control sensor (Signal circuit) Ignition switch is in the ON position Signal waveform MPX1 (B10-6) GND1 (B12-7) W - W-B Multiplex communication circuit Ignition switch is in the ON position Signal waveform BR - W-B Front fog lamp switch (Front fog lamp signal)
Fog lamp switch is in the OFF position
Fog lamp switch is in the ON position
10 to 14 V
Below 1 V IG (B9-5) - GND1 (B12-7) FFGO (B9-6) - GND1 (B12-7) FFOG (B10-10) GND1 (B12-7) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1731 05-1542 DIAGNOSTICS - LIGHTING SYSTEM BR - W-B Door lock position switch (Front passenger side door circuit)
Front passenger side door is in the unlock position
Front passenger side door is in the lock position
Below 1 V
10 to 14 V Y - W-B Headlamp dimmer switch (HIGH signal)
Headlamp dimmer switch is in the LOW position
Headlamp dimmer switch is in the HIGH or FLASH position
10 to 14 V
Below 1 V O - W-B Headlamp dimmer switch (FLASH signal)
Headlamp dimmer switch is in the LOW position
Headlamp dimmer switch is in the FLASH position
10 to 14 V
Below 1 V P - W-B Light control switch (AUTO signal)
Light control switch is in the OFF position
Light control switch is in the AUTO position
10 to 14 V
Below 1 V LG - W-B Light control switch (HEAD signal)
Light control switch is in the OFF position
Light control switch is in the HEAD position
Below 1 V
10 to 14 V V - W-B Light control switch (TAIL signal)
Light control switch is in the OFF position
Light control switch is in the TAIL position
10 to 14 V
Below 1 V B - W-B DRL Relay (DRL signal)
Light control switch is in the OFF or TAIL position
Light control switch is in the HEAD position
10 to 14 V
Below 1 V R - W-B HEAD Relay (HEAD signal)
Light control switch is in the OFF or TAIL position
Light control switch is in the HEAD position
10 to 14 V
Below 1 V BCTY (B11-6) - GND1 (B12-7) G - W-B Luggage room light (Illumination signal)
Luggage room light is OFF (When switch is in the DOOR position)
Luggage room light is ON (When switch is in the DOOR position)
10 to 14 V
Below 1 V DCTY (B11-1 1) GND1 (B12-7) B - W-B Courtesy switch (Driver side door circuit)
Driver side door is open
Driver side door is closed
Below 1 V
10 to 14 V DCYL (B11-19) GND1 (B12-7) L - W-B Door courtesy light circuit
Driver side courtesy light is OFF
Driver side courtesy light is ON
10 to 14 V
Below 1 V W-B Body ground Body ground Always Below 1 V G - W-B Battery (B+ circuit) Always 10 to 14 V BR - W-B Each of interior light (Illumination signal)
Interior light is OFF
Interior light is ON
10 to 14 V
Below 1 V
Front passenger side courtesy light is OFF
Front passenger side courtesy light is ON
10 to 14 V
Below 1 V
Parking brake is ON
Parking brake is released
Below 1 V
10 to 14 V
One of the rear doors is open
Rear doors are closed
Below 1 V
10 to 14 V LSWP (B10-11) GND1 (B12-7) HU (B10-14) - GND1 (B12-7) HF (B10-15) - GND1 (B12-7) A (B10-16) - GND1 (B12-7) HEAD (B10-17) GND1 (B12-7) TAIL (B10-18) - GND1 (B12-7) DRL (B11-2) GND1 (B12-7) (*1) HRLY (B11-3) - GND1 (B12-7) GND1 (B12-7) - Body ground BECU (B12-9) GND1 (B12-7) ILE (B12-11) - GND1 (B12-7) PCYL (B12-12) GND1 (B12-7) Y - W-B Door courtesy light circuit PKB (B12-14) - GND1 (B12-7) R - W-B Parking brake switch RCTY (B12-15) GND1 (B12-7) LG - W-B Courtesy switch (Rear door circuit) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1732 05-1543 DIAGNOSTICS PCTY (B12-16) GND1 (B12-7) LSWA (B12-17) GND1 (B12-7) - LIGHTING SYSTEM SB - W-B Courtesy switch (Front passenger side door circuit) B - W-B Door lock position switch (Rear and back door circuit)
Front passenger door is open
Front passenger door is closed
Below 1 V
10 to 14 V
One of the rear and back doors is in the unlock position
Rear and back doors are in the lock position
Below 1 V
10 to 14 V *1: w/ Daytime running light 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1733 05-1832 DIAGNOSTICS - NAVIGATION SYSTEM 05ISX-02 POWER SOURCE CIRCUIT (RADIO RECEIVER ASSY) CIRCUIT DESCRIPTION This circuit provides power to the radio receiver assy. WIRING DIAGRAM Center J/B 13 3A 4 3C V 20 IK3 L-Y 2 IL1 LG L-B 9 3I 10 3K GR L-B Radio Receiver Assy 11 R4 ACC 1 R4 B Engine Room J/B 4 2C RAD No.1 D.C.C 1 2I W I15 Ignition SW Instrument Panel J/B 3 1K RAD No.2 6 1C AM1 1 1A B 1 2 1C L BR 3 ACC AM1 2 20 R4 GND W 2 F7 FL Block ALT 2 3 W 1 FL MAIN IB Battery I39184 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2022 05-1833 DIAGNOSTICS - NAVIGATION SYSTEM INSPECTION PROCEDURE 1 INSPECT RADIO RECEIVER ASSY(B, ACC, GND) (a) (b) R4 B (c) GND ACC I39175 Disconnect the radio receiver assy connector R4. Measure the resistance according to the value in the table below. Standard: Tester connection Condition Specified condition GND - Body ground Always Below 1 Ω Measure the voltage according to the values in the table below. Standard: Tester connection Condition Specified condition B - GND Always 10 to 14 V ACC - GND Ignition SW ACC 10 to 14 V NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN DIAGNOSTIC TROUBLE CODE CHART (SEE PAGE 05-1791 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2023 05-1812 DIAGNOSTICS - NAVIGATION SYSTEM 05ISL-02 MAP DISC CANNOT BE INSERTED INSPECTION PROCEDURE 1 CHECK MAP DISC (a) I38584 Check that the map disc is not deformed or cracked. OK: No deformations or cracks appear on the map disc. NG REPLACE THE MAP DISC OK 2 (a) CHECK NAVIGATION ECU Check that the ”PUSH” indicator near the disc slot comes on. OK: It does not come on. NG PRESS THE EJECT SWITCH TO EJECT THE DISC OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1778 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2002 05-1813 DIAGNOSTICS - NAVIGATION SYSTEM 05ISM-02 VEHICLE POSITION MARK DEVIATES GREATLY INSPECTION PROCEDURE 1 CHECK THE GPS MARK (a) I39094 Check that the GPS mark is displayed. OK:The GPS mark is displayed. NG GO TO ”GPS MARK IS NOT DISPLAYED” IN THE FLOW CHART (SEE PAGE 05-1818 ) OK 2 (a) NAVIGATION CHECK MODE(VEHICLE SENSORS) Enter the ”Navigation Check” mode (Vehicle Sensors) (see page 05-1765 ). (b) While driving, compare the ”SPD” indicator to the reading on the speedometer. Check that these readings are almost the same. OK: The readings are almost the same. NG I38228 GO TO ”SPEED SIGNAL CIRCUIT (NAVIGATION ECU - COMBINATION METER ASSY)” IN THE FLOW CHART (SEE PAGE 05-1838 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2003 05-1814 DIAGNOSTICS 3 - NAVIGATION SYSTEM NAVIGATION CHECK MODE(VEHICLE SENSORS) (a) Move the shift lever to the R or P position. Standard: Shift lever Display P OFF R ON HINT: The display is updated once per second. As a result, it is normal for the display to lag behind the actual change in the switch. I38228 NG GO TO ”REVERSE SIGNAL CIRCUIT” IN THE FLOW CHART (SEE PAGE 05-1844 ) OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1778 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2004 05-1805 DIAGNOSTICS - NAVIGATION SYSTEM 05ISF-02 BLACK SCREEN (NO IMAGE APPEARS ON NAVIGATION AND AUDIO SCREEN) INSPECTION PROCEDURE 1 (a) CHECK DISPLAY SETTING Check that the display is not in ”Screen OFF” mode. OK: The display setting is not in ”Screen OFF” mode. NG CHANGE SCREEN TO ”SCREEN ON” MODE OK 2 (a) CHECK IMAGE QUALITY SETTING Check if screen color quality can be set. OK: Switching is possible. OK PRESS PANEL SWITCH ”DISPLAY” AND SET SCREEN COLOR QUALITY TO NORMAL NG 3 CHECK CABIN (a) Check if condensation is likely to occur, or the temperature is high or low (extremely cold) in the cabin. HINT: This problem occurs when the cabin is humid and the temperature rapidly changes. This condition may produce condensation, resulting in a short circuit. OK: The above condition is not observed. NG SET CABIN TEMPERATURE TO APPROPRIATE DEGREES (20 TO 30
C) (68 TO 86
F) OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1778 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1995 05-1815 DIAGNOSTICS - NAVIGATION SYSTEM 05ISN-02 CURSOR OR MAP ROTATES WHEN VEHICLE IS STOPPED INSPECTION PROCEDURE 1 CHECK CONDITION (a) Check with the customer if the vehicle has been turned by a turn-table at parking. OK: The vehicle has not been turned by a turntable. HINT: If the ignition switch is turned to the ACC or ON position while the vehicle is being turned by a turntable, the system may store the angular velocity at this time. For this reason, the vehicle position cursor could deviate. I38146 NG TURN IGNITION SWITCH TO ON POSITION WHEN VEHICLE IS COMPLETELY STOPPED OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1778 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2005 05-1816 DIAGNOSTICS - NAVIGATION SYSTEM 05ISO-02 VEHICLE POSITION MARK IS NOT UPDATED INSPECTION PROCEDURE 1 CHECK THE MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks appear on the map disc. I38584 NG REPLACE THE MAP DISC OK 2 (a) CHECK THE MAP DISPLAY Check if a touch scroll can be performed on the map display. OK: Touch scroll can be performed. NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1778 ) OK 3 (a) NAVIGATION CHECK MODE(VEHICLE SENSORS) Enter the ”Navigation Check” mode (Vehicle Sensors) (see page 05-1765 ). (b) While driving, compare the ”SPEED” indicator to the reading on the speedometer. Check if these readings are almost the same. OK: The readings are almost the same. NG I38228 GO TO ”SPEED SIGNAL CIRCUIT (NAVIGATION ECU - COMBINATION METER ASSY)” IN THE FLOW CHART (SEE PAGE 05-1838 ) OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1778 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2006 05-1817 DIAGNOSTICS - NAVIGATION SYSTEM 05ISP-02 CURRENT POSITION DISPLAY DOES NOT APPEAR INSPECTION PROCEDURE 1 CHECK THE MAP DISC (a) I38584 Check that the map disc is not deformed or cracked. OK: No deformations or cracks appear on the map disc. NG REPLACE THE MAP DISC OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1778 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2007 05-1818 DIAGNOSTICS - NAVIGATION SYSTEM 05ISQ-02 GPS MARK IS NOT DISPLAYED INSPECTION PROCEDURE 1 (a) CHECK CABIN Check the cabin for any object that might interrupt radio reception on the instrument panel. If such an object exists, remove it and check if the GPS mark appears. HINT: GPS works using extremely weak radio waves originating from satellites. If the signal is interrupted by obstructions or another radio wave, the GPS system may not be able to properly receive the signal. OK: Mark appears. OK NORMAL OPERATION NG 2 (a) CHECK SURROUNDINGS Check if the vehicle is in a location where GPS signal reception is bad. If the vehicle is in such a place, move it elsewhere and check if the GPS mark appears. HINT:

GPS uses 24 satellites in 6 orbits so that at any time 5 satellites will be in line-of-sight of your vehicle. GPS signals may not be received, however, depending on surroundings, vehicle direction, and time. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2008 05-1819 DIAGNOSTICS
- NAVIGATION SYSTEM The following illustrations show some conditions where it may be difficult to receive GPS signals. In a tunnel In a building Forest or tree-lined path Under an overpass Between tall buildings Under a cliff, overhang I38586 OK: GPS mark is displayed. OK RETURNS TO NORMAL NG 3 (a) NAVIGATION CHECK MODE(GPS IMFORMATION) Enter the ”Navigation Check” mode (GPS information) (see page 05-1764 ). (b) Check how many of the following codes occur in the ”STS” column. OK: At least 3 codes occur. OK I38226 REPLACE NAVIGATION ECU (SEE PAGE 67-9 ) NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1778 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2009 05-1820 DIAGNOSTICS - NAVIGATION SYSTEM 05ISR-02 VOICE GUIDANCE DOES NOT FUNCTION INSPECTION PROCEDURE 1 CHECK NAVIGATION SYSTEM SETTING (a) (b) Enter the ”MENU” screen by pressing the ”MENU” switch. Enter the volume adjustment screen by pressing the ”Volume” switch. (c) Check that ”OFF” is not selected. OK: OFF is not selected. I39095 I39096 NG TURN VOICE GUIDANCE VOLUME UP TO 4 USING VOICE ADJUSTMENT SWITCHES OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2010 05-1821 DIAGNOSTICS 2 - NAVIGATION SYSTEM CHECK NAVIGATION SETTING (a) (b) Enter the ”MENU” screen by pressing the ”MENU” switch. Enter the ”Setup” screen by pressing the ”Setup” switch. (c) Check that ”Auto Voice Guidance” is not OFF. OK: Auto voice guidance is not OFF. Check if ”Voice Guidance in All Modes” is ON. OK: Voice guidance in all modes is ON. I39097 (d) I39854 NG TURN AUTO VOICE GUIDANCE TO ”ON” OK 3 CHECK THE MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks appear on the map disc. I38584 NG REPLACE THE MAP DISC OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2011 05-1822 DIAGNOSTICS 4 (a) - NAVIGATION SYSTEM CHECK RADIO RECEIVER ASSY Check if audio sound can be heard from the driver’s side speaker. OK: Audio sound can be heard. NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1778 ) OK REPLACE NAVIGATION ECU (SEE PAGE 67-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2012 05-1823 DIAGNOSTICS - NAVIGATION SYSTEM 05ISS-02 MAP DISPLAY INCOMPLETE INSPECTION PROCEDURE 1 CHECK THE MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks appear on the map disc. I38584 NG REPLACE THE MAP DISC OK 2 (a) CHECK THE DISPLAY Check that displays other than the navigation display are complete. OK: No other incomplete displays are found. OK REPLACE NAVIGATION ECU (SEE PAGE 67-9 ) NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1778 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2013 05-1824 DIAGNOSTICS - NAVIGATION SYSTEM 05IST-02 ROUTE CANNOT BE CALCULATED INSPECTION PROCEDURE 1 CHECK THE MAP DISC (a) Check that the map disc is not deformed or cracked. OK: No deformations or cracks appear on the map disc. I38584 NG REPLACE THE MAP DISC OK 2 (a) SET DESTINATION Set another destination and check if the system can calculate the route correctly. OK: Route can be correctly calculated. OK NORMAL OPERATION NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1778 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2014 05-1825 DIAGNOSTICS - NAVIGATION SYSTEM 05ISU-02 GYRO ERROR INSPECTION PROCEDURE 1 (a) NAVIGATION CHECK MODE(VEHICLE SENSORS) Enter the ”Navigation Check” mode (Vehicle Sensors) (see page 05-1765 ). (b) Check the gyro voltage. Standard: 0.1 to 4.5 V I38228 NG REPLACE NAVIGATION ECU (SEE PAGE 67-9 ) OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN DIAGNOSTIC TROUBLE CODE CHART (SEE PAGE 05-1791 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2015 05-1826 DIAGNOSTICS - NAVIGATION SYSTEM 05ISV-02 MAP DISC READ ERROR INSPECTION PROCEDURE 1 CHECK THE MAP DISC (a) Check for dirt on the map disc surface. OK: No dirt is on the map disc surface. HINT: If dirt is on the map disc surface, wipe it with a soft cloth from inside to outside in a radial direction. NOTICE: Do not use conventional record cleaner or anti-static preservative. I38583 NG CLEAN THE MAP DISC OK 2 CHECK THE MAP DISC (a) I38584 Check that the map disc is not deformed or cracked. OK: No deformations or cracks appear on the map disc. NG REPLACE THE MAP DISC OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN DIAGNOSTIC TROUBLE CODE CHART (SEE PAGE 05-1791 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2016 05-1827 DIAGNOSTICS - NAVIGATION SYSTEM 05ISW-02 SPEED SIGNAL ERROR INSPECTION PROCEDURE 1 (a) NAVIGATION CHECK MODE(VEHICLE SENSORS) Enter the ”Navigation Check” mode (Vehicle Sensors) (see page 05-1765 ). (b) While driving, compare the ”SPD” indicator to the reading on the speedometer. Check if these readings are almost the same. OK: The readings are almost the same. I38228 OK REPLACE NAVIGATION ECU (SEE PAGE 67-9 ) NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN DIAGNOSTIC TROUBLE CODE CHART (SEE PAGE 05-1791 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2017 05-1806 DIAGNOSTICS - NAVIGATION SYSTEM 05ISG-02 ILLUMINATION FOR PANEL SWITCH DOES NOT COME ON WITH TAIL SWITCH ON INSPECTION PROCEDURE 1 (a) DISPLAY CHECK MODE(VEHICLE SIGNAL CHECK MODE) Enter the ”Display Check” mode (Vehicle Signal Check Mode) (see page 05-1763 ). (b) Turn the light control switch TAIL or ON and OFF. Standard: TAIL Switch Display TAIL or ON ON OFF OFF HINT: This display is updated once per second. As a result, it is normal for the display to lag behind the actual change in the switch. I38223 OK REPLACE MULTI-DISPLA Y (SEE PAGE 67-8 ) NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1778 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1996 05-1807 DIAGNOSTICS - NAVIGATION SYSTEM 05ISH-02 DISPLAY DOES NOT DIM (NIGHT SCREEN) WITH TAIL SWITCH ON INSPECTION PROCEDURE 1 (a) CHECK SYSTEM Turn the light control switch to the TAIL or HEAD position. Check if the illumination of the switches such as on the radio receiver assy comes on. OK: Illumination of the switches comes on. NG GO TO COMBINATION METER SYSTEM (SEE PAGE 05-1868 ) OK 2 CHECK IMAGE QUALITY SETTING (a) (b) (c) I39088 Enter the display adjustment screen by pressing the ”DISPLAY” switch. Turn the light control switch to TAIL. Check if ”DAY MODE” on the display adjustment is ON. OK: ”DAY MODE” is ON. OK TURN FORCED ”DAY MODE” SETTING OFF NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1778 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1997 05-1808 DIAGNOSTICS - NAVIGATION SYSTEM 05ISI-02 PANEL SWITCH DOES NOT FUNCTION INSPECTION PROCEDURE 1 (a) CHECK THE PANEL SWITCH Check for foreign matter around the switch that might prevent operation. OK: No foreign matter is found. NG REMOVE ANY FOREIGN MATTER FOUND OK 2 (a) DISPLAY CHECK MODE(PANEL SWITCH CHECK MODE) Enter the ”Display Check” mode (Panel Switch Check Mode) (see page 05-1762 ). (b) Operate the abnormal switch and check if the switch name and status are correctly displayed. OK: The switch name and status are correctly displayed as operated. OK I38221 REPLACE MULTI-DISPLA Y (SEE PAGE 67-8 ) NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1778 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1998 05-1809 DIAGNOSTICS - NAVIGATION SYSTEM 05ISJ-02 TOUCH PANEL SWITCH DOES NOT FUNCTION INSPECTION PROCEDURE 1 (a) CHECK TOUCH PANEL Check for dirt on the display surface. OK: The display surface is clean. NG REMOVE ANY DIRT FOUND AND RECHECK TOUCH PANEL OK 2 (a) DISPLAY CHECK MODE(TOUCH SWITCH CHECK) Enter the ”Display Check” mode (Touch Switch Check) (see page 05-1761 ). (b) Touch the display in the area where the abnormal switch occurs. OK: A ”+” mark appears at the touched position. OK I38219 REPLACE MULTI-DISPLA Y (SEE PAGE 67-8 ) NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1778 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1999 05-1810 DIAGNOSTICS - NAVIGATION SYSTEM 05ISK-02 SCREEN FLICKER OR COLOR DISTORTION INSPECTION PROCEDURE 1 CHECK DISPLAY SETTING (a) (b) Enter the display adjustment screen by pressing the ”DISPLAY” switch. Reset display settings (contrast, brightness) and check if the screen appears normal. I39089 (c) Press the ”INFO” switch and then the ”Screen Setting” switch. (d) Set the ”Background Color” to ”Green” (initial setting) and check if it is normal. OK: Returns to normal. I39090 I39091 OK END NG 2 (a) CHECK CABIN Check if the cabin temperature is -20
C (-4.0
F) or less. OK: Cabin is warmer than -20
C (-4.0
F). NG HEAT THE CABIN TEMPERATURE AND RECHECK THE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2000 05-181 1 DIAGNOSTICS 3 (a) - NAVIGATION SYSTEM DISPLAY CHECK MODE(COLOR BAR CHECK MODE) Enter the ”Display Check” mode (Color Bar Check Mode) (see page 05-1760 ). (b) Check that color bars match the displayed names. OK: Color bars match the displayed names. NG I38217 REPLACE MULTI-DISPLA Y (SEE PAGE 67-8 ) OK 4 (a) NAVIGATION CHECK MODE(NAVI COLOR BAR CHECK) Enter the ”Navigation Check” mode (NAVI Color Bar Check) (see page 05-1766 ). (b) Check that color bars match the displayed names. OK: Color bars match the displayed names. OK I38230 REPLACE MULTI-DISPLA Y (SEE PAGE 67-8 ) NG PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1778 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2001 05-1846 DIAGNOSTICS - NAVIGATION SYSTEM 05IT2-02 PARKING BRAKE SWITCH CIRCUIT CIRCUIT DESCRIPTION This is circuit from the parking brake switch to the multi-display. WIRING DIAGRAM Multi-display Passenger Side J/B B 9 4M 12 4H LG 4 IF3 Y 16 M3 PKB 1 P3 Parking Brake SW I40220 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2036 05-1847 DIAGNOSTICS - NAVIGATION SYSTEM INSPECTION PROCEDURE 1 (a) CHECK BRAKE WARNING LIGHT Check that the brake warning light comes on when parking brake pedal is depressed, and goes off when the parking brake pedal is released. OK Go to step 3 NG 2 INSPECT PARKING BRAKE SWITCH ASSY (a) (b) ON OFF Disconnect the parking brake switch assy. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition Switch connector Switch body ON (When shaft is not pressed) Below 1 Ω Switch connector Switch body OFF (When shaft is pressed) 10 kΩ or higher E71372 NG REPLACE PARKING BRAKE SWITCH ASSY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2037 05-1848 DIAGNOSTICS 3 - NAVIGATION SYSTEM CHECK HARNESS AND CONNECTOR(PARKING BRAKE SWITCH MULTI-DISPLA Y) (a) Multi-Display: (b) M3 PKB Disconnect the connector from multi-display and parking brake switch assy. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition PKB - P3-1 Always Below 1 Ω PKB - Body ground Always 10 kΩ or higher I38678 Wire Harness Side (Parking Brake Switch): P3 NG I40730 REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE MULTI-DISPLA Y (SEE PAGE 67-8 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2038 05-1760 DIAGNOSTICS - NAVIGATION SYSTEM 05IRZ-02 DISPLAY CHECK MODE (COLOR BAR CHECK) HINT:

1. This mode checks the color display on the multi-display. Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. Enter diagnostic mode (see page 05-1784 ). 2. Select ”Display Check” from the ”Diagnosis MENU” screen. 3. Select ”Color Bar Check” from the ”Display Check” screen. 4. Select a color bar from the ”Color Bar Check Mode” screen. I38215 I38216 HINT:

The entire screen turns to the color or stripe selected. Touching the display will return to the ”Color Bar Check” screen. I38217 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1950 05-1762 DIAGNOSTICS - NAVIGATION SYSTEM 05IS1-02 DISPLAY CHECK MODE (PANEL SWITCH CHECK) HINT:

1. This mode checks the panel switch operation response on the multi-display. Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. Enter diagnostic mode (see page 05-1784 ). 2. Select ”Display Check” from the ”Diagnosis Menu” screen. 3. Select ”Panel Switch Check” from the ”Display Check” screen. 4. Operate each switch and check that the switch name and condition is correctly displayed. I38215 I38220 HINT:
*1 *2 Pressing the ”DISPLAY” switch for 3 seconds will exit the diagnostic mode. *3 I38221 Display Push switch name/*1 Contents
Name of the pressed switch is displayed.
If more than one switch is pressed, ”MULTIPLE” is displayed. Rotary switch name/*2 Name of the rotary switch is displayed. Rotary switch direction/*3 Direction of the rotary switch is rotated. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1952 05-1761 DIAGNOSTICS - NAVIGATION SYSTEM 05IS0-02 DISPLAY CHECK MODE (TOUCH SWITCH CHECK) HINT:

1. This mode checks the touch switch operation condition on the multi-display. Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. Enter diagnostic mode (see page 05-1784 ). 2. Select ”Display Check” from the ”Diagnosis MENU” screen. 3. Select ”Touch Switch Check” from the ”Display Check” screen. 4. Touch the display anywhere in the open area to perform the check when the ”Touch Switch Check” screen is displayed. I38215 I38218 HINT:

A ”+” mark is displayed where the display is touched. The ”+” mark remains on the display even after the finger is removed. I38219 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1951 05-1763 DIAGNOSTICS - NAVIGATION SYSTEM 05IS2-02 DISPLAY CHECK MODE (VEHICLE SIGNAL CHECK) HINT:

1. This mode checks the vehicle signal status input to the multi-display. Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. Enter diagnostic mode (see page 05-1784 ). 2. Select ”Display Check” from the ”Diagnosis MENU” screen. 3. Select ”Vehicle Signal Check” from the ”Display Check” screen. 4. When the ”Vehicle Signal Check Mode” screen is displayed, check all the vehicle signal conditions. I38215 I38222 HINT:

Only conditions having inputs are displayed. This screen is updated once per second when input signals to the vehicle are changed. I38223 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1953 05-1768 DIAGNOSTICS - NAVIGATION SYSTEM 05IS7-02 DIAGNOSIS DISPLAY DETAILED DESCRIPTION HINT:

1. (a) This section contains a detailed description of displays within diagnostic mode. Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. System Check System Check Mode Display *1 *2 *1 *3 *2 *4 I38587 Device Names and Hardware Address/*1 HINT:
Registered device names are displayed below.
If a device name is unknown to the system, its physical address is shown instead. Address No. Name Address No. Name 110 EMV 120 AVX 128 1DIN TV 140 AVN 144 G-BOOK 178 NAVI 17C MONET 190 AUDIO H/U 1AC CAMERA-C 1B0 Rr-TV 1C0 Rr-CONT 1C2 TV-TUNER2 1C4 PANEL 1C6 G/W 1C8 FM-M-LCD 1D8 CONT-SW 1EC Body 1F0 RADIO TUNER 1F1 XM 1F2 SIRIUS 230 TV-TUNER 240 CD-CH2 250 DVD-CH 280 CAMERA 360 CD-CH1 3A0 MD-CH 17D TEL 440 DSP-AMP 530 ETC 5C8 MAYDAY 1A0 DVD-P 1C6 CLOCK 1F4 RSA 1F6 RSE 480 AMP 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1958 05-1769 DIAGNOSTICS - NAVIGATION SYSTEM Check Result/*2 HINT: Result codes for all devices are shown below. Result Meaning Action OK The device did not respond with a DTC (excluding communication DTCs from the AVC-LAN). - EXCH The device responds with a ”replace”-type DTC. Look up the DTC in ”Unit Check Mode” and replace the device. CHEK The device responds with a ”check”-type DTC. Look up the DTC in ”Unit Check Mode”. NCON The device was previously present, but does not respond in diagnostic mode. 1. Check power supply wire harness of the device. 2. Check the AVC-LAN of the device. The device responds with an ”old”-type DTC. Look up the DTC in ”Unit Check Mode”. The device responds in diagnostic mode, but gives no DTC information. 1. Check power supply wire harness of the device. 2. Check the AVC-LAN of the device. Old NRES Code Clear/*3 Present DTCs are cleared. Memory Clear/*4 Present and past DTCs and registered connected device names are cleared. (b) Diagnosis MENU Display I38666 HINT: Each item is grayed out or not displayed based on the device settings. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1959 05-1770 DIAGNOSTICS (c) - NAVIGATION SYSTEM Unit Check Mode Screen *1 *6 *5 *2 *3 *4 I38588 Screen Description Display Contents Device name/*1 Target Device Segment/*2 Target Device Logical address DTC/*3 DTC (Diagnostic Trouble Code) The time and date of past DTCs are displayed. (The year is displayed in 2 digit format.) Timestamp/*4 Present Code/*5 The DTC output at the service check is displayed. Past Code/*6 (d) Diagnostic memory results and recorded DTCs are displayed. LAN Monitor (Original) Screen *1 I38589 Check Result HINT: Check results of all the devices are displayed. Result Meaning Action No Err (OK) There are no communication DTCs. CHEK The device responds with a ”check”-type DTC. Look up the DTC in ”Unit Check Mode”. NCON The device was previously present, but does not respond in diagnostic mode. 1. Check power supply wire harness of the device. 2. Check the AVC-LAN of the device. The device responded with an old-type DTC. Look up the DTC in ”Unit Check Mode”. Device responds in diagnostic mode, but gives no DTC information. 1. Check power supply wire harness of the device. 2. Check the AVC-LAN of the device. Old NRES - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1960 05-1771 DIAGNOSTICS (e) - NAVIGATION SYSTEM LAN Monitor (Individual) Screen *1 *2 *3 *4 *5 *6 I38590 Screen Description Display Device name/*1 Segment/*2 DTC/*3 Sub-Code (device address)/*4 Connection check No./*5 DTC occurrence/*6 2. (a) Contents Target device Target logical address DTC (Diagnostic Trouble Code) Physical address stored with DTC. (If there is no address, nothing is displayed.) Connection check number stored with DTC. Number of times the same DTC has been recorded. DISPLAY CHECK Vehicle Signal Check Mode Screen I38591 Screen Description Name Battery Contents Battery voltage is displayed. PKB Parking brake ON/OFF state is displayed. REV Reverse signal ON/OFF state is displayed. IG ADIM/TCAN SPEED TAIL IG switch ON/OFF state is displayed. Brightness state DIM (with)/ BRIGHT (without) is displayed. The vehicle speed, displayed in km/h. TAIL signal (Head lamp dimmer switch) ON/OFF state is displayed. HINT:

Only items sending a vehicle signal will be displayed. This screen is updated once per second when input signals to the vehicle are changed. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1961 05-1772 DIAGNOSTICS 3. (a) - NAVIGATION SYSTEM NAVIGATION CHECK Navigation Check MENU Screen I38667 HINT: Each item is grayed out or not displayed based on the device settings. (b) GPS information Screen *1 *1 *2 *2 *5 *3 *4 I38592 Satellite information/*1 Information from a maximum of 12 satellites is displayed on the screen. This information includes the target GPS satellite number, elevation angle, direction and signal level. Receiving condition/*2 (DENSO model) Display Contents T The system is receiving a GPS signal, but is not using it for location. P The system is using the GPS signal for location. - The system cannot receive a GPS signal. (AISIN AW Model) Display Contents 01H The system cannot receive a GPS signal. 02H The system is tracing a satellite. 03H The system is receiving a GPS signal, but is not using it for location. 04H The system is using the GPS signal for location. Measurement information/*3 Display Contents 2D 2-dimensional location method is being used. 3D 3-dimensional location method is being used. NG Location data cannot be used. Error Reception error has occurred. - Any other state. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1962 05-1773 DIAGNOSTICS - NAVIGATION SYSTEM Position information/*4 Display Position Contents Latitude and longitude information on the current position is displayed. Date information/*5 Display Date (c) Contents The date/time information obtained from GPS signal is displayed in Greenwich mean time (GMT). The last 4 digits are displayed. Vehicle Signal Check Screen *1 *2 *3 I38593 Vehicle signal Display Contents REV/*1 REV signal ON/OFF state is displayed. SPD/*2 SPD signal condition is displayed. Sensor signal Display Gyro sensor/*3 Contents Gyro sensor output condition is displayed (when the vehicle runs straight or is stationary, the voltage is approximately 2.5 V). HINT: Signals are updated once per second only when vehicle sensor signals are changed. (d) Parts Information Screen *1 *2 *3 *4 I38594 Screen description Display Navigation Manufacturer/*1 Contents Navigation ECU manufacturer is displayed. Navigation Version No./*2 Navigation ECU version is displayed. Disc Manufacturer/*3 Map disc manufacturer is displayed. Disc Version No./*4 Map disc version is displayed. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1963 05-1774 DIAGNOSTICS (e) - NAVIGATION SYSTEM Memory Copy/Paste Screen I38595 HINT: This function cannot be used. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1964 05-1784 DIAGNOSTICS - NAVIGATION SYSTEM 05ISA-02 DIAGNOSTIC START-UP/FINISH HINT:

1. Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. After the ignition switch is turned on, check that the map is displayed before starting the diagnostic mode. Otherwise, some items cannot be checked. There are 2 methods to start diagnostic mode. Start the mode by using one of them. 2. (a) (b) (c) Method 1 Start the engine. While pressing and holding ”INFO” switch, operate light control switch, OFF → TAIL → OFF → TAIL → OFF → TAIL → OFF. The diagnostic mode starts and the service check screen (”System Check Mode”) will be displayed. Service inspection starts automatically and the result will be displayed. I40190 3. (a) (b) (c) (d) I38204 4. (a) Method 2 Start the engine. Switch to the ”Display Check” screen. From the display adjustment screen, touch the corners of the screen in the following order: upper left → lower left →upper left → lower left → upper left → lower left. The diagnostic mode starts and ”Service Check” screen will be displayed. Service inspection starts automatically and the result will be displayed. Diagnosis MENU Diagnostic screen will be displayed by pressing the menu switch on the service check screen. I38205 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1974 05-1785 DIAGNOSTICS 5. (a) (b) - NAVIGATION SYSTEM There are 2 methods to exit. Use one of them. Turn the ignition switch off. Press the ”Display” switch for 3 seconds. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1975 05-1864 DIAGNOSTICS - NAVIGATION SYSTEM 05IT9-02 AVC-LAN CIRCUIT (MULTI-DISPLA Y CONTROLLER SUB-ASSY RADIO RECEIVER ASSY CIRCUIT DESCRIPTION Each unit of the navigation system connected to AVC-LAN (communication bus) communicates by transferring the signals from each switch. When +B short and GND short occur in this AVC-LAN, navigation system will not function normally as communication is discontinued. In AVC-LAN, multi-display becomes the communication master, and the radio receiver assy has enough resistance necessary for transmitting the communication. WIRING DIAGRAM Multi-display Controller Sub-assy Radio Receiver Assy 31 TX+ R29 LG 9 IP1 Y 9 R23 TX1+ 30 TX- R29 GR 19 IP1 L 10 R23 TX1- I39199 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2054 05-1865 DIAGNOSTICS - NAVIGATION SYSTEM INSPECTION PROCEDURE 1 INSPECT RADIO RECEIVER ASSY (a) R23 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition TX1+ - TX1- Always 60 to 80 Ω TX1TX1+ I40222 NG REPLACE RADIO RECEIVER ASSY (SEE PAGE 67-6 ) OK 2 CHECK HARNESS AND CONNECTOR(MULTI-DISPLA Y CONTROLLER SUB-ASSY - RADIO RECEIVER ASSY) (a) Multi-display Controller Sub-assy: (b) R29 TX+ TXI34639 Disconnect the connectors from the multi-display controller sub-assy R29 and radio receiver assy R23. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition TX+ - TX1+ Always Below 1 Ω TX- - TX1- Always Below 1 Ω TX+ - Body ground Always 10 kΩ or higher TX- - Body ground Always 10 kΩ or higher Radio Receive Assy: R23 TX1+ TX1- NG I40203 REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN DIAGNOSTIC TROUBLE CODE CHART (SEE PAGE 05-1791 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2055 05-1834 DIAGNOSTICS - NAVIGATION SYSTEM 05ISY-02 POWER SOURCE CIRCUIT (GATEWAY ECU) CIRCUIT DESCRIPTION This circuit provides power to the gateway ECU. WIRING DIAGRAM G RAD No.2 2 1C L Gateway ECU Center J/B Instrument Panel J/B IG1 7 10 1C 1K GR 10 3A 1 3I B 2 G5 IG W 8 3A 1 3D SB 9 G5 ACC 9 3F 8 3F LG 8 G5 BATT 6 1J Passenger Side J/B LG 11 IL2 11 4D V I15 IGNITION SW ACC 3 4 W 1 V 12 IK3 V Instrument Panel J/B W IG1 AM1 F7 FL Block ALT 6 4H 2 AM1 6 1C 2 1 1A 1 B 2 Engine Room J/B W 3 D.C.C 1 2I DOME 3 2A Center J/B W-B 13 3F 5 3G W-B 6 3G W-B 7 G5 CG 14 G5 GND FL MAIN Battery IB 2005 HIGHLANDER REPAIR MANUAL (RM1144U) I39187 Author
: Date
: 2024 05-1835 DIAGNOSTICS - NAVIGATION SYSTEM INSPECTION PROCEDURE 1 INSPECT GATEWAY ECU(BATT, ACC, IG, GND ,CG) (a) (b) G5 CG IG BATT GND (c) ACC I40180 Disconnect the gateway ECU connector G5. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition GND - Body ground Always Below 1 Ω CG - Body ground Always Below 1 Ω Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition BATT - GND or CG Always 10 to 14 V ACC - GND or CG Ignition SW ACC 10 to 14 V IG - GND or CG Ignition SW ON 10 to 14 V NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN DIAGNOSTIC TROUBLE CODE CHART (SEE PAGE 05-1791 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2025 05-1858 DIAGNOSTICS - NAVIGATION SYSTEM 05IT6-02 AVC-LAN CIRCUIT (MULTI-DISPLA Y CONTROLLER SUB-ASSY MULTI-DISPLA Y) CIRCUIT DESCRIPTION Each unit of the navigation system connected to AVC-LAN (communication bus) communicates by transferring the signals from each switch. When +B short and GND short occur in this AVC-LAN, navigation system will not function normally as communication is discontinued. In AVC-LAN, multi-display becomes the communication master, and the radio receiver assy has enough resistance necessary for transmitting the communication. WIRING DIAGRAM Multi-display controller sub-assy Multi-display 17 TX3+ R29 BR *1 1 IP1 LG *1 13 M4 TX+ 18 TX3- R29 Y *1 11 IP1 O *1 14 M4 TX- *1: w/ Rear Seat Entertainment System I39199 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2048 05-1859 DIAGNOSTICS - NAVIGATION SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(MULTI-DISPLA Y CONTROLLER SUB-ASSY - MULTI-DISPLA Y) (a) Multi-display Controller Sub-assy: R29 (b) TX3+ TX3I34639 Disconnect the connector from the multi-display controller sub-assy R29 and multi-display M4. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition TX3+ - TX+ Always Below 1 Ω TX3- - TX- Always Below 1 Ω TX3+ - Body ground Always 10 kΩ or higher TX3- - Body ground Always 10 kΩ or higher Multi-Display: M4 TX+ NG TXI38998 REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN DIAGNOSTIC TROUBLE CODE CHART (SEE PAGE 05-1791 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2049 05-1854 DIAGNOSTICS - NAVIGATION SYSTEM 05IT5-02 DIMMER SIGNAL CIRCUIT CIRCUIT DESCRIPTION When the light control switch is in the TAIL or HEAD position, the TAILLIGHT relay activates and supplies power to illuminate the multi-display panel. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2044 05-1855 DIAGNOSTICS - NAVIGATION SYSTEM WIRING DIAGRAM C11 Combination Meter Center J/B B 7 V 12 22 W-B Multi-display Assy 5 3F 3 3F 3 3D 9 3F 10 13 3F 4 3I 3E 12 3A 2 M3 ILL- B LG W-B 1 M3 ILL+ G Passenger Side J/B 12 IK3 6 4H V 11 4D V 11 IL2 Engine Room J/B 3 2A R DOME D.C.C 1 2I W Instrument Panel J/B 7 1K 4 1J O Taillight System PANEL TAILLIGHT Relay 1 1A 3 5 2 B 1 F7 FL Block W 1 ALT 2 3 FL MAIN Battery IB I40219 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2045 05-1856 DIAGNOSTICS - NAVIGATION SYSTEM INSPECTION PROCEDURE 1 (a) CHECK SYSTEM Turn the light control switch to the TAIL or HEAD position. Check if the illumination of the switches such as on the radio receiver assy comes on. OK: Illumination of the switches comes on. NG GO TO COMBINATION METER SYSTEM (SEE PAGE 05-1868 ) OK 2 INSPECT MULTI-DISPLA Y(ILL+) (a) (b) M3 ILL+ I38678 Disconnect the connector from the multi-display. Measure the voltage according to the values in the table below. Standard: Tester connection Condition Specified condition ILL+ - Body ground Light control switch TAIL or HEAD 10 to 14 V NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2046 05-1857 DIAGNOSTICS 3 - NAVIGATION SYSTEM CHECK HARNESS AND CONNECTOR(COMBINATION METER ASSY MULTI-DISPLA Y) (a) Combination Meter Assy: (b) C11 ILL Disconnect the connectors from the combination meter assy and Multi-display. Measure the resistance according to the values in the table below. Standard: Tester connection Condition Specified condition ILL - ILL- Always Below 1 Ω ILL - Body ground Always 10 kΩ or higher I40182 Multi-Display: M3 ILL- NG I38678 REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN ON PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1778 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2047 05-1849 DIAGNOSTICS - NAVIGATION SYSTEM 05IT3-02 SPEAKER CIRCUIT (NAVIGATION VOICE) CIRCUIT DESCRIPTION This circuit is used when the voice guidance in the navigation system is on. WIRING DIAGRAM T11 Front No.2 Speaker Assy LH R 3 F10 Front No.1 Speaker Assy LH Navigation ECU P 7 IB1 P 10 IF3 G 2 N3 AUO+ V 6 IB1 G 20 IF3 B 11 N3 AUO- 1 1 2 W 4 2 I39193 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2039 05-1850 DIAGNOSTICS - NAVIGATION SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(FRONT NO. 2 SPEAKER ASSY NAVIGATION ECU) (a) Navigation ECU: (b) N3 AUO+ AUO- Disconnect the connectors from the navigation ECU and speaker. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition AUO+ - T11-1 Always Below 1 Ω AUO- - T11-2 Always Below 1 Ω AUO+ - Body ground Always 10 kΩ or higher AUO- - Body ground Always 10 kΩ or higher Wire Harness Side: Front No.2 Speaker Assy T11 NG I40178 I38999 REPAIR OR CONNECTOR REPLACE HARNESS OR I40553 OK 2 (a) INSPECT FRONT NO. 2 SPEAKER ASSY Check that malfunction disappears when another speaker in a good condition is installed. OK: Malfunction disappears HINT:

Connect all the connectors to the speakers. When there is a possibility that either right or left front speaker is defective, inspect by interchanging the right one and the left one. OK REPLACE FRONT NO. 2 SPEAKER ASSY (SEE PAGE 67-1 1) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2040 05-1851 DIAGNOSTICS 3 - NAVIGATION SYSTEM CHECK HARNESS AND CONNECTOR(FRONT NO. 2 SPEAKER ASSY - FRONT NO. 1 SPEAKER ASSY) (a) Wire Harness Side: Front No.2 Speaker Assy T11 (b) Wier Harness Side: Front No.1 Speaker Assy Disconnect the connectors from the front No.2 speaker assy and front No.1 speaker assy. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 3 (No.2 speaker) 1 (No.1 speaker) Always Below 1 Ω 4 (No.2 speaker) 2 (No.1 speaker) Always Below 1 Ω 3 (No.2 speaker) Body ground Always 10 kΩ or higher 4 (No.2 speaker) Body ground Always 10 kΩ or higher F10 I38999 I38233 NG I40554 REPAIR OR CONNECTOR REPLACE HARNESS OR OK 4 INSPECT FRONT NO. 1 SPEAKER ASSY (a) Resistance check. (1) Measure the resistance between the terminals of the speaker. NOTICE: The speaker should not be removed for checking. Standard: Approximately 4 Ω NG REPLACE FRONT NO. 1 SPEAKER ASSY (SEE PAGE 67-10 ) OK REPLACE NAVIGATION ECU (SEE PAGE 67-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2041 05-1830 DIAGNOSTICS - NAVIGATION SYSTEM 05CEG-08 POWER SOURCE CIRCUIT (NAVIGATION ECU) CIRCUIT DESCRIPTION This circuit provides power to the navigation ECU. WIRING DIAGRAM Instrument Panel J/B RAD No.2 2 1C Navigation ECU Center J/B 3 1K V 13 3A 9 3F 10 3I 7 3I GR W 18 N3 ACC 9 N3 +B Passenger Side J/B LG 11 IL2 I15 IGNITION SW L W 3 ACC AM1 F7 FL Block 6 4H 11 4D V 2 1 12 IK3 Instrument Panel J/B AM1 1 6 1C 1A 2 1 ALT W V B 2 W 3 Engine Room J/B D.C.C DOME 1 2I 3 2A V 2 3I W-B Center J/B W-B 13 3F 17 N3 GND1 FL MAIN Battery IB I39189 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2020 05-1831 DIAGNOSTICS - NAVIGATION SYSTEM INSPECTION PROCEDURE 1 INSPECT NAVIGATION ECU(+B, ACC, GND1) (a) (b) N3 +B Tester connection Condition Specified condition GND1 - Body ground Always Below 1 Ω (c) ACC GND1 I40178 Disconnect the navigation ECU connector N3. Measure the resistance according to the value(s) in the table below. Standard: Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition +B - GND1 Always 10 to 14 V ACC - GND1 Ignition SW ACC 10 to 14 V NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE OR DIAGNOSTIC TROUBLE CODE CHART (SEE PAGE 05-1778 OR 05-1791 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2021 05-1838 DIAGNOSTICS - NAVIGATION SYSTEM 05IT0-02 SPEED SIGNAL CIRCUIT (NAVIGATION ECU - COMBINATION METER ASSY) CIRCUIT DESCRIPTION The navigation ECU receives the vehicle speed signal and information about the GPS antenna, and then adjusts the vehicle position. WIRING DIAGRAM Combination Meter Assy Navigation ECU Center J/B 13 C12 W 9 3J 12 3K O 5 N3 SPD I39191 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2028 05-1839 DIAGNOSTICS - NAVIGATION SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(COMBINATION METER ASSY NAVIGATION ECU) (a) Navigation ECU: (b) N3 SPD Disconnect the connector from the navigation ECU N3 and combination meter assy C12. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition SPD - C12-13 Always Specified condition Below 1 Ω SPD - Body ground Always 10 kΩ or higher I40178 Combination Meter Assy: C12 13 NG I40181 REPAIR OR CONNECTOR REPLACE HARNESS OR OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2029 05-1840 DIAGNOSTICS 2 - NAVIGATION SYSTEM INSPECT COMBINATION METER ASSY (a) (b) C12 13 I40187 Connect the combination meter assy connector C12. Measure voltage. (1) Adjust the shift lever to the neutral position. (2) Jack up either one of the front wheels. (3) Turn ignition switch to the ON position. (4) Measure the voltage between terminal C12-13 and body ground of combination meter assy when the front wheels are turned slowly. OK: Voltage is pulsed as shown below. IG Voltage (9 to 14 V) Below 2 V 0 NG Turn the wheel GO TO COMBINATION METER SYSTEM (SEE PAGE 05-1868 ) OK REPLACE NAVIGATION ECU (SEE PAGE 67-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2030 05-1866 DIAGNOSTICS - NAVIGATION SYSTEM 05ITA-02 AVC-LAN CIRCUIT (RADIO RECEIVER ASSY - MULTI-DISPLA Y) CIRCUIT DESCRIPTION Each unit of the navigation system connected to AVC-LAN (communication bus) communicates by transferring the signals from each switch. When +B short and GND short occur in this AVC-LAN, navigation system will not function normally as communication is discontinued. In AVC-LAN, multi-display becomes the communication master, and the radio receiver assy has enough resistance necessary for transmitting the communication. WIRING DIAGRAM Radio Receiver Assy Multi-Display 9 TX+ R22 LG *1 13 M4 TX+ 10 TX- R22 O *1 14 M4 TX- *1: w/o Rear Seat Entertainment System I34965 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2056 05-1867 DIAGNOSTICS - NAVIGATION SYSTEM INSPECTION PROCEDURE 1 INSPECT RADIO RECEIVER ASSY (a) R22 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition TX+ - TX- Always 60 to 80 Ω TXTX+ I40221 NG REPLACE RADIO RECEIVER ASSY (SEE PAGE 67-6 ) OK 2 CHECK HARNESS AND CONNECTOR(RADIO RECEIVER ASSY MULTI-DISPLA Y) (a) Radio Receiver Assy: R22 (b) Disconnect the connector from the radio receiver assy and multi-display. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition TX+ - TX+ Always Below 1 Ω TX- - TX- Always Below 1 Ω TX+ - Body ground Always 10 kΩ or higher TX- - Body ground Always 10 kΩ or higher TX+ TX- I40185 Multi-Display: M4 TX+ TX- NG I38998 REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN DIAGNOSTIC TROUBLE CODE CHART (SEE PAGE 05-1791 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2057 05-1828 DIAGNOSTICS - NAVIGATION SYSTEM 05CEF-10 POWER SOURCE CIRCUIT (MULTI-DISPLA Y) CIRCUIT DESCRIPTION This circuit provides power to the multi-display. WIRING DIAGRAM Instrument Panel J/B Multi-Display Center J/B 7 1C ECU-IG 9 1K R 1 3A 7 3G O 10 M3 IG 2 1C RAD No.2 3 1K V 13 3A 3 3E BR 11 M3 ACC V 12 M3 +B1 G L J17 J/C 16 IK2 V 6 IL1 V A A Engine Room R/B CRT V 2 I15 IGNITION SW ACC 3 4 AM1 1 Instrument Panel J/B 6 1C W IG1 2 2 2 AM1 2 1 1A 1 F7 FL Block ALT W 1 B 2 W 3 FL MAIN Battery Center J/B W-B 13 3F 6 3I W-B 3 M3 GND1 IB I39188 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2018 05-1829 DIAGNOSTICS - NAVIGATION SYSTEM INSPECTION PROCEDURE 1 INSPECT MULTI-DISPLA Y(+B1, ACC, IG, GND1) (a) (b) IG ACC M3 +B1 GND1 Tester connection Condition Specified condition GND1 - Body ground Always Below 1 Ω (c) I38678 Disconnect the multi-display connector M3. Measure the resistance according to the value(s) in the table below. Standard: Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition +B1 - GND1 Always 10 to 14 V ACC - GND1 Ignition SW ACC 10 to 14 V IG - GND1 Ignition SW ON 10 to 14 V NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE OR DIAGNOSTIC TROUBLE CODE CHART (SEE PAGE 05-1778 OR 05-1791 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2019 05-1841 DIAGNOSTICS - NAVIGATION SYSTEM 05CEI-08 SPEED SIGNAL CIRCUIT (MULTI-DISPLA Y - COMBINATION METER ASSY CIRCUIT DESCRIPTION The multi-display performs the switch operation control during running by receiving the vehicle speed signal from the combination meter assy. WIRING DIAGRAM Multi-Display Combination Meter Assy Center J/B 13 C12 W 9 3J 6 3F W 25 M3 SPD I39195 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2031 05-1842 DIAGNOSTICS - NAVIGATION SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(COMBINATION METER ASSY MULTI-DISPLA Y) (a) Multi-Display: (b) M3 SPD Disconnect the connector from the multi-display M3 and combination meter assy C12. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition SPD - C12-13 Always Specified condition Below 1 Ω SPD - Body ground Always 10 kΩ or higher I38678 Combination Meter Assy: C12 13 NG I40181 REPAIR OR CONNECTOR REPLACE HARNESS OR OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2032 05-1843 DIAGNOSTICS 2 - NAVIGATION SYSTEM INSPECT COMBINATION METER ASSY (a) (b) C12 13 I40187 Connect the combination meter assy connector C12. Measure voltage. (1) Adjust the shift lever to the neutral position. (2) Jack up either one of the front wheels. (3) Turn ignition switch to the ON position. (4) Measure the voltage between terminal C12-13 and body ground of combination meter assy when the front wheels are turned slowly. OK: Voltage is pulsed as shown below. IG Voltage 9 to 14 V Below 2 V 0 NG Turn the wheel GO TO COMBINATION METER SYSTEM (SEE PAGE 05-1868 ) OK REPLACE MULTI-DISPLA Y(SEE PAGE 67-8 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2033 05-1852 DIAGNOSTICS - NAVIGATION SYSTEM 05IT4-02 DISPLAY SIGNAL CIRCUIT (NAVIGATION ECU - MULTI-DISPLA Y) CIRCUIT DESCRIPTION This is the display signal circuit from the navigation ECU to the multi-display. WIRING DIAGRAM Navigation ECU Multi-display Assy 24 R M4 W 2 N4 R 25 G M4 R 7 N4 G 26 M4 G 3 N4 B 23 VR M4 B 1 N4 VR 27 SYNC M4 Y B 28 VG M4 8 N4 6 N4 Shielded SYNC VG I39192 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2042 05-1853 DIAGNOSTICS - NAVIGATION SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(NAVIGATION ECU - MULTI-DISPLA Y) (a) Navigation ECU: (b) N4 R B VR VG SYNC G I40183 Multi-Display: M4 VG SYNC B VR G R I38998 Disconnect the connector from the navigation ECU N4 and multi-display M4. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition R (N4) - R (M4) Always Below 1 Ω G (N4) - G (M4) Always Below 1 Ω B (N4) - B (M4) Always Below 1 Ω SYNC (N4) - SYNC (M4) Always Below 1 Ω VR (N4) - VR (M4) Always Below 1 Ω VG (N4) - VG (M4) Always Below 1 Ω R (N4 or M4) Body ground Always 10 kΩ or higher G (N4 or M4) Body ground Always 10 kΩ or higher B (N4 or M4) Body ground Always 10 kΩ or higher SYNC (N4 or M4) Body ground Always 10 kΩ or higher VR (N4 or M4) Body ground Always 10 kΩ or higher VG (N4 or M4) Body ground Always 10 kΩ or higher NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN ON PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1778 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2043 05-1860 DIAGNOSTICS - NAVIGATION SYSTEM 05IT7-02 AVC-LAN CIRCUIT (NAVIGATION ECU - MULTI-DISPLA Y) CIRCUIT DESCRIPTION Each unit of the navigation system connected to AVC-LAN (communication bus) communicates by transferring the signals from each switch. When +B short and GND short occur in this AVC-LAN, navigation system will not function normally as communication is discontinued. In AVC-LAN, multi-display becomes the communication master, and the radio receiver assy has enough resistance necessary for transmitting the communication. WIRING DIAGRAM Multi-display Navigation ECU 4 TX1+ M3 SB 5 N4 TX+ 5 M3 BR 10 N4 TX- TX1- I39190 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2050 05-1861 DIAGNOSTICS - NAVIGATION SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(NAVIGATION ECU - MULTI-DISPLA Y) (a) Navigation ECU: (b) N4 TX+ TX- I40183 Multi-Display: Disconnect the connector from the navigation ECU N4 and multi-display M3. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition TX1+ - TX+ Always Below 1 Ω TX1- - TX- Always Below 1 Ω TX1+ Body ground Always 10 kΩ or higher TX1- Body ground Always 10 kΩ or higher M3 TX1- TX1+ I38678 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN DIAGNOSTIC TROUBLE CODE CHART (SEE PAGE 05-1791 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2051 05-1862 DIAGNOSTICS - NAVIGATION SYSTEM 05IT8-02 AVC-LAN CIRCUIT (MULTI-DISPLA Y - GATEWAY ECU) CIRCUIT DESCRIPTION Each unit of the navigation system connected to AVC-LAN (communication bus) communicates by transferring the signals from each switch. When +B short and GND short occur in this AVC-LAN, navigation system will not function normally as communication is discontinued. In AVC-LAN, multi-display becomes the communication master, and the radio receiver assy has enough resistance necessary for transmitting the communication. WIRING DIAGRAM Multi-Display Gateway ECU 11 TX3+ M4 BR 5 G5 GTX+ 12 M4 L 12 G5 GTX- TX3- I34966 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2052 05-1863 DIAGNOSTICS - NAVIGATION SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(MULTI-DISPLA Y - GATEWAY ECU) (a) Multi-Display: (b) M4 TX3+ TX3- I38998 Disconnect the connector from the multi-display M4 and gateway ECU G5. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition TX3+ - GTX+ Always Below 1 Ω TX3- - GTX- Always Below 1 Ω TX3+ - Body ground Always 10 kΩ or higher TX3- - Body ground Always 10 kΩ or higher Gateway ECU: G5 GTX+ GTXI40180 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN DIAGNOSTIC TROUBLE CODE CHART (SEE PAGE 05-1791 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2053 05-1764 DIAGNOSTICS - NAVIGATION SYSTEM 05IS3-02 NAVIGATION CHECK MODE (GPS INFORMATION) HINT:

1. This mode displays GPS satellite information. Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. Enter diagnostic mode (see page 05-1784 ). 2. Select ”Navigation Check” from the ”Diagnosis MENU” screen. 3. Select ”GPS Information” from the ”Navigation Check” screen. 4. When GPS information is displayed, check the GPS conditions. I38224 I38225 HINT: This screen is updated once per second when input signals to the vehicle are changed. I38226 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1954 05-1766 DIAGNOSTICS - NAVIGATION SYSTEM 05IS5-02 NAVIGATION CHECK MODE (NAVI COLOR BAR CHECK) HINT:

1. This mode checks the color display on the navigation ECU. Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. Enter diagnostic mode (see page 05-1784 ). 2. Select ”Navigation Check” from the ”Diagnosis MENU” screen. 3. Select ”Color Bar Check” from the ”Navigation Check” screen. 4. Check each color of the color bar when the ”NAVI Color Bar Check” screen is displayed. I38224 I38229 HINT: Colors will not be displayed full-screen as in ”Display Check Mode”. I38230 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1956 05-1767 DIAGNOSTICS - NAVIGATION SYSTEM 05IS6-02 NAVIGATION CHECK MODE (PARTS INFORMATION) HINT:

1. This mode displays product information on the navigation systems and discs. Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. Enter diagnostic mode (see page 05-1784 ). 2. Select ”Navigation Check” from the ”Diagnosis MENU” screen. 3. Select ”Parts Information” from the ”Navigation Check” screen. 4. Check the navigation and disc information when the ”Parts Information” screen is displayed. I38224 I38231 *1 *2 *3 *4 I38232 Display Navigation Manufacturer/*1 Contents Navigation ECU manufacturer name is displayed. Navigation Version/*2 Navigation ECU version is displayed. Disc Manufacturer/*3 Map disc manufacturer is displayed. Disc Version/*4 Map disc version is displayed. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1957 05-1765 DIAGNOSTICS - NAVIGATION SYSTEM 05IS4-02 NAVIGATION CHECK MODE (VEHICLE SENSORS) HINT:

1. This mode checks the vehicle signal status to the navigation ECU. Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. Enter diagnostic mode (see page 05-1784 ). 2. Select ”Navigation Check” from the ”Diagnosis MENU” screen. 3. Select ”Vehicle Sensors” from the ”Navigation Check” screen. 4. Check all the signals and sensors when vehicle signal information is displayed. I38224 I38227 HINT: This screen is updated once per second when input signals to the vehicle are changed. I38228 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1955 05-1778 DIAGNOSTICS - NAVIGATION SYSTEM 05IS9-02 PROBLEM SYMPTOMS TABLE HINT:

Before performing verification listed in the table below, check the fuse and relay. Methods used to verify the cause of the problem are listed in order of probability in the verification column.
If there are two or more parts to be replaced in the verification column, check the symptom after replacing each part. If the symptom still occurs, replace the following part in the colummn. Display function Symptom Verification See page 05-1805 Black screen (No image appears on navigation/audio screen). 1. ”BLACK SCREEN (NO IMAGE APPEARS ON NAVIGATION AND AUDIO SCREEN)” 2. Power source circuit (multi-display) 3. Replace multi-display 1. ”ILLUMINATION FOR PANEL SWITCH DOES NOT COME ON WITH TAIL SWITCH ON” 2. Dimmer signal circuit 3. Replace multi-display 05-1806 Illumination for panel switch does not come on with TAIL switch on. 05-1807 Display does not dim (Night Screen) with TAIL switch on. 1. ”DISPLAY DOES NOT DIM (NIGHT SCREEN) WITH TAIL SWITCH ON” 2. Replace multi-display 3. Replace gateway ECU 4. Replace combination meter assy Power does not turn off (The screen remains on). 1. Power source circuit (multi-display) 2. Replace multi-display 05-1828 67-8 Panel switch does not function. 1. ”PANEL SWITCH DOES NOT FUNCTION” 2. Power source circuit (multi-display) 3. Replace multi-display 05-1808 05-1828 67-8 Touch panel switch does not function. 1. ”TOUCH PANEL SWITCH DOES NOT FUNCTION” 2. Power source circuit (multi-display) 3. Replace multi-display 05-1809 05-1828 67-8 Screen is distorted. 1. Display signal circuit (navigation ECU - multi-display) 2. Replace navigation ECU 3. Replace multi-display 05-1852 67-9 67-8 Screen flicker or color distortion. 1. 2. 3. 4. 05-1810 05-1852 67-9 67-8 Switches can be operated while vehicle is running 1. Speed signal circuit (multi-display - combination meter assy) 05-1841 DVD image cannot be displayed on front screen. (Parking brake is on.) *1 1. Parking brake switch circuit 05-1846 ”SCREEN FLICKER OR COLOR DISTORTION” Display signal circuit (navigation ECU - multi-display) Replace navigation ECU Replace multi-display 05-1828 67-8 05-1854 67-8 67-8 67-21 71-18 *1: w/ Rear Seat Entertainment System 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1968 05-1779 DIAGNOSTICS - NAVIGATION SYSTEM Navigation function Symptom Verification See page Map disc cannot be inserted. 1. ”MAP DISC CANNOT BE INSERTED” 2. Power source circuit (navigation ECU) 3. Replace navigation ECU 05-1812 05-1830 67-9 Vehicle position mark deviates greatly. 1. ”VEHICLE POSITION MARK DEVIATES GREATLY” 2. Replace GPS antenna assy 3. Replace navigation ECU 05-1813 67-19 67-9 1. ”CURSOR OR MAP ROTATES WHEN VEHICLE IS STOPPED” 2. Replace navigation ECU 05-1815 Cursor or map rotates when vehicle is stopped. Vehicle position mark is not updated. 1. ”VEHICLE POSITION MARK IS NOT UPDATED” 2. Replace map disc 3. Replace navigation ECU 05-1816 67-9 05-1817 Current position display does not appear. 1. ”CURRENT POSITION DISPLAY DOES NOT APPEAR” 2. Replace map disc 3. Replace navigation ECU GPS mark is not displayed. 1. ”GPS MARK IS NOT DISPLAYED” 2. Replace GPS antenna assy 3. Replace navigation ECU 05-1818 67-19 67-9 Voice guidance does not function. 1. ”VOICE GUIDANCE DOES NOT FUNCTION” 2. Speaker circuit (navigation voice) 05-1820 05-1849 Map display is incomplete. 1. ”MAP DISPLAY INCOMPLETE” 2. Replace map disc 3. Replace navigation ECU 05-1823 67-9 Route cannot be calculated. 1. ”ROUTE CANNOT BE CALCULATED” 2. Replace map disc 3. Replace navigation ECU 05-1824 67-9 67-9 67-9 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1969 05-1844 DIAGNOSTICS - NAVIGATION SYSTEM 05IT1-02 REVERSE SIGNAL CIRCUIT CIRCUIT DESCRIPTION The navigation ECU receives the reverse signal from the park/neutral position switch and information about the GPS antenna, and then adjusts the vehicle position. WIRING DIAGRAM P1 Park/Neutral Position Switch Navigation ECU Center J/B 11 IF3 G 1 3C 13 3K Y 14 N3 RL Passenger Side J/B GR RL 13 4K 6 4A L 20 IM1 R-B 1 I39194 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2034 05-1845 DIAGNOSTICS - NAVIGATION SYSTEM INSPECTION PROCEDURE 1 (a) INSPECT REVERSE POSITION INDICATOR(COMBINATION METER ASSY) When moving the shift lever to the R position, check if ”R” lights up in the combination meter. OK: ”R” lights up. NG Go to step 3 OK 2 INSPECT NAVIGATION ECU(RL) (a) (b) N3 Disconnect the navigation ECU connector N3. Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition RL - Body ground Shift lever R position → Except R position 10 to 14 V → Below 1 V NG RL I40178 REPAIR OR CONNECTOR REPLACE HARNESS OR OK REPLACE NAVIGATION ECU (SEE PAGE 67-9 ) 3 INSPECT PARK/NEUTRAL POSITION SWITCH ASSY (a) (b) Park/Neutral Position Switch Assy: P1 Disconnect the park/neutral position switch connector. Measure the resistance according to the value(s) in the table below. Standard: Tester connection G26080 Condition Specified condition P1-1 - P1-2 Shift lever is moved to R position. P1-1 - P1-2 Shift lever is moved to except R position. NG Below 1 Ω 10 kΩ or higher REPLACE PARK/NEUTRAL POSITION SWITCH ASSY OK REPAIR OR REPLACE HARNESS OR CONNECTOR 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2035 05-1836 DIAGNOSTICS - NAVIGATION SYSTEM 05ISZ-02 POWER SOURCE CIRCUIT(MULTI-DISPLA Y CONTROLLER SUB-ASSY) CIRCUIT DESCRIPTION This circuit provides power to the multi-display controller sub-assy. WIRING DIAGRAM J17 J/C Engine Room R/B W *1 CRT 1 16 IK2 V *1 2 2 V *1 Passenger Side J/B 8 4D A G A A B 1 1H RAD No.2 1 1A AM1 1 F7 FL Block 2 1C 6 1C I15 Ignition SW L 3 ACC 2 AM1 W 2 7 W-B 2 ALT R31 SELD C W J18 J/C 1 3 16 R29 +B1 32 R29 ACC G *1 Instrument Panel J/B Y Y *1 J18 J/C 14 IO1 W 21 IO2 V *1 A 2 2 4E Multi-display Controller Sub-assy C W-B 29 R29 GND C W-B FL MAIN BF Battery *1: w/ Rear Seat Entertainment System I37210 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2026 05-1837 DIAGNOSTICS - NAVIGATION SYSTEM INSPECTION PROCEDURE 1 INSPECT MULTI-DISPLA Y CONTROLLER SUB-ASSY(+B1, ACC, GND, SELD) R29 (a) R31 (b) +B1 ACC GND SELD I37211 (c) Disconnect the connectors from the multi-display controller sub-assy. Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition GND - Body ground Always Below 1 Ω SELD - Body ground Always Below 1 Ω Measure the voltage according to the value(s) in the table below. Standard: Tester connection Condition Specified condition +B1 - GND Always 10 - 14 V ACC - GND Ignition SW ACC 10 - 14 V NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN DIAGNOSTIC TROUBLE CODE CHART (SEE PAGE 05-1791 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2027 05-1803 DIAGNOSTICS - NAVIGATION SYSTEM 05ISE-02 SCREEN NOISE AUTOMATIC ADJUSTMENT HINT:


1. This adjustment is performed to reduce noise when screen noise occurs upon replacing the multi-display, the navigation ECU or the television camera ECU. Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. Perform both procedures below when the multi-display is replaced. When either the multi-display or the navigation ECU is replaced: (a) (b) Turn the ignition switch to the ACC position and wait for at least 6 seconds to activate the diagnostic mode (see page 05-1784 ). Select ”Navigation Check” from the ”Diagnosis MENU” screen. I39965 (c) Completion mark (orange) (d) The screen enters ”Navigation Check” with a beeping sound. Adjustment is completed when the completion mark is displayed. Cancel the diagnostic mode (see page 05-1784 ). I38225 2. When either the multi-display or the television camera ECU is replaced: (a) (b) Turn the ignition switch to the ACC position and wait for at least 6 seconds to activate the diagnostic mode (see page 05-1784 ). Select ”Camera Check” from the ”Diagnosis MENU” screen. I39965 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1993 05-1804 DIAGNOSTICS (c) (d) HINT:
I39966
- NAVIGATION SYSTEM Adjustment is completed when the steering angle setting screen is displayed. Cancel the diagnostic mode (see page 05-1784 ). If the automatic adjustment is not performed (only step 1) only upon replacing the multi-display, a beeping sound can be heard for 3 seconds (while the initial screen is displayed) after turning the ignition switch to the ACC position. Perform the automatic adjustment again if a beeping sound can be heard within 3 seconds. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1994 05-1751 DIAGNOSTICS - NAVIGATION SYSTEM 05IRW-01 SYSTEM DESCRIPTION 1. (a) Navigation system outline Vehicle position tracking methods It is essential that the navigation system correctly tracks the current vehicle position and displays it on the map. There are 2 methods to track the current vehicle position: autonomous (dead reckoning) and GPS* (satellite) navigation. Both navigation methods are used in conjunction with each other. *GPS (Global Positioning System) GPS satellite Navigation ECU Location by autonomous navigation Gyro Sensor Location by GPS navigation GPS Antenna ECU Vehicle Speed Sensor Navigation ECU GPS Antenna Receive satellite radio wave Detect the measurement position Vehicle Speed Sensor Detect vehicle running distance GPS correction Create the current vehicle position tracking data Detect direction change Gyro Sensor Map matching correction Map disc Multi-display Map and current vehicle position data processing Navigation screen Map scrolling Map scale switching I39857 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1941 05-1752 DIAGNOSTICS - NAVIGATION SYSTEM Operation Description Vehicle Position Calculation The navigation ECU calculates the current vehicle position (direction and current position) using the direction deviation signal from the gyro sensor and the running distance signal from the vehicle speed sensor and creates the driving route. Map Display processing The navigation ECU displays the vehicle track on the map by processing the vehicle position data, vehicle running track, and map data from the map disc. Map Matching The map data from the map disc is compared to the vehicle position and running track data. Then, the vehicle position is matched with the nearest road. GPS Correction The vehicle position is matched to the position measured by GPS. Then, the measurement position data from the GPS unit is compared with the vehicle position and running track data. If the position is widely different, the GPS measurement position is used. Distance Correction The running distance signal from the vehicle speed sensor includes the error caused by tire wear and slippage between the tires and road surface. Distance correction is performed to account for this. The navigation ECU automatically offsets the running distance signal to make up for the difference between it and the distance data of the map. The offset is automatically updated. HINT: The combination of autonomous and GPS navigation makes it possible to display the vehicle position even when the vehicle is in places where the GPS radio wave cannot receive a signal. When only autonomous navigation is used, however, the mapping accuracy may slightly decline. GPS satellite Navigation performed even where the GPS radio wave does not reach.
In a tunnel
In an indoor parking lot
Between tall buildings
Under an overpass
On a forest or tree-lined path Autonomous navigation Autonomous navigation and GPS navigation I38172 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1942 05-1753 DIAGNOSTICS (b) (c) - NAVIGATION SYSTEM Autonomous navigation This method determines the relative vehicle position based on the running track determined by the gyro and vehicle speed sensors located in the navigation ECU. (1) Gyro sensor Calculates the direction by detecting angular velocity. It is located in the radio and navigation assy. (2) Vehicle speed sensor Used to calculate the vehicle running distance. GPS navigation (Satellite navigation) This method detects the absolute vehicle position using radio wave from a GPS satellite. * GPS satellites were launched by the U.S. Department of Defence for military purposes. Current longitude/latitude/altitude is determined using the radio wave arrival time from four satellites. GPS I38174 Number of satellites Measurement 2 or less Measurement impossible Vehicle position cannot be obtained because the number of satellites is not enough. Description 3 2-dimensional measurement is possible Vehicle position is obtained based on the current longitude and latitude. (This is less precise than 3-dimensional measurement) 4 3-dimensional measurement is possible Vehicle position is obtained based on the current longitude, latitude and altitude. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1943 05-1754 DIAGNOSTICS (d) - NAVIGATION SYSTEM Map matching The current driving route is calculated by autonomous navigation (according to the gyro sensor and vehicle speed sensor) and GPS navigation. This information is then compared with possible road shapes from the map data in the map disc and the vehicle position is set onto the most appropriate road. Start Actual driving route Driving route on the display (Route by estimation) Roads A The system compares the shape of the roads L1, L2 and L3 to the estimated running track after the vehicle makes a right turn. At point A, the vehicle position differs enough from the shape of L1 that the display switches to the road L2. Map Matching I38177 2. DVD (Digital Versatile Disc) player outline (for navigation map) (a) The navigation ECU uses a laser pickup to read the digital signals recorded on a DVD. HINT:  Do not disassemble any part of the navigation ECU.  Do not apply oil to the navigation ECU.  Do not insert anything but a DVD into the navigation ECU. CAUTION: Because the navigation ECU uses an invisible laser beam, do not look directly at the laser pickup. Be sure to only operate the navigation as instructed. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1944 05-1755 DIAGNOSTICS 3. (a) - NAVIGATION SYSTEM Multi-display outline Touch switch Touch switches are touch-sensitive (interactive) switches operated by touching the screen. When a switch is pressed, the outer glass bends in to contact the inner glass at the pressed position. By doing this, the voltage ratio is measured and the pressed position is detected. Outer Inner Vx1 (Vy1) Vy1 Glass Contact Vx1 Vx2 Vy2 Vx2 (Vy2) The touch switch detects the voltage ratio and calculates the position on the screen. Touch-sensitive switch position I38179 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1945 05-1756 DIAGNOSTICS 4. (a) - NAVIGATION SYSTEM AVC-LAN Description What is AVC-LAN? AVC-LAN, an abbreviation for ”Audio Visual Communication Local Area Network”, is a unified standard developed by the manufacturers in affiliation with Toyota Motor Corporation. This standard pertains to audio and visual signals as well as switch and communication signals. Example: Radio Receiver Assy (Resister 60 to 80 Ω) AVC-LAN Multi-display I39082 (b) Purpose: Recently, car audio systems have rapidly developed and the functions vastly changed. The conventional car audio system is being integrated with multi-media interfaces similar to those in navigation systems. At the same time, customers are demanding higher quality from their audio systems. This is merely an overview of the standardization background. The specific purposes are as follows. (1) To solve sound problems, etc. caused by using components of different manufacturers through signal standardization. (2) To allow each manufacturer to concentrate on developing products they do best. From this, reasonably priced products can be produced. HINT:      5. (a) (b) (c) 6. (a) (b) If a +B or GND short is detected in the AVC-LAN circuit, communication is interrupted and the audio system will stop functioning. If an audio system is equipped with a navigation system, the multi-display unit acts as the master unit. If the navigation system is not equipped, the audio head unit acts as the master unit instead. If the radio and navigation assy is equipped, it is the master unit. The radio receiver assy provides resistance to make communication possible. The car audio system with an AVC-LAN circuit has a diagnostic function. Each component has a specified number (3-digit) called a physical address. Each function has a number (2-digit) called a logical address. Communication system outline Components of the navigation system communicate with each other via the AVC-LAN. Radio receiver assy has enough resistance (60 to 80 Ω) necessary for transmitting the communication. This is essential for communication. If a short circuit or open circuit occurs in the AVC-LAN circuit, communication is interrupted and the navigation system will stop functioning. Diagnostic function outline The audio system has a diagnostic function (the result is indicated on the master unit). A 3-digit hexadecimal component code (physical address) is allocated to each component on the AVC-LAN. Using this code, the component in the diagnostic function can be displayed. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1946 05-1775 DIAGNOSTICS - NAVIGATION SYSTEM 05IS8-02 SYSTEM NORMAL CONDITION CHECK (f) If the symptom is applicable to any of the following, it is intended behavior, and not a malfunction. Symptom Answer A longer route than expected is chosen. Depending on the road conditions, the navigation ECU may determine that a longer route is quicker. Even when distance priority is high, the shortest route is not shown. Some paths may not be advised due to safety concerns. When the vehicle is put into motion immediately after the engine starts, the navigation system deviates from the actual position. If the vehicle starts before the navigation system activates, the system may not react. When running on certain types of roads, especially new roads, the vehicle position deviates from the actual position. When the vehicle is driving on new roads not available on the map disc, the system attempts to match it to another nearby road, causing the position mark to deviate. (g) The following symptoms are not a malfunction, but are caused by errors inherent in the GPS, gyro sensor, speed sensor, and navigation ECU. (1) The current position mark may be displayed on a nearby parallel road the vehicle actually runs on. I38139 (2) Immediately after a fork in the road, the current vehicle position mark may be displayed on the wrong road. (3) When the vehicle turns right or left at an intersection, the current vehicle position mark may be displayed on a nearby parallel road. I38140 I38141 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1965 05-1776 DIAGNOSTICS - NAVIGATION SYSTEM (4) When the vehicle is carried, such as on a ferry, and the vehicle itself is not running, the current vehicle position mark may be displayed in the position where the vehicle was until a measurement can be performed by GPS. (5) When the vehicle runs on a steep hill, the current vehicle position mark may deviate from the correct position. (6) When the vehicle makes a continuous turn of 360, 720, 1,080, etc. degrees, the current vehicle position mark may deviate from the correct position. (7) When the vehicle moves erratically, such as constant lane changes, the current vehicle position mark may deviate from the correct position. (8) When the ignition switch is put into the ACC/OFF position on a turn table before parking, the current vehicle position mark may not point in the correct direction. The same will occur when the vehicle comes out of parking. I38142 I38143 I38144 I38145 I38146 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1966 05-1777 DIAGNOSTICS - (9) NAVIGATION SYSTEM When the vehicle runs on the snowy road or a mountain path with the chains installed or using a spare tire, the current vehicle position mark may deviate from the correct position. I38147 (10) When a tire is changed, the current vehicle position mark may deviate from the correct position. HINT:

Diameter of the tire may change, causing a speed sensor error. Performing the ”tire change” in calibration mode will allow the system to correct the current vehicle position faster. I38148 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1967 05-1789 DIAGNOSTICS - NAVIGATION SYSTEM 05ISC-02 SYSTEM CHECK MODE (DTC CLEAR/RECHECK) HINT: Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. 1. Enter the diagnostic mode (see page 05-1784 ). 2. (a) Clear DTC Press the ”Code CLR” switch for 3 seconds. (b) 3. (a) Check result is cleared. Recheck Press the ”Recheck” switch. I38211 I38212 (b) Confirm that all diagnostic codes are ”OK” when the check results are displayed. If a code other than ”OK” is displayed, troubleshoot again. I38213 (c) Press the ”LAN Mon” switch to change to ”LAN Monitor” mode. I38213 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1979 05-1790 DIAGNOSTICS - NAVIGATION SYSTEM (d) Confirm that all diagnostic codes are ”No Err”. If a code other than ”No Err” is displayed, troubleshoot again. I38214 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1980 05-1786 DIAGNOSTICS - NAVIGATION SYSTEM 05ISB-02 SYSTEM CHECK MODE (DTC CHECK) HINT: Illustrations may differ from the actual vehicle depending on the device settings and options. Therefore, some detailed areas may not be shown exactly the same as on the actual vehicle. 1. Enter the diagnostic mode (see page 05-1784 ). 2. (a) Read the system check result. If all check results of other devices are ”EXCH,” ”CHEK” or ”Old,” touch the display to check the contents on the ”Unit Check Mode” screen and record them on the customer problem analysis check sheet. HINT:

Diagnostic Code Logical Address If all check results are ”OK,” go to communication DTC check (go to step 3). If a device name is not known, its physical address is displayed. I38206 HINT: If ”EXCH”, ”CHEK” and ”Old” as well as ”OK” exist, press the service switch to return to the ”System Check Mode”. Then, check the ”Unit Check Mode” screen and record them on the customer problem analysis check sheet. Diagnostic Code Logical Address I38207 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1976 05-1787 DIAGNOSTICS - NAVIGATION SYSTEM 3. (a) Read the communication diagnostic check result. Return to the ”System Check Mode”, and press ”LAN Mon” switch to enter the LAN monitor screen. (b) If the result is ”CHEK” or ”Old,” touch the result switch to check the contents on the individual communication diagnostic screen and record them on the customer problem analysis check sheet. I38208 HINT:

Diagnostic Code Logical Address If all check results are ”No Err,” the system judges that no DTC exists. The sub-code (relevant device) will be indicated by its physical address. Sub-Code I38209 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1977 05-1788 DIAGNOSTICS - NAVIGATION SYSTEM HINT: If check results of other devices are ”CHEK,” press the ”Service” switch to return to the original ”LAN Monitor” screen. Then, check the individual communication diagnostic screen for the next device and record the result on the customer problem analysis check sheet. I38210 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1978 05-1749 DIAGNOSTICS - NAVIGATION SYSTEM NAVIGATION SYSTEM 05IRV-01 SYSTEM DIAGRAM : AVC-LAN Front Driver Side Speaker GPS Antenna Vehicle Speed Signal Reverse Signal Navigation ECU RGB Image Signal Gateway ECU Multi-display *1 Radio Receiver Assy Vehicle Speed Signal Parking Brake Signal *2 Multi-display Controller Sub-assy *2 *1: w/o Rear Seat Entertainment System *2: w/ Rear Seat Entertainment System I40742 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1939 05-1759 DIAGNOSTICS - NAVIGATION SYSTEM 05IRY-02 CUSTOMER PROBLEM ANALYSIS CHECK NAVIGATION SYSTEM Check Sheet Inspector’s name: VIN Production Date Customer’s Name Licence Plate No. Date Vehicle Brought in / / / Date Problem First Occurred Frequency Problem Occurs km mile Odometer Reading
Always
Intermittently ( / Times a day) DTC Check 1st time trouble code. 2nd time trouble code. Problem Symptom I39529 I38696 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1949 05-1791 DIAGNOSTICS - NAVIGATION SYSTEM 05ISD-02 DIAGNOSTIC TROUBLE CODE CHART Terms Description Physical address 3-digit, hexadecimal code assigned to all components connected to the AVC-LAN. Individual symbols are specified based on function. Units whose names are unknown or relevant units are displayed with physical addresses. Logical address 2-digit, hexadecimal code assigned to all the functions in the AVC-LAN system. HINT: Titles for each unit are stated in the following order: parts name (physical address) [Name indicated by DTC] 1. MULTI-DISPLA Y (physical address: 110) [EMV] (a) Logical address: 01 (Communication control) DTC Name Diagnosis D5 *1 *5 Absence of registration unit A device that the sub code shows is (was) disconnected from the system when turning the ignition switch to the ACC or ON position. The communication condition with the device that the code shows cannot be obtained when the engine starts. Inspection for the device indicated by the sub code. (Refer to the inspection list for the device indicated by the sub code.) Refer to step 6 D8 *2 *5 No response for connection check The device indicated by the sub code is (was) disconnected from the system after engine start. Inspection for the device indicated by the sub code. (Refer to the inspection list for the device indicated by the sub code.) Refer to step 6 D9 *1 *5 Last mode error The device (for audio visual system) that had functioned before the engine stopped is (was) disconnected from the system when the ignition switch is (was) in the ACC or ON position. Inspection for the device indicated by the sub code. (Refer to the inspection list for the device indicated by the sub code.) Refer to step 6 DA *5 No response against ON/OFF command No response is identified when changing mode (audio and visual mode change). Detected when sound and image do not change by switch operation. Inspection for the device indicated by the sub code. (Refer to the inspection list for the device indicated by the sub code.) Refer to step 6 This code detects a dual alarm. Inspection for the device indicated by the sub code. (Refer to the inspection list for the device indicated by the sub code.) Refer to step 6 This code indicates a transmission failure to the device indicated by the sub code. NOTE: This DTC may have no direct relationship with the malfunction. Inspection for the device indicated by the sub code. (Refer to the inspection list for the device indicated by the sub code.) Refer to step 6 Refer to step 6 DB *1 *5 DC *3 *5 Mode status error Failure in transmission Verification See page DE *4 *5 Slave reset Inspection for the device indicated This code is stored when a slave device has been by the sub code. disconnected after engine start. (Refer to the inspection list for the device indicated by the sub code.) 21 ROM error This code is output when a malfunction exists in ROM. Replace multi-display 67-8 22 RAM error This code is output when a malfunction exists in RAM. Replace multi-display 67-8 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1981 05-1792 DIAGNOSTICS - NAVIGATION SYSTEM HINT:




(b) *1: This code may be recorded depending on the battery condition or engine start voltage even if no failure is detected. *2: If the power connector is disconnected after the engine starts, this code is recorded after 180 seconds. *3: This code may be stored if the ignition key is turned to the START position again with the engine running. *4: This code may be stored if the ignition key is held in the START position for 1 minute or more before returning to the ON position. *5: If the device is reported as not existing during verification, check the power source circuit and AVCLAN circuit for the device. Logical address: 21 (SW): 23 (SW with name): 24 (SW converting): 25 (command SW) DTC Name 10 Panel switch error Diagnosis Verification The panel SW detection circuit has a failure. Replace multi-display See page 67-8 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1982 05-1793 DIAGNOSTICS - NAVIGATION SYSTEM 2. NAVIGATION ECU (Physical address: 178) [NAVI] (a) Logical address: 01 (Communication control) HINT: Methods used to verify the cause of the problem are listed in order of probability in the verification column. DTC D6 *1 D7 DC *3 *5 DD *3 DF *4 E0 *1 E1 *1 Name No master Connection check error Diagnosis Verification See page 05-1828 When either the following condition meets.
The device that stores (stored) the code has (had) been disconnected when the ignition switch is in ACC or ON position.
The master device has (had) been disconnected when this code is stored. 1. Power source circuit (multi-display) 2. AVC-LAN circuit (multi-display navigation ECU) 3. Power source circuit (navigation ECU) 4. Replace multi-display 5. Replace navigation ECU 05-1828 When either the following condition meets.
The device that stored this code has (had) been disconnected after the engine starts (started).
The master device has (had) been disconnected when this code is (was) stored. 1. Power source circuit (multi-display) 2. AVC-LAN circuit (multi-display navigation ECU) 3. Power source circuit (navigation ECU) 4. Replace multi-display 5. Replace navigation ECU 05-1860 05-1830 67-8 67-9 05-1860 05-1830 67-8 67-9 This code indicates a transmission failure to the device indicated by the sub code. NOTE: This DTC may have no direct relationship with the malfunction. Inspection for the device indicated by the sub code (Refer to the inspection list for the device indicated by the sub code) 05-1828 When the device that should be the master has been disconnected after engine starts. 1. Power source circuit (multi-display) 2. AVC-LAN circuit (multi-display navigation ECU) 3. Replace multi-display When the device with a display fails and the master is switched to the audio device. Also when a communication error between sub master (audio) and master occurs, this code is stored. 1. Power source circuit (multi-display) 2. AVC-LAN circuit (multi-display navigation ECU) 3. Replace multi-display 05-1828 Registration complete indication error When ”Registration complete” command from the master device cannot be received. This code will be detected when signal receiving time is delayed Voice processing device ON error When the AMP device records that the AMP output does not function even while the source device operates. 1. Power source circuit (multi-display) 2. AVC-LAN circuit (multi-display navigation ECU) 3. Replace multi-display Failure in transmission Master reset Master error Refer to step 6 05-1860 67-8 05-1860 67-8 05-1828 05-1860 67-8 ON/OFF indication parameter error When the command for ON/OFF control from the master device has a problem. E3 *1 Registration demand transmission When the registration demand command from the slave device is output, or when the registration demand command is output by receiving connection confirmation command from the sub master device. - - E4 Multiple frame incomplete When the multiple frame transmission ends incomplete. - - Date
: 1983 E2 Replace multi-display 67-8 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: 05-1794 DIAGNOSTICS - NAVIGATION SYSTEM HINT:
*1: This code may be recorded depending on the battery condition or engine start voltage even if no failure is detected. *2: If the power connector is disconnected after the engine starts, this code is recorded after 180 seconds. *3: This code may be stored if the ignition key is turned to the START position again with the engine running. *4: This code may be stored if the ignition key is held in the START position for 1 minute or more before returning to the ON position. *5: If the device is reported as not existing during verification, check the power source circuit and AVCLAN circuit for the device. Logical address: 58 (Navigation): 80 (GPS)



(b) HINT: Methods used to verify the cause of the problem are listed in order of probability in the verification column. DTC Name Diagnosis 10 Gyro error Ground short, power supply short, or open circuit in the gyro signal, gyro failure. 1. Inspect the gyro error 2. Replace GPS antenna 3. Replace navigation ECU 11 GPS receiver error RTC, ROM, and RAM of the GPS receiver and TCXO errors. GPS receiver is failed. Replace navigation ECU 67-9 40 GPS antenna error GPS antenna error 1. Replace GPS antenna 2. Replace navigation ECU 67-19 67-9 41 GPS antenna power source error Error of the power source to the GPS antenna 1. Replace GPS antenna 2. Replace navigation ECU 67-19 67-9 42 Map disc read error Player error. A scratch or dirt on the disc. Access to an invalid address due to software error. 1. Inspect map disc read error 2. Replace map disc 3. Replace navigation ECU 05-1826 67-9 43 SPD signal error The difference between the GPS speed and SPD pulse is detected. 1. Inspect speed signal error 2. Speed signal circuit 3. Replace navigation ECU 05-1827 05-1838 67-9 67-9 Map player error is detected. 1. Check if the disc can be inserted and ejected. If a malfunction is found, replace the navigation ECU 2. If the same code is detected again, replace the navigation ECU 1. Park the vehicle in a cool place. Turn the engine off. After checking that the temperature of the radio and navigation assy becomes sufficiently low, turn the engine on to verify the malfunction symptom. 2. If the same code is detected, replace the navigation ECU - 44 45 Player error High temperature High map player temperature is detected. Verification See page 05-1825 67-19 67-9 67-9 67-9 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1984 05-1795 DIAGNOSTICS - NAVIGATION SYSTEM 3. RADIO RECEIVER ASSY (Physical address: 190) [AUDIO H/U] (a) Logical address: 01 (Communication control) HINT: Methods used to verify the cause of the problem are listed in order of probability in the verification column. DTC D6 *1 D7 DC *3 *5 Name No master Connection check error Failure in transmission Diagnosis Verification See page 05-1828 When either of the following conditions meets.
The device that stores (stored) the code has (had) been disconnected when the ignition switch is (was) in ACC or ON position.
The master device has (had) been disconnected when this code is (was) stored. 1. Power source circuit (multi-display) 2. AVC-LAN circuit (multi-display radio receiver assy) *6 3. Power source circuit (radio receiver assy) 4. Power source circuit (multi-display controller sub-assy) 5. AVC-LAN circuit (multi-display controller sub-assy-radio receiver assy) 6. AVC-LAN circuit (multi-display controller sub-assy-multi-display) 7. Replace multi-display 8. Replace radio receiver assy 9. Replace multi-display controller sub-assy 1. Power source circuit (multi-display) 2. AVC-LAN circuit (multi-display radio receiver assy) *6 3. Power source circuit (radio receiver assy) 4. Power source circuit (multi-display controller sub-assy) 5. AVC-LAN circuit (multi-display controller sub-assy-radio receiver assy) 6. AVC-LAN circuit (multi-display controller sub-assy-multi-display) 7. Replace multi-display 8. Replace radio receiver assy 9. Replace multi-display controller sub-assy 05-1828 When either of the following conditions meets.
The device that stored this code has (had) been disconnected after the engine starts (started).
The master device has (had) been disconnected when this code is (was) stored. This code indicates a transmission failure to the device indicated by the sub code. NOTE: This DTC may have no direct relationship with the malfunction. Inspection for the device indicated by the sub code. (Refer to the inspection list for the device indicated by the sub code.) 05-1866 05-1832 05-1836 05-1864 05-1858 67-8 67-6 67-23 05-1866 05-1832 05-1836 05-1864 05-1858 67-8 67-6 67-23 Refer to step 6 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1985 05-1796 DIAGNOSTICS DD *3 DF *4 E0 *1 E1 *1 E2 Master reset Master error Registration complete indication error Voice processing device ON error ON/OFF indication parameter error - NAVIGATION SYSTEM When the device that should be the master has been disconnected after engine starts. When the device with a display fails and the master is switched to the audio device. Also when a communication error between sub master (audio) and master occurs, this code is stored. 1. Power source circuit (multi-display) 2. AVC-LAN circuit (multi-display radio receiver assy) *6 3. Power source circuit (radio receiver assy) 4. Power source circuit (multi-display controller sub-assy) 5. AVC-LAN circuit (multi-display controller sub-assy-radio receiver assy) 6. AVC-LAN circuit (multi-display controller sub-assy-multi-display) 7. Replace multi-display 8. Replace radio receiver assy 9. Replace multi-display controller sub-assy 05-1828 1. Power source circuit (multi-display) 2. AVC-LAN circuit (multi-display radio receiver assy) *6 3. Power source circuit (radio receiver assy) 4. Power source circuit (multi-display controller sub-assy) 5. AVC-LAN circuit (multi-display controller sub-assy-radio receiver assy) 6. AVC-LAN circuit (multi-display controller sub-assy-multi-display) 7. Replace multi-display 8. Replace radio receiver assy 9. Replace multi-display controller sub-assy 05-1828 When ”Registration complete” command from the master device cannot be received. This code will be detected when signal receiving time is delayed. When the AMP device records that the AMP output does not function even while the source device operates. 1. Power source circuit (multi-display) 2. AVC-LAN circuit (multi-display radio receiver assy) *6 3. Power source circuit (radio receiver assy) 4. Power source circuit (multi-display controller sub-assy) 5. AVC-LAN circuit (multi-display controller sub-assy-radio receiver assy) 6. AVC-LAN circuit (multi-display controller sub-assy-multi-display) 7. Replace multi-display 8. Replace radio receiver assy 9. Replace multi-display controller sub-assy When the command for ON/OFF control from the master device has a problem. Replace multi-display 05-1866 05-1832 05-1836 05-1864 05-1858 67-8 67-6 67-23 05-1866 05-1832 05-1836 05-1864 05-1858 67-8 67-6 67-23 05-1828 05-1866 05-1832 05-1836 05-1864 05-1858 67-8 67-6 67-23 67-8 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1986 05-1797 DIAGNOSTICS E3 *1 Registration demand transmission E4 Multiple frame incomplete - NAVIGATION SYSTEM When the registration demand command from the slave device is output, or when the registration demand command is output by receiving connection confirmation command from the sub master device. - - When the multiple frame transmission ends incompletely - - Verification See page *6: w/o Rear Seat Entertainment System (b) Logical address: 01 (Communication control) DTC Name Diagnosis D5 *1 *5 Absence of registration unit A device that the sub code shows is (was) disconnected from the system when turning the ignition switch to the ACC or ON position. The communication condition with the device that the code shows cannot be obtained when the engine starts. Inspection for the device indicated by the sub code. (Refer to the inspection list for the device indicated by the sub code.) Refer to step 6 D8 *2 *5 No response for connection check The device indicated by the sub code is (was) disconnected from the system after engine start Inspection for the device indicated by the sub code. (Refer to the inspection list for the device indicated by the sub code.) Refer to step 6 D9 *1 *5 Last mode error The device (for audio visual system) that had functioned before the engine stopped is (was) disconnected from the system when the ignition switch is (was) in the ACC or ON position. Inspection for the device indicated by the sub code. (Refer to the inspection list for the device indicated by the sub code.) Refer to step 6 DA *5 No response against ON/OFF command No response is identified when changing mode (audio and visual mode change). Detected when sound and image do not change by switch operation. Inspection for the device indicated by the sub code. (Refer to the inspection list for the device indicated by the sub code.) Refer to step 6 This code detects a dual alarm. Inspection for the device indicated by the sub code. (Refer to the inspection list for the device indicated by the sub code.) Refer to step 6 This code indicates a transmission failure to the device indicated by the sub code. NOTE: This DTC may have no direct relationship with the malfunction. Inspection for the device indicated by the sub code. (Refer to the inspection list for the device indicated by the sub code.) Refer to step 6 Inspection for the device indicated This code is stored when a slave device has been by the sub code. disconnected after engine start. (Refer to the inspection list for the device indicated by the sub code.) Refer to step 6 DB *1 *5 DC *3 *5 DE *4 *5 Mode status error Failure in transmission Slave reset HINT:




*1: This code may be recorded depending on the battery condition or engine start voltage even if no failure is detected. *2: If the power connector is disconnected after the engine starts, this code is recorded after 180 seconds. *3: This code may be stored if the ignition key is turned to the START position again with the engine running. *4: This code may be stored if the ignition key is held in the START position for 1 minute or more before returning to the ON position. *5: If the device is reported as not existing during verification, check the power source circuit and AVCLAN circuit for the device. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1987 05-1798 DIAGNOSTICS - NAVIGATION SYSTEM (c) Logical address: 62 (CD): 63 (CD changer) HINT: Methods used to verify the cause of the problem are listed in order of probability in the verification column. DTC Name 10 CD player mechanical error 11 CD insertion & eject error 12 CD reading abnormal 40 No disc Diagnosis Verification See page A mechanical error in the CD player is detected while the CD is not being inserted or ejected. Replace radio receiver assy 67-6 CD insertion or ejection is failed. Replace radio receiver assy 67-6 CD reading problem occurs. Replace radio receiver assy 67-6 67-6 No disc is inserted. 1. Check whether the CD is inserted or not. If the CD is inserted, check whether it can be ejected or not. If it cannot be ejected, replace radio receiver assy. 2. Inspect CD 3. If the same code is detected, replace the radio receiver assy 05-1682 67-6 An unsuitable disc is inserted. 1. Inspect CD 2. If the same code is detected, replace the radio receiver assy 05-1682 67-6 Disc cannot be read The disc cannot be read. 1. Inspect CD 2. If the same code is detected, replace the radio receiver assy 05-1682 67-6 CD-ROM abnormal CD-ROM operation is abnormal. Replace radio receiver assy 1. After clearing the DTC, check the malfunction symptom 2. If the same code is detected, replace the radio receiver assy 41 Wrong disc 42 43 67-6 - 44 CD abnormal Operation error in the CD mechanism (except for code 10). 45 EJECT error Magazine cannot be ejected. Replace radio receiver assy 46 Disc has scratches in the reverse surface CD has dirt or scratches in the reverse side. 1. Inspect CD 2. If the same code is detected, replace the radio receiver assy 05-1682 67-6 - The sensor detects that the CD unit temperature is high. 1. Park the vehicle in a cool place. Turn the engine off. After checking that the temperature of the radio and navigation assy becomes sufficiently low, turn the engine on in order to verify the malfunction symptom. 2. If the same code is detected, replace the radio receiver assy 47 CD temperature is high 48 Excess current 50 Tray insertion/ejection error 51 Elevator error 52 Clamp error 67-6 67-6 67-6 Excess current is applied to disc player changer. Replace radio receiver assy 67-6 Malfunction in insertion/ejection system Replace radio receiver assy 67-6 Mechanical error occurred during elevator operation Replace radio receiver assy 67-6 Clamp unusually generating Replace radio receiver assy 67-6 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1988 05-1799 DIAGNOSTICS - NAVIGATION SYSTEM (d) Logical address: 61 (Cassette) HINT: Methods used to verify the cause of the problem are listed in order of probability in the verification column. DTC Name 10 Belt cut 40 Mechanical error of media Diagnosis Verification The inside belt is cut or came off. Replace radio receiver assy A malfunction due to mechanical problem, cassette tape is cut or entangled. 1. Replace the cassette tape and recheck the symptom 2. If the same code is detected, replace the radio receiver assy See page 67-6 67-6 41 EJECT error A malfunction due to mechanical problem. Replace radio receiver assy 67-6 42 Tape tangling Cassette tape is tangled. Replace radio receiver assy 67-6 Head is dirty. 1. Clean the head and recheck the symptom 2. If the same code is detected, replace the radio receiver assy A short or open in the power circuit. 1. Power source circuit (radio receiver assy) 2. Replace radio receiver assy 43 Head dirt 44 Device power supply problem 67-6 05-1832 67-6 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1989 05-1800 DIAGNOSTICS - NAVIGATION SYSTEM 4. MULTI-DISPLA Y CONTROLLER SUB-ASSY (Physical address: 1F6, 16C, 16D) [RSE ECU] (a) Logical address: 01 (Communication control) HINT: Methods used to verify the cause of the problem are listed in order of probability in the verification column. DTC D6 *1 D7 DC *2 *5 DD *3 DF *4 E0 *1 Name No master Connection check error Transmission error Master reset Master error Registration complete indication error Diagnosis Verification See page 05-1828 When either of the following conditions meets.
The device that stores (stored) the code has (had) been disconnected when the ignition switch is (was) in ACC or ON position.
The master device has (had) been disconnected when this code is (was) stored. 1. Power source circuit (multi-display) 2. AVC-LAN circuit (multi-display multi-display controller subassy) 3. Power source circuit (multi-display controller sub-assy) 4. Replace multi-display 5. Replace multi-display controller sub-assy 05-1828 When either of the following conditions meets.
The device that stored this code has (had) been disconnected after the engine starts (started).
The master device has (had) been disconnected when this code is (was) stored. 1. Power source circuit (multi-display) 2. AVC-LAN circuit (multi-display multi-display controller subassy) 3. Power source circuit (multi-display controller sub-assy) 4. Replace multi-display 5. Replace multi-display controller sub-assy 05-1858 05-1836 67-8 67-23 05-1858 05-1836 67-8 67-23 The device stores the fact that transmission to the device indicated by the sub code has failed. Inspection for the device indicated by the sub code (Refer to the inspection list for the device indicated by the sub code) 05-1828 When the device that should be the master has been disconnected after engine starts. 1. Power source circuit (multi-display) 2. AVC-LAN circuit (multi-display multi-display controller subassy) 3. Power source circuit (multi-display controller sub-assy) 4. Replace multi-display 5. Replace multi-display controller sub-assy 1. Power source circuit (multi-display) 2. AVC-LAN circuit (multi-display multi-display controller subassy) 3. Power source circuit (multi-display controller sub-assy) 4. Replace multi-display 5. Replace multi-display controller sub-assy 05-1828 When the device with a display fails and the master is switched to the audio device. Also when a communication error between sub master (audio) and master occurs, this code is stored. When ”Registration complete” command from the master device cannot be received. This code is detected when signal receiving time is delayed. Refer to step 6 05-1858 05-1836 67-8 67-23 05-1858 05-1836 67-8 67-23 - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1990 05-1801 DIAGNOSTICS E1 *1 Voice processing device ON error - NAVIGATION SYSTEM When the AMP device records that the AMP output does not function even while the source device operates. 1. Power source circuit (multi-display) 2. AVC-LAN circuit (multi-display multi-display controller subassy) 3. Power source circuit (multi-display controller sub-assy) 4. Replace multi-display 5. Replace multi-display controller sub-assy 05-1828 05-1858 05-1836 67-8 67-23 ON/OFF indication parameter error When the command for ON/OFF control from the master device has a problem. E3 *1 Registration demand transmission When the registration demand command from the slave device is output, or when the registration demand command is output by receiving connection confirmation command from the sub master device. - - E4 Multiple frame incomplete When the multiple frame transmission ends incomplete - - 21 ROM error This code is output when a malfunction exists in ROM. Replace multi-display 67-8 22 RAM error This code is output when a malfunction exists in RAM. Replace multi-display 67-8 E2 Replace multi-display 67-8 HINT:




*1: This code may be recorded depending on the battery condition or engine start voltage even if no failure is detected. *2: If the power connector is disconnected after the engine starts, this code is recorded after 180 seconds. *3: This code may be stored if the ignition key is turned to the START position again with the engine running. *4: This code may be stored if the ignition key is held in the START position for 1 minute or more before returning to the ON position. *5: If the device is reported as not existing during verification, check the power source circuit and AVCLAN circuit for the device. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1991 05-1802 DIAGNOSTICS - NAVIGATION SYSTEM 5. GATEWAY ECU (Physical address: 1C6) [G/W] (a) Logical address: 01 (Communication control) HINT: Methods used to verify the cause of the problem are listed in order of probability in the verification column. DTC D4 Name Diagnosis Regular Communication Error Component in which this code is recorded has been disconnected from system with ignition in the ACC or ON position. Either that, or the multidisplay was disconnected when this code was recorded. Verification See page 1. Power source circuit (multi-display) 2. AVC-LAN circuit (multi-display gateway ECU) 3. Power source circuit (gateway ECU) 4. Replace multi-display 5. Replace gateway ECU 05-1828 05-1862 05-1834 67-8 67-21 HINT: This code is stored 210 seconds after the power supply connector of the master component is disconnected with the ignition switch in the ACC or ON position. 6. THE INSPECTION LIST FOR THE DEVICE INDICATED BY THE SUB CODE HINT: Methods used to verify the cause of the problem are listed in order of probability in the verification column. Sub code address (Device name) 110 (Multi-display) 178 (Navigation ECU) 190 (Radio receiver assy) IF6, 16C, 16D (Multi-display controller sub-assy) 1C6 (Gateway ECU) Verification See page 1. Power source circuit (multi-display) 2. AVC-LAN circuit (multi-display - radio receiver assy) *1 3. Replace multi-display 05-1828 05-1866 67-8 1. Power source circuit (navigation ECU) 2. AVC-LAN circuit (multi-display - navigation ECU) 3. Replace navigation ECU 05-1830 05-1860 67-9 1. Power source circuit (radio receiver assy) 2. AVC-LAN circuit (multi-display controller sub-assy - radio receiver assy) *2 3. Replace radio receiver assy 05-1832 05-1864 67-6 1. Power source circuit (multi-display controller sub-assy) *2 2. AVC-LAN circuit (multi-display controller sub-assy - multi-display) *2 3. Replace multi-display controller sub-assy *2 05-1836 05-1858 67-23 1. Power source circuit (gateway ECU) 2. AVC-LAN circuit (multi-display - gateway ECU) 3. Replace gateway ECU 05-1834 05-1862 67-21 *1: w/o Rear Seat Entertainment System *2: w/ Rear Seat Entertainment System 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1992 05-1757 DIAGNOSTICS - NAVIGATION SYSTEM 05IRX-02 HOW TO PROCEED WITH TROUBLESHOOTING 1 Vehicle brought into a workshop 2 Diagnostic questioning and symptom confirmation (SEE PAGE 05-1759 ) Ask the customer about symptoms and confirm malfunctions. Fill out the Customer Problem Analysis check sheet. The screen displays nothing (GO TO STEP 7, proceed to ”BLACK SCREEN (NO IMAGE APPEARS ON NAVIGATION/AUDIO SCREEN)”) Other symptoms (GO TO STEP 3) 3 Check multiplex communication system (SEE PAGE 05-2040 ) Use the hand-held tester to check for normal function of the body multiplex communication system. A code is output (PROCEED TO ”BODY MULTIPLEX COMMUNICATION SYSTEM”) A code is not output (GO TO STEP 4) 4 Confirm the system normal condition (SEE PAGE 05-1775 ) Applicable (This is not a malfunction.) Not applicable (GO TO STEP 5) 5 Check the diagnostic trouble codes (SEE PAGE 05-1791 ) HINT:



If the system cannot enter the diagnosis mode, inspect each AVC-LAN communication signal and repair or replace problem parts (see page 05-1828 - 05-1866 ). Even if the malfunction symptom is not confirmed, check the diagnostic trouble codes. This is because the system stores past diagnostic trouble codes. Refer to the detailed description on the diagnostic screen, as necessary (see page 05-1768 ). Check and clear the past diagnostic trouble code. Check the diagnostic trouble code and inspect the area the code indicates. A code is output (GO TO STEP 6) A code is not output (GO TO STEP 7) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1947 05-1758 DIAGNOSTICS 6 - NAVIGATION SYSTEM Diagnostic trouble code chart (SEE PAGE 05-1791 ) Find the output code on the diagnostic trouble code chart. Output the diagnostic trouble code (GO TO STEP 9) 7 Problem symptoms table (SEE PAGE 05-1778 ) Find the applicable symptom code in the problem symptoms table. HINT: If the symptom does not recur and no code is output, perform the symptom reproduction method (see page 01-26 ). There is an applicable symptom code in the table (GO TO STEP 9) There is no applicable symptom code in the table (GO TO STEP 8) 8 Check the ECU terminal arrangement based on the malfunction symptom (SEE PAGE 05-1780 ) 9 Check the circuit Adjust, repair or replace as necessary. 10 Recheck the diagnostic trouble code (SEE PAGE 05-1791 ) HINT:

After deleting the DTC, recheck the diagnostic trouble code. Perform the screen noise adjustment when the multi-display or the navigation ECU is replaced (see page 05-1803 ). 11 Perform confirmation test END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1948 05-1750 DIAGNOSTICS - NAVIGATION SYSTEM 05CE7-07 LOCATION Engine Room J/B Engine Room R/B Fusible Link Block
CRT Fuse
DOME Fuse
ALT Fuse
RAD No.1 Fuse Front No.2 Speaker Assy Park/Neutral Position Switch Assy *2 Front No.1 Speaker Assy *1 Navigation ECU Multi-display Controller Sub-assy Combination Meter Assy Center J/B Multi-display GPS Antenna Gateway ECU Passenger Side J/B Parking Brake Switch Instrument Panel J/B
ECU-IG Fuse
RAD No.2 Fuse
AM1 Fuse
IGN Fuse
PANEL Fuse
TAIL LIGHT Relay Radio Receiver Assy *1: w/ 3rd Seat, w/ RSE *2: w/ 2rd Seat, w/ RSE I40210 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1940 05-1780 DIAGNOSTICS - NAVIGATION SYSTEM 05CEE-06 TERMINALS OF ECU 1. MULTI-DISPLA Y ASSY: M5 M4 M3 I40205 Symbols (Terminals No.) Wiring Color Terminal Description Condition Specification G - W-B Illumination (rheostat) signal Turn light control switch OFF → TAIL or HEAD Below 1 V → 10 to 14 V B - Body ground Illumination (rheostat) signal Turn light control switch OFF → TAIL or HEAD 10 to 14 V → Below 1 V GND1 (M3-3) - Body ground W-B Body ground Ground TX1+ (M3-4) - GND1 (M3-3) SB - W-B AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V TX1- (M3-5) - GND1 (M3-3) BR - W-B AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V TC (M3-7) - GND1 (M3-3) P - W-B Diagnosis ON signal Ignition switch to OFF and connect terminals TC and GND1 of check connector IG (M3-10) - GND1 (M3-3) O - W-B Ignition (ON) ACC (M3-11) - GND1 (M3-3) BR - W-B Accessory (ON) +B1 (M3-12) - GND1 (M3-3) V - W-B Battery PKB (M3-16) - GND1 (M3-3) Y - W-B Parking brake signal SPD (M3-25) - GND1 (M3-3) W - W-B Speed signal from combination meter TX3+ (M4-11) -GND1 (M3-3) BR - W-B AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V TX3- (M4-12) - GND1 (M3-3) L - W-B AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V TX+ (M4-13) GND1 (M3-3) *1 LG - W-B AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V TX- (M4-14) GND1 (M3-3) *1 O - W-B AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V VR (M4-23) - GND1 (M3-3) B - W-B Video return signal Turn ignition switch OFF Below 1 V R (M4-24) - GND1 (M3-3) W - W-B Display signal (red) Navigation display is on - G (M4-25) - GND1 (M3-3) R - W-B Display signal (green) Navigation display is on - B (M4-26) - GND1 (M3-3) G - W-B Display signal (blue) Navigation display is on - Y - W-B Display signal (synchronize) Navigation display is on - ILL+ (M3-1) - GND1 (M3-3) ILL- (M3-2) - Body ground SYNC (M4-27) - GND1 (M3-3) Always Below 1 V Below 1 Ω Turn ignition switch OFF → ON Below 1 V → 10 to 14 V Turn ignition switch OFF → ACC or ON Below 1 V → 10 to 14 V Always 10 to 14 V Below 1 V → 10 to 14 V Turn parking brake switch ON → OFF See ”vehicle signal check mode” - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1970 05-1781 DIAGNOSTICS - NAVIGATION SYSTEM Shielded Body ground Shielded ground NTSC (M5-1) GND1 (M3-3) *1 G - W-B Display signal SGD1 (M5-4) Body ground *1 R - Body ground Shielded ground Always Below 1 V SGND (M5-5) Body ground *1 Shielded Body ground Shielded ground Always Below 1 V VG (M4-28) - Body ground Always Below 1 V DVD is playing on multi-display - *1: w/ Rear Seat Entertainment System 2. NAVIGATION ECU: N3 N4 I40206 Symbols (Terminals No.) Wiring Color Terminal Description Condition AUI+ (N3-1) - GND1 (N3-17) LG - W-B Sound signal (input) Audio system is playing - AUO+ (N3- 2) - GND1 (N3-17) G - W-B Sound signal (output) Audio system is playing - SPD (N3-5) - GND1 (N3-17) O - W-B Speed signal from combination meter See ”Vehicle Signal Check Mode” (see page 05-1763 ) - +B (N3-9) - GND1 (N3-17) W - W-B Battery AUI- (N3-10) - GND1 (N3-17) R - W-B Sound signal (input) Audio system is playing - AUO- (N3-11) GND1 (N3-17) B - W-B Sound signal (output) Audio system is playing - RL (N3-14) - GND1 (N3-17) Y - W-B park/neutral position switch GND1 (N3-17) - Body ground W-B Body ground Ground ACC (N3-18) - GND1 (N3-17) GR - W-B Accessory (ON) VR (N4-1) - GND1 (N3-17) B - W-B Video return signal Turn ignition switch OFF Below 1 V R (N4-2) - GND1 (N3-17) W - W-B Display signal (red) Navigation display is on - B (N4-3) - GND1 (N3-17) G - W-B Display signal (blue) Navigation display is on - TX+ (N4-5) - GND1 (N3-17) SB - W-B AVC-LAN communication signal Turn ignition switch to ACC VG (N4-6) - Body ground Shielded Body ground Shielded ground G (N4-7) - GND1 (N3-17) R - W-B Display signal (green) Navigation display is on - SYNC (N4-8) - GND1 (N3-17) Y - W-B Display signal (synchronize) Navigation display is on - TX- (N4-10) - GND1 (N3-17) BR - W-B AVC-LAN communication signal Reverse signal from Specification Always 10 to 14 V Park/neutral position switch is ”R” position 10 to 14 V Always Below 1 V Turn ignition switch OFF → ACC or ON Below 1 V → 10 to 14 V 2 to 3 V Always Below 1 V Turn ignition switch to ACC 2 to 3 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1971 05-1782 DIAGNOSTICS 3. - NAVIGATION SYSTEM RADIO RECEIVER ASSY: R4 R22 R23 I40207 Wiring Color Terminal Description B (R4-1) - GND (R4-20) Symbols (Terminal No.) L-B - BR Battery Condition Specification ACC (R4-11) - GND (R4-20) GR - BR Accessory (ON) GND (R4-20) - Body ground BR - Body ground Ground TX+ (R22-9) GND (R4-20) *2 LG - BR AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V TX- (R22-10) GND (R4-20) *2 O - BR AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V TX1+ (R23-9) GND (R4-20) *1 Y - BR AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V TX1- (R23-10) GND (R4-20) *1 L - BR AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V Always 10 to 14 V Turn ignition switch OFF → ACC or ON Below 1 V → 10 to 14 V Always Below 1 V *1: w/ Rear Seat Entertainment System *2: w/o Rear Seat Entertainment System 4. GATEWAY ECU G5 I40209 Symbols (Terminal No.) IG (G5-2) - GND (G5-14) Wiring Color Terminal Description Condition Specification Turn ignition switch OFF → ON Below 1 V → 10 to 14 V B - W-B Ignition (ON) BR - W-B AVC-LAN communication signal W-B Body ground Ground Always Below 1 V BATT (G5-8) - GND (G5-14) LG - W-B Battery Always 10 to 14 V ACC (G5-9) - GND (G5-14) SB - W-B Accessory (ON) Turn ignition switch OFF → ACC or ON Below 1 V → 10 to 14 V L - W-B AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V W-B Body ground Ground GTX+ (G5-5) - GND (G5-14) CG (G5-7) - Body ground GTX- (G5-12) - GND (G5-14) GND (G5-14) - Body ground Turn ignition switch to ACC 2 to 3 V Below 1 Ω Always 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1972 05-1783 DIAGNOSTICS 5. - NAVIGATION SYSTEM MULTI DISPLAY CONTROLLER SUB-ASSY: R31 R29 I40208 Wiring Color Terminal Description +B1 (R29-16) GND (R29-29) *1 Symbols (Terminal No.) Y - W-B Battery TX3+ (R29-17) GND (R29-29) BR - W-B AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V TX3- (R29-18) GND (R29-29) Y - W-B AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V W-B Body ground Ground TX- (R29-30) GND (R29-29) *1 GR - W-B AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V TX+ (R29-31) GND (R29-29) *1 LG - W-B AVC-LAN communication signal Turn ignition switch to ACC 2 to 3 V ACC (R29-32) GND (R29-29) G - W-B Accessory (ON) Turn ignition switch OFF → ACC or ON Below 1 V → 10 to 14 V W-B Body ground Ground GND (R29-29) - Body ground SELD (R31-7) - Body ground Condition Specification Always 10 to 14 V Always Below 1 V Always Below 1 V *1: w/ Rear Seat Entertainment System 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1973 05-1028 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05EK3-06 CHECK MODE PROCEDURE 1. DTC CHECK (CHECK MODE) HINT: Hand-held tester only: Compared to the normal mode, the check mode has more sensing ability to detect malfunctions. Furthermore, the same diagnostic items which are detected in the normal mode can also be detected in the check mode. Hand-Held Tester DLC3 G30830 0.13 sec. 0.13 sec. ON OFF BR3904 (a) Procedure for Check Mode using the hand-held tester. (1) Check the initial conditions.
Battery positive voltage 11 V or more
Throttle valve fully closed
Transaxle in the P or N position
A/C switch is off (2) Turn the ignition switch off. (3) Connect the hand-held tester to the DLC3. (4) Turn the ignition switch to the ON position and push the hand-held tester main switch on. (5) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/ CHECK MODE” (Check that the MIL flashes). NOTICE: All DTCs and freeze frame data recorded will be erased if: 1) the hand-held tester is used to change the ECM from normal mode to check mode or vice-versa; or 2) during check mode, the ignition switch is turned from ON to ACC or OFF. (6) Start the engine (MIL goes off after the engine starts). (7) Perform ”MONITOR DRIVE PATTERN” for the ECT test (see page 05-1014 ). (Or, simulate the conditions of the malfunction described by the customer). NOTICE: Leave the ignition switch in the ON position until you have checked the DTCs, etc. (8) After simulating malfunction conditions, use the hand-held tester diagnosis selector to check the DTCs and freeze frame data, etc. (9) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/ DTC INFO/CURRENT CODES”. (10) After checking the DTC, inspect the applicable circuit. (11) See page 05-1034 to confirm the details of the DTCs. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1218 DIAGNOSTICS 2. (a) - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1029 DTC CLEAR When using the OBD II scan tool or hand-held tester: Clearing the DTCs. (1) Connect the OBD II scan tool or hand-held tester to the DLC3. (2) Turn the ignition switch to the ON position and push the OBD II scan tool or the hand-held tester main switch on. (3) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/ DTC INFO/CLEAR CODES [YES] button”. HINT: When operating the OBD II scan tool (complying with SAE J1978) or hand-held tester to erase the codes, the DTCs and freeze frame data will be erased. (See the OBD II scan tool’s instruction book for operating instructions.) (b) When not using the OBD II scan tool or hand-held tester: Clearing the DTCs. (1) Disconnecting the battery terminal or remove the EFI and ETCS fuses from the engine room J/B for 60 seconds or more. But if you disconnect the battery terminal, you should do the ”INITIALIZE” procedure. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1219 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-987 05EK7-06 DEFINITION OF TERMS Term Definition Monitor description Description of what the ECM monitors and how it detects malfunctions (monitoring purpose and its details). Related DTCs A group of diagnostic trouble codes that are output by the ECM based on the same malfunction detection logic. Typical enabling condition Preconditions that allow the ECM to detect malfunctions. With all preconditions satisfied, the ECM sets the DTC when the monitored value(s) exceeds the malfunction threshold(s). Sequence of operation The priority order that is applied to monitoring, if multiple sensors and components are used to detect the malfunction. While another sensor is being monitored, the next sensor or component will not be monitored until the previous monitoring has concluded. Required sensor/components The sensors and components that are used by the ECM to detect malfunctions. Frequency of operation The number of times that the ECM checks for malfunctions per driving cycle. ”Once per driving cycle” means that the ECM detects malfunction only one time during a single driving cycle. ”Continuous” means that the ECM detects malfunction every time when enabling condition is met. Duration The minimum time that the ECM must sense a continuous deviation in the monitored value(s) before setting a DTC. This timing begins after the ”typical enabling conditions” are met. Malfunction thresholds Beyond this value, the ECM will conclude that there is a malfunction and set a DTC. MIL operation MIL illumination timing after a defect is detected. ”Immediately” means that the ECM illuminates MIL the instant the ECM determines that there is a malfunction. ”2 driving cycle” means that the ECM illuminates MIL if the same malfunction is detected again in the 2nd driving cycle. Component operating range Normal operation range of sensors and solenoids under normal driving conditions. Use these ranges as a reference. They cannot be used to judge if a sensor or solenoid is defective or not. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1177 05-1024 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05EK0-05 DIAGNOSIS SYSTEM 1. (a) DIAGNOSIS SYSTEM Description (1) When troubleshooting OBD II vehicles, the only difference from the usual troubleshooting procedure is that you need to connect an OBD II scan tool complying with SAE J1987 or a hand-held tester to the vehicle, and read off various data output from the vehicle’s ECM. (2) FI0534 OBD II regulations require that the vehicle’s onboard computer illuminate the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in the computer itself or in the drive system components which affect the vehicle emissions. In addition to the MIL illuminating when a malfunction is detected, the applicable DTCs prescribed by SAE J2012 are recorded in the ECM memory (see page 05-1034 ). If the malfunction does not occur in 3 consecutive trips, the MIL goes off but the DTCs remain in the ECM memory. (3) To check the DTCs, connect the OBD II scan tool or hand-held tester to the DLC3 of the vehicle. The OBD II scan tool or hand-held tester also enables you to erase the DTCs and check freeze frame data and various forms of engine data (For instruction book). (4) The DTCs include SAE controlled codes and Manufacturer controlled codes. SAE controlled codes must be set as prescribed by the SAE, while Manufacturer controlled codes can be set freely by a manufacturer within the prescribed limits (see the DTC chart on page 05-1034 ). (5) The diagnosis system operates in the normal mode during the normal vehicle use, and also has a check mode for technicians to simulate malfunction symptoms and perform troubleshooting. Most DTCs use 2 trip detection logic(*) to prevent erroneous detection. By switching the ECM to the check mode when troubleshooting, the technician can cause the MIL to illuminate for a malfunction that is only detected once or momentarily (hand-held tester). (6) *2 trip detection logic: When a malfunction is first detected, the malfunction is temporarily stored in the ECM memory. If the same malfunction is detected again during the second test drive, this second detection causes the MIL to illuminate. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1214 DIAGNOSTICS (b) D1 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1025 Inspect the DLC3. The vehicle’s ECM uses ISO 9141-2 for communication. The terminal arrangement of DLC3 complies with SAE J1962 and matches the ISO 9141-2 format. 1 23 4 5 6 78 9 10111213141516 DLC3 A04550 Tester connection 7 (Bus
Line) - 5 (Signal ground) Condition Specified condition During communication Pulse generation 4 (Chassis Ground) - Body Always 1 Ω or less 5 (Signal Ground) - Body Always 1 Ω or less 16 (B+) - Body Always 9 to 14 V HINT: If your display shows UNABLE TO CONNECT TO VEHICLE when you have connected the cable of the OBD II scan tool or hand-held tester to the DLC3, turned the ignition switch to the ON position and operated the scan tool, there is a problem on the vehicle side or tool side.
If the communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle.
If the communication is still impossible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool’s instruction manual. (c) Measure the battery voltage. Battery Voltage: 11 to 14 V If voltage is below 11 V, recharge the battery before proceeding. (d) Check the MIL. (1) The MIL comes on when the ignition switch is turned to the ON position and the engine is not running. HINT: If the MIL does not light up, troubleshoot the combination meter. (2) When the engine is started, the MIL should go off. If the lamp remains on, it means that the diagnosis system has detected a malfunction or abnormality in the system. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1215 05-1032 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05EK5-07 DATA LIST/ACTIVE TEST 1. DATA LIST HINT: According to the DATA LIST displayed by the OBD II scan tool or hand-held tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the OBD II scan tool or hand-held tester to the DLC3. (d) Turn the ignition switch to the ON position. (e) Push the ”ON” button of the OBD II scan tool or the hand-held tester. (f) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/DATA LIST”. (g) According to the display on tester, read the ”DATA LIST”. Item Measurement Item/ Range (display) STOP LIGHT SW Stop light SW Status/ ON or OFF Normal Condition Diagnostic Note
Brake Pedal is depressed: ON
Brake Pedal is released: OFF - PNP SW [NSW] PNP SW Status/ ON or OFF Shift lever position is; P and N: ON Except P and N: OFF When the shift lever position displayed on the hand-held tester differs from the actual position, adjustment of the PNP switch or the shift cable may be incorrect. HINT: When the failure still occurs even after adjusting these parts, see page 05-1036 . LOW PNP SW Status/ ON or OFF Shift lever position is; L: ON Except L: OFF ↑ 2ND PNP SW Status/ ON or OFF Shift lever position is; 2 and L: ON Except 2 and L: OFF ↑ REVERSE PNP SW Status/ ON or OFF Shift lever position is; R: ON Except R: OFF ↑ DRIVE PNP SW Status/ ON or OFF Shift lever position is; D: ON Except D: OFF ↑ O/D SW Status/ ON or OFF
IG SW ON: ON ↓
O/D SW Push: OFF ↓
O/D SW Push: ON - Shift lever position is;
L: 1st
2: 1st or 2nd
3: 1st, 2nd or 3rd
D(O/D OFF): 1st, 2nd, 3rd or 4th
D(O/D ON): 1st, 2nd, 3rd, 4th or 5th - OVERDRV CUT SW2 SHIFT Actual Gear Position/ 1st, 2nd, 3rd, 4th or 5th (O/D) LOCK UP SOL Lock Up Solenoid Status/ ON or OFF
Lock Up: ON
Except Lock Up: OFF - SOLENOID (SLT) Shift Solenoid SLT Status/ ON or OFF
Accelerator pedal is depressed: OFF
Accelerator pedal is released: ON - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1222 DIAGNOSTICS AT FLUID TEMP SPD (NC) ATF Temp. Sensor Value/ min.: -40C (-40F) max.: 215C (419F) Counter Gear Speed/ display: 50 r/min - 05-1033 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F)
After Stall Test; Approx. 80C (176F)
Equal to ambient temperature when the engine is cold If the value is ”-40C (-40F)” or ”215C (419F)”, ATF temp. sensor circuit is opened or shorted. [HINT] 3rd when shift lever position is D position (After warming up the engine);
Intermediate shaft speed (NC) becomes close to the engine speed. - 2. ACTIVE TEST HINT: Performing the ACTIVE TEST using the hand-held tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the hand-held tester to the DLC3. (d) Turn the ignition switch to the ON position. (e) Push the ”ON” button of the hand-held tester. (f) Select the item ”DIAGNOSIS/ENHANCED OBD II/ACTIVE TEST”. (g) According to the display on tester, perform the ”ACTIVE TEST”. Item Test Details Diagnostic Note SHIFT [Test Details] Operate the shift solenoid valve and set the each shift position by yourself. [Vehicle Condition] Less than 50 km/h (31 mph) [Others]
Press ”→” button: Shift up
Press ”←” button: Shift down Possible to check the operation of the shift solenoid valves. [Test Details] Control the shift solenoid DSL to set the automatic transaxle to the lock-up condition. [Vehicle Condition] Vehicle Speed: 60 km/h (37 mph) or more, and 5th gear Possible to check the DSL operation. LOCK UP LINE PRESS UP * [Test Details] Operate the shift solenoid SLT and raise the line pressure. [Vehicle Condition]
Vehicle Stopped.
IDL: ON [HINT] OFF: Line pressure up (When the active test of ”LINE PRESS UP” is performed, the ECM commands the SLT solenoid to turn off). ON: No action (normal operation) - *: ”LINE PRESS UP” in the ACTIVE TEST is performed to check the line pressure changes by connecting the SST to the automatic transaxle, which is used in the HYDRAULIC TEST (see page 05-1002 ) as well. HINT: The pressure values in ACTIVE TEST and HYDRAULIC TEST are different from each other. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1223 05-1026 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05EK1-06 DTC CHECK/CLEAR 1. DTC CHECK (NORMAL MODE) NOTICE: When the diagnostic system is switched from the normal mode to the check mode, all the DTCs and freeze frame data recorded in the normal mode will be erased. So before switching modes, always check the DTCs and freeze frame data, and note them down. Hand-Held Tester DLC3 G30830 (a) Checking DTCs using the OBD II scan tool or hand-held tester. (1) Turn the ignition switch off. (2) Connect the OBD II scan tool or hand-held tester to DLC3. (3) Turn the ignition switch to the ON position and push the OBD II scan tool or the hand-held tester main switch on. (4) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/ DTC INFO/CURRENT CODES”. (5) Use the OBD II scan tool or hand-held tester to check the DTCs and freeze frame data and note them down (For operating instructions, see the OBD II scan tool’s instruction book). (6) See page 05-1034 to confirm the details of the DTCs. NOTICE: When simulating symptoms with an OBD II scan tool (excluding hand-held tester) to check the DTCs, use the normal mode. For codes on the DTCs chart subject to ”2 trip detection logic”, turn the ignition switch off after the symptom is simulated once. Then repeat the simulation process again. When the problem has been simulated twice, the MIL is indicated on the instrument panel and DTCs are recorded in the ECM. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1216 DIAGNOSTICS 2. (a) - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1027 DTC CLEAR When using the OBD II scan tool or hand-held tester: Clearing the DTCs. (1) Connect the OBD II scan tool or hand-held tester to the DLC3. (2) Turn the ignition switch to the ON position and push the OBD II scan tool or the hand-held tester main switch on. (3) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/ DTC INFO/CLEAR CODES [YES] button”. HINT: When operating the OBD II scan tool (complying with SAE J1978) or hand-held tester to erase the codes, the DTCs and freeze frame data will be erased. (See the OBD II scan tool’s instruction book for operating instructions.) (b) When not using the OBD II scan tool or hand-held tester: Clearing the DTCs. (1) Disconnecting the battery terminal or remove the EFI and ETCS fuses from the engine room J/B for 60 seconds or more. But if you disconnect the battery terminal, you should do the ”INITIALIZE” procedure. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1217 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1 111 05ITF-02 PATTERN SELECT SWITCH CIRCUIT CIRCUIT DESCRIPTION Multiplex network body ECU receives pattern select switch information, and sends it through the multiplex communication system to the ECM. ECT SNOW is the system that operates the throttle motor to control engine output to reduce skidding of the driving wheels, guarantee takeoff acceleration, driving straightness and turning stability. WIRING DIAGRAM E4 Electronically Controlled Transmission Pattern Select SW * Center J/B W-B 13 3F 8 3D W-B Y 4 3 Multiplex Network Body ECU 15 B9 SNOW IB (*) Pattern Select Switch (ECT SNOW Switch) When the ECT SNOW switch is pushed, the switch contact is made and the ECT SNOW mode is selected. To cancel the ECT SNOW mode, push the ECT SNOW switch once again. The ECT SNOW mode is automatically cancelled when the ignition switch is turned ”OFF”. G30835 G32449 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1301 05-1 112 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) INSPECTION PROCEDURE 1 (a) (b) (c) (d) DRIVING TEST Start the engine. Turn the ECT SNOW switch ”OFF” (Normal drive mode). Confirm vehicle response by driving from a parked position to fully depressing the accelerator pedal. Turn the ECT SNOW switch ”ON” and perform the same check as (c). Confirm that there is a difference between ECT SNOW switch ”ON” and ”OFF”. HINT:

Driving test should be done on a paved road (a nonskid road). Make sure not to use the TRAC system when testing a vehicle equipped with one. OK: There is a difference in acceleration between ”ON” and ”OFF”. NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1016 ) 2 CHECK HARNESS AND CONNECTOR(PATTERN SELECT SWITCH ASSY NO.1 BODY GROUND) (a) Wire Harness Side: (Connector Front View): (b) Disconnect the connector of pattern select switch (ECT SNOW switch). Measure the resistance according to the value(s) in the table below. Standard: E4 NG G23382 Tester Connection Specified Condition 4 - Body ground Below 1 Ω REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK 3 INSPECT PATTERN SELECT SWITCH ASSY NO.1 (a) Switch Side: (Connector Front View): Measure the resistance according to the value(s) in the table below. Standard: Switch Condition E4 Tester Connection Press continuously Pattern select switch Below 1 Ω 3-4 Release Pattern select switch C82813 Specified Condition D25463 NG 10 kΩ or higher REPLACE PATTERN SELECT SWITCH ASSY NO.1 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1302 DIAGNOSTICS 4 - 05-1 113 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) CHECK HARNESS AND CONNECTOR(PATTERN SELECT SWITCH ASSY NO.1 MULTIPLEX NETWORK BODY ECU) (a) (b) (c) Connect the connector of pattern select switch (ECT SNOW switch). Disconnect the multiplex network body ECU connector. Measure the resistance between terminals SNOW of multiplex network body ECU and body ground. Standard: Switch Condition Tester Connection Press continuously Pattern select switch Release Pattern select switch Multiplex Network Body ECU: Back Side: Specified Condition Below 1 Ω B9 - 15 (SNOW) Body ground 10 kΩ or higher B9 B9 SNOW G32072 NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1016 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1303 05-1030 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05EK2-05 FAIL-SAFE CHART 1. FAIL-SAFE This function minimizes the loss of the ECT functions when any malfunction occurs in each sensor or solenoid. (a) ATF (Automatic Transmission Fluid) temperature sensor: When the ATF temperature sensor has a malfunction, 5th upshift is prohibited. (b) Counter gear speed sensor NC (Speed sensor NC): When the counter gear speed sensor has a malfunction, 5th upshift is prohibited. (c) Shift solenoid valve DSL: When the solenoid valve DSL has a malfunction, the current to the solenoid valve is stopped. This stops lock-up control, then fuel economy decreases. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1220 DIAGNOSTICS - 05-1031 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) (d) Shift solenoid valve SL1, SL2, SL3 and S4: Fail safe function: If either of the shift solenoid valve circuits develops an open or short, the ECM turns the other shift solenoid ”ON” and ”OFF” in order to shift into the gear positions shown in the table below. Manual shifting as shown in the following table must be done (In case of a short circuit, the ECM stops sending the current to the short circuit solenoid). Even if starting the engine in the fail-safe mode, the gear position remain in the same position. : ON : According to Flex Lock-up : OFF : Condition in the normal operation is shown on the left of ” ”. Condition in the fail-safe mode is shown on the right of ” ”. Normal Solenoid Valve SL1 SL2 SL3 S4 Gear Position SL1 Malfunction (During driving at 1st or 2nd) Solenoid Valve 1st SL1 Malfunction (During driving at 3rd) Solenoid Valve Solenoid Valve SL3 Malfunction 1st 2nd 1st 4th 2nd 4th 3rd 4th 1st 4th 2nd 4th 3rd 1st 4th 2nd 4th 3rd Solenoid Valve Solenoid Valve Gear Position 2nd 4th 2nd 5th 2nd 4th 5th 4th 4th 4th 5th 4th 4th 4th 5th 4th 1st 2nd 3rd 4th 5th 4th 1st 2nd 3rd 4th 5th 4th 4th 5th 4th SL1 SL2 SL3 S4 Gear Position SL1, SL2, SL3, and S4 Malfunction 3rd SL1 SL2 SL3 S4 Gear Position S4 Malfunction 2nd SL1 SL2 SL3 S4 Gear Position Solenoid Valve 5th SL1 SL2 SL3 S4 Gear Position SL2 Malfunction 4th SL1 SL2 SL3 S4 Gear Position SL1 Malfunction (During driving at 4th or 5th) 3rd SL1 SL2 SL3 S4 Gear Position Solenoid Valve 2nd SL1 SL2 SL3 S4 1st 4th 2nd 4th 3rd 4th 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1221 05-1002 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05EJX-05 HYDRAULIC TEST Test Plug A: D Position (CO) SST Test Plug B: R Position (C2) SST G30832 1. PERFORM HYDRAULIC TEST (a) Measure the line pressure. NOTICE:
Perform the test at the normal operation fluid temperature the 50 to 80°C (122 to 176°F)
The line pressure test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is performing the test.
Be careful to prevent SST hose from interfering with the exhaust pipe.
This check must be conducted after checking and adjusting engine.
Perform under condition that A/C is OFF.
When conducting stall test, do not continue more than 10 seconds. (1) Warm up the ATF (Automatic Transmission Fluid). (2) Lift the vehicle up. (3) Remove the engine under cover. (4) Connect hand-held tester to DLC3. (5) Remove the test plug A on the transaxle case front left side and install the SST. SST 09992-00095 (09992- 00231, 09992-00271) NOTICE: There is a difference in installation point between D position and R position. (6) Start the engine. (7) Using hand-held tester, shift to D position and hold 3rd gear by active test, and measure the line pressure in idling. Specified line pressure: (8) Condition D position Idling 372 to 412 kPa (3.8 to 4.2 kgf/cm2, 54 to 60 psi) Turn the ignition switch off. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1192 DIAGNOSTICS - (9) ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1003 Disconnect the connector of the transmission wire. HINT: Disconnect the connector only when performing the D position stall test. (10) Start the engine. (11) Firmly depress the brake pedal, shift to the D position, depress the accelerator pedal all the way down and check the line pressure while the stall test is performed. Specified line pressure: Transmission Wire G30833 Condition D position Stall test 931 to 1,031 kPa (9.5 to 10.5 kgf/cm2, 135 to 150 psi) (12) Turn the ignition switch off. (13) Remove the SST, install the test plug A. (14) Remove the test plug B, install the SST and start engine. SST 09992-00095 (09992- 00231, 09992-00271) (15) Connect the transmission wire connector, depress the brake pedal firmly, shift to the R position and check that the line pressure while the engine is idling and during the stall test. Specified line pressure: Condition R position Idling 672 to 742 kPa (6.9 to 7.6 kgf/cm2, 97 to 108 psi) Stall test 1,768 to 1,968 kPa (18.0 to 20.1 kgf/cm2, 256 to 285 psi) (16) Remove the SST, install the test plug B. (17) Clear the DTC. Evaluation: Problem Possible cause If the measured values at all position are higher
Shift solenoid valve (SLT) defective
Regulator valve defective If the measured values at all position are lower
Shift solenoid valve (SLT) defective
Regulator valve defective
Oil pump defective
U/D (Underdrive) direct clutch defective If pressure is low in the D position only
D position circuit fluid leak
Forward clutch defective If pressure is low in the R position only
R position circuit fluid leak
Reverse clutch defective
1st and reverse brake defective 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1193 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1005 05EJZ-07 INITIALIZATION 1. RESET MEMORY CAUTION: Perform the RESET MEMORY (AT initialization) when replacing the automatic transaxle assy, engine assy or ECM. NOTICE: Hand-held tester only HINT: The ECM memorizes the condition that the ECT controls the automatic transaxle assy and engine assy according to those characteristics. Therefore, when the automatic transaxle assy, engine assy, or ECM has been replaced, it is necessary to reset the memory so that the ECM can memorize the new information. Reset procedure is as follows. (a) Turn the ignition switch off. (b) Connect the hand-held tester to the DLC3. (c) Turn the ignition switch to the ON position and push the hand-held tester main switch on. (d) Select the item ”DIAGNOSIS/ENHANCED OBD II”. (e) Perform the reset memory procedure from the ENGINE menu. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1195 05-1006 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) CAUTION: After performing the RESET MEMORY, be sure to perform the ROAD TEST (see page 05-997 ) described earlier. HINT: The ECM is learned by performing the ROAD TEST. Tester menu flow: G23367 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1196 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1007 05IRB-02 LIST OF DISABLE A MONITOR HINT: This table indicates ECM monitoring status for the items in the upper columns if the DTCs in each line on the left are being set. As for the ”X” mark, when the DTC on the left is stored, detection of the DTC in the upper column is not performed. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1197 05-1008 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) A98648 A92385 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1198 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1009 A92386 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1199 05-1010 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) A98729 A92387 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1200 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-101 1 A92388 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1201 05-1012 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) A92389 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1202 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1013 A92390 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1203 05-1014 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05F2S-04 MONITOR DRIVE PATTERN 1. (a) MONITOR DRIVE PATTERN FOR ECT TEST Perform this drive pattern as one method to simulate the detection conditions of the ECT malfunctions. (The DTCs may not be detected due the actual driving conditions. And some codes may not be detected through this drive pattern). HINT: Preparation for driving
Warm up the engine sufficiently. (Engine coolant temperature is 60 °C (140 °F) or higher)
Drive the vehicle when the atmospheric temperature is -10 °C (14 °F) or higher. (Malfunction is not detected when the atmospheric temperature is -10 °C (14 °F) or less) Driving note
Drive the vehicle through all gears. Stop → 1st → 2nd → 3rd → 4th → 5th → 5th (lock-up ON).
Repeat the above driving pattern three times or more. NOTICE:
The monitor status can be checked using the OBD II scan tool. When using the hand-held tester, monitor status can be found in the ”ENHANCED OBD II/DATA LIST” or under ”CARB OBD II”.
In the event that the drive pattern must be interrupted (possibly due to traffic conditions or other factors) the drive pattern can be resumed and, in most cases, the monitor can be completed. CAUTION: Perform this drive pattern on a level road as much as possible and strictly observe the posted speed limits and traffic laws while driving. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1204 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1015 Vehicle Speed Maintain a constant speed or gradual acceleration (with the throttle open) for 3 minutes or more.*1 Lock-up ON Vehicle Speed Approx.100 km/h (62 mph) Approx. 80 km/h (50 mph) 0 Warmed up sufficiently Stop (Idling) Normal acceleration through all the gears from 1st to 5th G31593 HINT: *1: Drive at such a speed in the uppermost gear, to engage lock-up. The vehicle can be driven at a speed lower than that in the above diagram under the lock-up condition. NOTICE: It is necessary to drive the vehicle for approximately 30 minutes to detect DTC P0711 (ATF temperature sensor malfunction). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1205 05-1000 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05EJW-06 MECHANICAL SYSTEM TESTS 1. (a) PERFORM MECHANICAL SYSTEM TESTS Measure the stall speed. The object of this test is to check the overall performance of the transaxle and engine by measuring the stall speeds in the D positions. NOTICE:
Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature 50 to 80°C (122 to 176°F).
Do not continuously run this test for longer than 10 seconds.
To ensure safety, do this test in a wide, clear level area which provides good traction.
The stall test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test. (1) Chock the 4 wheels. (2) Connect an OBD II scan tool or hand-held tester to the DLC3. (3) Fully apply the parking brake. (4) Keep your left foot pressed firmly on the brake pedal. (5) Start the engine. (6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot. (7) Quickly read the stall speed at this time. Stall speed: U151E: 2,240
150 rpm U151F: 2,550
150 rpm Evaluation: Problem Possible cause (a) Stall engine speed is low in D and R positions
Engine power output may be insufficient
Stator one-way clutch not operating properly HINT: If the value is less than the specified value by 600 rpm or more, the torque converter could be faulty. (b) Stall engine speed is high in D position
Line pressure is too low
Forward clutch slipping
U/D (Underdrive) brake slipping
U/D (Underdrive) one-way clutch not operating properly
No.1 one-way clutch not operating properly
Line pressure is too low
Improper fluid level 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1190 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1001 (b) Measure the time lag. (1) When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before the shock can be felt. This is used for checking the condition of the direct clutch, forward clutch, and 1st and reverse brake. NOTICE:
Perform the test at the normal operating ATF temperature 50 to 80°C (122 to 176°F).
Be sure to allow 1 minute interval between tests.
Perform the test three times, and measure the time lags. Calculate the average value of the three time lags. (2) Connect an OBD II scan tool or hand-held tester to the DLC3. (3) Fully apply the parking brake. (4) Start and warm up the engine and check idle speed. Idle speed: approx. 700 rpm (In N position and A/C OFF) (5) Shift the lever from N to D position. Using a stop watch, measure the time from when the lever is shifted until the shock is felt. Time lag: N → D less than 1.2 seconds (6) In the same way, measure the time lag for N → R. Time lag: N → R less than 1.5 seconds Evaluation (If N → D or N → R time lag is longer than the specified): Problem Possible cause N → D time lag is longer
Line pressure is too low
Forward clutch worn
No.1 one-way clutch not operating properly
U/D (Underdrive) one-way clutch not operating
U/D (Underdrive) brake worn N → R time lag is longer
Line pressure is too low
Reverse clutch worn
1st and reverse brake worn
U/D (Underdrive) brake worn 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1191 05-1004 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05EJY-07 MANUAL SHIFTING TEST 1. PERFORM MANUAL SHIFTING TEST HINT:
With this test, it can be determined whether the trouble occurs in the electrical circuit or is a mechanical problem in the transaxle.
If any abnormalities are found in the following test, the problem is in the transaxle itself. (a) Disconnect the transmission wire connector. (b) Drive with the transmission wire disconnected. Shifting the shift lever to the L, 2, 3 and D position to check whether the shifting condition changes the table below. Transmission Wire G30833 Shift Position Shifting Condition L⇔2 No Shift (Not Change) 2⇔3 Down Shift ⇔ Up Shift 3⇔D No Shift (Not Change) HINT: When driving with the transmission wire disconnected, the gear position will be as follows:
When the shift lever is in the L or the 2 position, the gear is held in the 3rd position.
When the shift lever is in the D position, the gear is held in the 4th position.
When the shift lever is in the R or the P position, the gear is also in the R or the P position respectively. (c) Connect the transmission wire connector. (d) Clear the DTC (see page 05-1026 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1194 DIAGNOSTICS - 05-1 109 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05ITE-02 O/D MAIN SWITCH CIRCUIT CIRCUIT DESCRIPTION The O/D main switch (transmission control switch) is a momentary type switch. When pressing the O/D main switch, the O/D OFF indicator light lights up and the ECM prohibits shifting into O/D, and when pressing it once again, the O/D OFF indicator light goes off and the ECM allows shifting into O/D. Turning the IG switch OFF will reset the O/D OFF indicator light. WIRING DIAGRAM Center J/B W-B 13 3F T16 Transmission Control SW and Transmission Shift Main SW 2 8 L 3H IF3 W-B 6 2 ECM GR 16 E5 ODMS IB G30835 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1299 05-1 110 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(TRANSMISSION CONTROL SWITCH-BODY GROUND) (a) (b) Wire Harness Side: (Connector Front View) Disconnect the transmission control switch connector. Measure the resistance according to the value(s) in the table below. Standard: T16 NG Tester Connection Specified Condition 6 - Body ground Below 1 Ω REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR G23398 OK 2 INSPECT TRANSMISSION CONTROL SWITCH (a) Switch Side: (Connector Front View): T16 G28380 Measure the resistance according to the value(s) in the table below. Standard: Switch Condition Tester Connection Specified Condition Press continuously transmission control switch 2-6 Below 1 Ω Release transmission control switch ↑ 10 kΩ or higher NG REPLACE TRANSMISSION CONTROL SWITCH (SEE PAGE 40-61 ) OK 3 CHECK HARNESS AND CONNECTOR(TRANSMISSION CONTROL SWITCH-ECM) E7 E8 E9 E6 (a) (b) (c) E5 ODMS G25190 Connect the transmission control switch connector. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard: Switch Condition Tester Connection Specified Condition Press continuously transmission control switch E5 - 16 (ODMS) Body ground Below 1 Ω Release transmission control switch ↑ 10 kΩ or higher NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1016 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1300 05-1036 DIAGNOSTICS DTC P0705 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05EK9-08 TRANSMISSION RANGE SENSOR CIRCUIT MALFUNCTION (PRNDL INPUT) CIRCUIT DESCRIPTION The park/neutral position switch detects the shift lever position and sends signals to the ECM. DTC No. DTC Detection Condition Trouble Area (A) Any 2 or more signals of the following are ON simultaneously (2-trip detection logic)
P input signal is ON.
N input signal is ON.
R input signal is ON.
D input signal is ON.
3 input signal is ON.
2 input signal is ON. (B) Any 2 or more signals of the following are ON simultaneously (2-trip detection logic)
NSW input signal is ON.
R input signal is ON.
D input signal is ON.
3 input signal is ON.
2 input signal is ON. P0705
Open or short in park/neutral position switch circuit
Park/neutral position switch
ECM MONITOR DESCRIPTION The park/neutral position switch detects the shift lever position and sends a signal to the ECM. For security, the park/neutral position switch detects the shift lever position so that engine can be started only when the vehicle is in P or N shift position. When the park/neutral position switch sends more than one signal at a time from switch positions P, R, N or D, the ECM interprets this as a fault in the switch. The ECM will turn on the MIL and store the DTC. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0705: Park/neutral position switch/Verify switch input Park/neutral position switch Continuous 2 sec. 2 driving cycles None TYPICAL ENABLING CONDITIONS Condition (A) The monitor will run whenever this DTC is not present. See page 05-1007 Ignition switch ON Battery voltage 10.5 V or more Condition (B) The monitor will run whenever this DTC is not present. See page 05-1007 Ignition switch ON Battery voltage 10.5 V or more 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1226 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1037 TYPICAL MALFUNCTION THRESHOLDS One of the following conditions is met: Condition (A) or (B) Condition (A) Number of the following signal input at the same time 2 or more P switch ON R switch ON N switch ON D switch ON 3 switch ON 2 switch ON Condition (B) Number of the following signal input at the same time 2 or more NSW switch ON R switch ON D switch ON 3 switch ON 2 switch ON COMPONENT OPERATING RANGE Park/neutral Position switch The park/neutral position switch sends only one signal to the ECM. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1227 05-1038 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) WIRING DIAGRAM ECM 17 STA E7 B 4 EB2 B L-W to STARTER Relay P1 Park/Neutral Position SW N 4 5 P 16 E7 B-R T16 Transmission Control SW and Transmission Shift Main SW 12 8 BR R IF3 IF3 5 1 G 7 IM1 Y-G LL 8 9 2 E6 G B B NSW 8 L E6 R J17 J/C G +B G 18 IM1 P 20 3 E6 L-W 8 IM1 Y 10 D E6 2L 3 DL 7 Passenger Side J/B 2 RB R-B 20 IM1 L-Y 9 IM1 RL 1 R PL 6 9 10 IM1 1 2 B ALT 6 P E5 J6 J/C GR C 7 1C IG1 2 1G R 11 R E6 L V C 1 1A 1 G 6 1C AM1 7 N E5 GR I15 Ignition SW Instrument Panel J/B F7 FL Block W 5 4K J6 J/C B B 19 IM1 Y-R NL 6 4A L 4 IG1 AM1 2 W 2 FL MAIN Battery G30834 G32477 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1228 DIAGNOSTICS - 05-1039 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) INSPECTION PROCEDURE HINT: According to the DATA LIST displayed by the OBD II scan tool or hand-held tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. (a) Turn the ignition switch off. (b) Connect the OBD II scan tool or hand-held tester to the DLC3. (c) Turn the ignition switch to the ON position. (d) Push the ”ON” button of the OBD II scan tool or the hand-held tester. (e) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/DATA LIST”. (f) According to the display on tester, read the ”DATA LIST”. Item Measurement Item/ Range (display) Normal Condition Diagnostic Note When the shift lever position displayed on the hand-held tester differs from the actual position, adjustment of the PNP switch or the shift cable may be incorrect. PNP SW [NSW] PNP SW Status/ ON or OFF Shift lever position is; P and N: ON Except P and N: OFF LOW PNP SW Status/ ON or OFF Shift lever position is; L: ON Except L: OFF ↑ 2ND PNP SW Status/ ON or OFF Shift lever position is; 2 and L: ON Except 2 and L: OFF ↑ REVERSE PNP SW Status/ ON or OFF Shift lever position is; R: ON Except R: OFF ↑ DRIVE PNP SW Status/ ON or OFF Shift lever position is; D: ON Except D: OFF ↑ 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1229 05-1040 1 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) INSPECT PARK/NEUTRAL POSITION SWITCH ASSY (a) (b) Switch Side: (Connector Front View): Disconnect the park/neutral position switch connector. Measure resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard: Shift Position Tester Connection Specified Condition P 2 - 6 and 4 - 5 Below 1 Ω Except P ↑ 10 kΩ or higher R 2-1 Below 1 Ω Except R ↑ 10 kΩ or higher N 2 - 9 and 4 - 5 Below 1 Ω Except N ↑ 10 kΩ or higher D 2-7 Below 1 Ω Except D ↑ 10 kΩ or higher 3 2-3 Below 1 Ω Except 3 ↑ 10 kΩ or higher 2 and L 2-8 Below 1 Ω Except 2 and L ↑ 10 kΩ or higher P1 G26080 NG REPLACE PARK/NEUTRAL POSITION SWITCH ASSY (SEE PAGE 40-7 ) OK 2 INSPECT TRANSMISSION SHIFT MAIN SWITCH (a) (b) Switch Side: (Connector Front View): (c) T16 Connect the park/neutral position switch connector. Disconnect the transmission control switch connector of shift lever assy. Measure resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard: Shift Position Tester Connection Specified Condition 2 1-5 10 kΩ or higher L ↑ Below 1 Ω G28380 NG REPLACE TRANSMISSION SWITCH (SEE PAGE 40-61 ) SHIFT MAIN OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1230 DIAGNOSTICS 3 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1041 CHECK HARNESS AND CONNECTOR(PARK/NEUTRAL POSITION SWITCH ECM) E1(-) NSW(+) E7 E8 (a) D(+) L(+) N(+) 2(+) P(+) R(+) ON E9 E6 (b) Connect the transmission control switch connector of shift lock control unit assy. Turn the ignition switch to the ON position, and measure the voltage according to the value(s) in the table below when the shift lever is moved to each position. E5 3(+) ECM: G20666 Standard: Shift Position Tester connection Specified condition P and N E7 - 16 (NSW) - Body ground Below 1 V Except P and N ↑ 10 to 14 V P E5 - 6 (P) - Body ground 10 to 14 V Except P ↑ Below 1 V N E5 - 7 (N) - Body ground 10 to 14 V Except N ↑ Below 1 V R E6 - 11 (R) - Body ground 10 to 14 V* Except R ↑ Below 1 V D E6 - 10 (D) - Body ground 10 to 14 V Except D ↑ Below 1 V 3 E6 - 20 (3) - Body ground 10 to 14 V Except 3 ↑ Below 1 V 2 and L E6 - 9 (2) - Body ground 10 to 14 V Except 2 and L ↑ Below 1 V L E6 - 8 (L) - Body ground 10 to 14 V Except L ↑ Below 1 V HINT: *: The voltage will drop slightly due to lighting up of the back up light. NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK REPLACE ECM (SEE PAGE 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1231 05-1042 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) DTC P0710 TRANSMISSION FLUID TEMPERATURE SENSOR ”A” CIRCUIT DTC P0712 TRANSMISSION FLUID TEMPERATURE SENSOR ”A” CIRCUIT LOW INPUT DTC P0713 TRANSMISSION FLUID TEMPERATURE SENSOR ”A” CIRCUIT HIGH INPUT 0527N-32 CIRCUIT DESCRIPTION The ATF (Automatic Transmission Fluid) temperature sensor converts the fluid temperature into a resistance value which is input into the ECM. The ECM applies a voltage to the temperature sensor through ECM terminal THO1. The sensor resistance changes with the transmission fluid temperature. As the temperature becomes higher, the sensor resistance decreases. One terminal of the sensor is grounded so that the sensor resistance decreases and the voltage goes down as the temperature becomes higher. The ECM calculates the fluid temperature based on the voltage signal. DTC No. DTC Detection Condition Trouble Area P0710 (a) and (b) is detected momentary within 0.5 sec. when neither P0712 or P0713 is not detected (1-trip detection logic) (a) ATF temperature sensor resistance is less than 79 Ω. (b) ATF temperature sensor resistance is more than 156 kΩ. HINT: Within 0.5 sec., the malfunction switches from (a) to (b) or from (b) to (a)
Open or short in ATF temperature sensor circuit
Transmission wire (ATF temperature sensor)
ECM P0712 ATF temperature sensor resistance is less than 79 Ω for 0.5 sec. or more (1-trip detection logic)
Short in ATF temperature sensor circuit
Transmission wire (ATF temperature sensor)
ECM P0713 ATF temperature sensor resistance is more than 156 kΩ when 15 minutes or more after the engine start DTC is detected for 0.5 sec. or more (1-trip detection logic)
Open in ATF temperature sensor circuit
Transmission wire (ATF temperature sensor)
ECM MONITOR DESCRIPTION The automatic transmission fluid (ATF) temperature sensor converts ATF temperature to an electrical resistance value. Based on the resistance, the ECM determines the ATF temperature, and the ECM detects an opens or shorts in the ATF temperature circuit. If the resistance value of the ATF temperature is less than 79 Ω*1 or more than 156 kΩ*2, the ECM interprets this as a fault in the ATF sensor or wiring. The ECM will turn on the MIL and store the DTC. *1: 150C (302F) or more is indicated regardless of the actual ATF temperature. *2: -40C (-40F) is indicated regardless of the actual ATF temperature. HINT: The ATF temperature can be checked on the OBD II scan tool or hand-held tester display. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1232 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1043 MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0710: ATF temperature sensor/Range check (Fluttering) P0712: ATF temperature sensor/Range check (Low resistance) P0713: ATF temperature sensor/Range check (High resistance) ATF temperature sensor (TFT sensor) Continuous 0.5 sec. Immediate None TYPICAL ENABLING CONDITIONS P0710: Range check (Fluttering) P0712: Range check (Low resistance) The monitor will run whenever these DTCs are not present. See page 05-1007 The typical enabling condition is not available. - P0713: Range check (High resistance) The monitor will run whenever this DTC is not present. See page 05-1007 Time after engine start 15 min. or more TYPICAL MALFUNCTION THRESHOLDS P0710: Range check (Fluttering) Less than 79 Ω or More than 156 kΩ TFT (transmission fluid temperature) sensor P0712: Range check (Low resistance) Less than 79 Ω TFT (transmission fluid temperature) sensor P0713: Range check (High resistance) TFT (transmission fluid temperature) sensor More than 156 kΩ COMPONENT OPERATING RANGE TFT (transmission fluid temperature) Atmospheric temperature - approx. 130C (266F) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1233 05-1044 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) WIRING DIAGRAM E1 Electronically Controlled Transmission Solenoid ECM O BR E2 O 7 THO 1 Short Connector 5 5 S28 S29 BR 28 E7 E2 5V 32 E8 G-Y THO1 G30836 G32447 INSPECTION PROCEDURE HINT: According to the DATA LIST displayed by the OBD II scan tool or hand-held tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the OBD II scan tool or hand-held tester to the DLC3. (d) Turn the ignition switch to the ON position. (e) Push the ”ON” button of the OBD II scan tool or the hand-held tester. (f) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/DATA LIST”. (g) According to the display on tester, read the ”DATA LIST”. Item Measurement Item/ Range (display) AT FLUID TEMP ATF Temp. Sensor Value/ min.: -40C (-40F) max.: 215C (419F) Normal Condition Approx. 80C (176F) (After Stall Test) HINT: When DTC P0712 is output and OBD II scan tool or hand-held tester output is 150C (302F), there is a short circuit. When DTC P0713 is output and OBD II scan tool or hand-held tester output is -40C (-40F), there is an open circuit. Measure the resistance between terminal THO1 (THO) and body ground. Temperature Displayed Malfunction -40 °C (-40°F) Open circuit 150°C (302°F) or more Short circuit 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1234 DIAGNOSTICS 1 - 05-1045 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) INSPECT TRANSMISSION WIRE(ATF TEMPERATURE SENSOR) (a) Transmission Wire Side: (Connector Front View): THO (b) E1 (c) E2 G26426 Disconnect the transmission wire connector from the transaxle. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 1 (THO) - 7 (E2) 79 Ω to 156 kΩ Measure the resistance according to the value(s) in the table below. Standard (Check for short): NG Tester Connection Specified Condition 1 (THO) - Body ground 10 kΩ or higher 7 (E2) - Body ground ↑ REPAIR OR REPLACE TRANSMISSION WIRE (SEE PAGE 40-37 ) OK 2 CHECK HARNESS AND CONNECTOR(TRANSMISSION WIRE - ECM) E7 E8 E9 E6 (a) (b) (c) E5 THO1 ECM: E2 (d) G20668 Connect the transmission wire connector to the transaxle. Disconnect the ECM connectors. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition E8 - 32 (THO1) - E7 - 28 (E2) 79 Ω to 156 kΩ Measure the resistance according to the value(s) in the table below. Standard (Check for short): Tester Connection Specified Condition E8 - 32 (THO1) - Body ground 10 kΩ or higher E7 - 28 (E2) - Body ground ↑ NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK REPLACE ECM (SEE PAGE 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1235 05-1046 DIAGNOSTICS DTC P0711 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05F2P-04 TRANSMISSION FLUID TEMPERATURE SENSOR ”A” PERFORMANCE CIRCUIT DESCRIPTION The ATF (Automatic Transmission Fluid) temperature sensor converts the fluid temperature into a resistance value which is input into the ECM. DTC No. P0711 DTC Detection Condition Trouble Area Both (a) and (b) are detected: (2-trip detection logic) (a) Intake air and engine coolant temperatures are more than -10°C (14F) at engine start (b) After normal driving for over 19 min. and 9 km (6 mile) or more, ATF temp. is less than 10°C (50F)
Open or short in ATF temperature sensor circuit
Transmission wire (ATF temperature sensor)
ECM MONITOR DESCRIPTION The ATF temperature sensor converts the ATF temperature to an electrical resistance value. Based on the resistance, the ECM determines the ATF temperature and detects an opens or shorts in the ATF temperature circuit or a fault of the ATF temperature sensor. After running the vehicle for a certain period, the ATF temperature should increase. If the ATF temperature is below 10C (50F) after running the vehicle for a certain period, the ECM interprets this as a fault, and turns on the MIL. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0711: ATF temperature sensor/Rationality check ATF temperature sensor (TFT sensor) Continuous 3 sec. 2 driving cycles None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. Time after engine start See page 05-1007 16 min. and 40 sec. or more ECT (Engine coolant temperature) -15 C (5F) or more TFT (transmission fluid temperature) sensor circuit Not circuit malfunction ECT sensor circuit Not circuit malfunction IAT (Intake air temperature) sensor circuit Not circuit malfunction Time after engine start 18 min. and 20 sec. Driving distance after engine start 9 km (5.6 mile) or more IAT (12 sec. after starting engine) -10 C (14F) or more ECT (12 sec. after starting engine) -10 C (14F) or more TYPICAL MALFUNCTION THRESHOLDS TFT (transmission fluid temperature) Less than 10C (50F) COMPONENT OPERATING RANGE TFT (transmission fluid temperature) Atmospheric temperature to approx. 130C (266F) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1236 DIAGNOSTICS - 05-1047 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) WIRING DIAGRAM E1 Electronically Controlled Transmission Solenoid ECM O BR E2 O 7 THO 1 Short Connector 5 5 S28 S29 BR 28 E7 E2 5V 32 E8 G-Y THO1 G30836 G32447 INSPECTION PROCEDURE HINT: According to the DATA LIST displayed by the OBD II scan tool or hand-held tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the OBD II scan tool or hand-held tester to the DLC3. (d) Turn the ignition switch to the ON position. (e) Push the ”ON” button of the OBD II scan tool or the hand-held tester. (f) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/DATA LIST”. (g) According to the display on tester, read the ”DATA LIST”. Item Measurement Item/ Range (display) AT FLUID TEMP ATF Temp. Sensor Value/ min.: -40C (-40F) max.: 215C (419F) Normal Condition Approx. 80C (176F) (After Stall Test) HINT: When DTC P0712 is output and OBD II scan tool or hand-held tester output is 150C (302F), there is a short circuit. When DTC P0713 is output and OBD II scan tool or hand-held tester output is -40C (-40F), there is an open circuit. Measure the resistance between terminal THO1 (THO) and body ground. Temperature Displayed Malfunction -40 °C (-40°F) Open circuit 150°C (302°F) or more Short circuit 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1237 05-1048 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) HINT: If a circuit related to the ATF temperature sensor becomes open, P0713 is immediately set (in 0.5 second). When P0713 is set, P0711 cannot be detected. It is not necessary to inspect the circuit when P0711 is set. 1 CHECK OTHER DTCS OUTPUT(IN ADDITION TO DTC P0711) (a) (b) Connect the OBD II scan tool or the hand-held tester to the DLC3. Turn the ignition switch to the ON position and push the OBD II scan tool or the hand-held tester main switch ON. (c) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/DTC INFO/CURRENT CODES”. (d) Read the DTCs using the OBD II scan tool or the hand-held tester. Result: Display (DTC output) Proceed to Only ”P0711” is output A ”P0711” and other DTCs B HINT: If any other codes besides ”P0711” is output, perform the troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART (SEE PAGE 05-1034 ) A 2 CHECK TRANSAXLE FLUID LEVEL (SEE PAGE 40-2 ) OK: Automatic transaxle fluid level is correct. NG ADD FLUID OK REPLACE TRANSMISSION WIRE (SEE PAGE 40-37 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1238 DIAGNOSTICS DTC P0717 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1049 05F2Q-04 TURBINE SPEED SENSOR CIRCUIT NO SIGNAL CIRCUIT DESCRIPTION This sensor detects the rotation speed of the input turbine. By comparing the input turbine speed signal (NT) with the counter gear speed sensor signal (NC), the ECM detects the shift timing of the gears and appropriately controls the engine torque and hydraulic pressure according to various conditions. Thus, providing smooth gear shift. DTC No. P0717 DTC Detection Condition Trouble Area ECM detects conditions (a), (b) and (c) continuity for 5 sec. or more: (1-trip detection logic) (a) Vehicle speed: 50 km/h (31 mph) or more (b) Park/neutral position switch (NSW and R) is OFF (c) Speed sensor (NT): less than 300 rpm 5 V/DIV
Open or short in transmission revolution sensor NT (speed sensor NT) circuit
Transmission revolution sensor NT (speed sensor NT)
ECM
Automatic transaxle assembly Reference (Using an oscilloscope): Check the waveform between the terminals NT+ and NTof the ECM connector. Standard: Refer to the illustration. Terminal NT+ - NT- Tool setting 5V/DIV, 0.5ms/DIV Vehicle condition Vehicle speed 20 km/h (12 mph) 0.5 ms/DIV C53419 C42920 MONITOR DESCRIPTION The NT terminal of the ECM detects a revolution signal from the speed sensor (NT) (input RPM). The ECM calculates a gearshift comparing the speed sensor (NT) with the speed sensor (NC). While the vehicle is operating in 2nd, 3rd, 4th or 5th gear in the shift position of D, if the input shaft revolution is less than 300 rpm*1 although the output shaft revolution is more than 1,000 rpm*2, the ECM detects the trouble, illuminates the MIL and stores the DTC. *1: Pulse is not output or is irregularly output. *2: The vehicle speed is 50 km/h (31 mph) or more. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0717: Speed sensor (NT)/Verify pulse input Speed sensor (NT), Speed sensor (NC) Continuous 5 sec. Immediate None 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1239 05-1050 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. See page 05-1007 Shift change Shift change is completed and before starting next shift change operation ECM selected gear 2nd, 3rd, 4th or 5th Output shaft rpm 1,000 rpm or more NSW switch OFF R switch OFF L switch OFF Engine Running Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Sensor signal rpm Less than 300 rpm COMPONENT OPERATING RANGE Speed sensor (NT) Turbine speed is equal to engine speed when lock-up ON WIRING DIAGRAM ECM T3 Turbine Speed Sensor 27 E8 W 1 2 NT+ 5V 35 E8 R-W NTE1 G31763 INSPECTION PROCEDURE 1 INSPECT SPEED SENSOR INSTALLATION (a) OK Check the speed sensor installation. OK: The installation bolt is tightened properly and there is no clearance between the sensor and transaxle case. NG BR3795 NG REPLACE SPEED SENSOR(NT) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1240 DIAGNOSTICS 2 - 05-1051 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) INSPECT SPEED SENSOR(NT) (a) Sensor Side: (Connector Front View): (b) T3 2 Disconnect the speed sensor connector from the transaxle. Measure the resistance according to the value(s) in the table below. Standard: 1 C58536 NG Tester Connection Specified Condition 20 C (68 F) 1-2 560 to 680 Ω REPLACE SPEED SENSOR(NT) OK 3 CHECK HARNESS AND CONNECTOR(SPEED SENSOR - ECM) E7 E8 E9 E6 (a) (b) (c) E5 Connect the speed sensor connector. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard: NT+ NTECM: C82158 C91565 (d) Tester Connection Specified Condition 20C (68F) E8 - 27 (NT+) - E8 - 35 (NT-) 560 to 680 Ω Measure the resistance according to the value(s) in the table below. Standard (Check for short): Tester Connection Specified Condition E8 - 27 (NT+) - Body ground 10 kΩ or higher E8 - 35 (NT-) - Body ground ↑ NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK REPLACE ECM (SEE PAGE 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1241 05-1052 DIAGNOSTICS DTC P0724 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05EKC-05 BRAKE SWITCH ”B” CIRCUIT HIGH CIRCUIT DESCRIPTION The purpose of this circuit is to prevent the engine from stalling while driving in lock-up condition, when brakes are suddenly applied. When the brake pedal is depressed, this switch sends a signals to the ECM. Then the ECM cancels the operation of the lock-up clutch while braking is in progress. DTC No. DTC Detecting Condition Trouble Area The stop light switch remains ON even when the vehicle is driven in a GO (30 km/h) and STOP (3 km/h) fashion 5 times. (2-trip detection logic). P0724
Short in stop light switch signal circuit
Stop light switch
ECM MONITOR DESCRIPTION This DTC indicates that the stop light switch remains on. When the stop light switch remains ON during ”stop and go” driving, the ECM interprets this as a fault in the stop light switch and the MIL comes on and the ECM stores the DTC. The vehicle must stop (less than 3 km/h (2 mph)) and go (30 km/h (19 mph) or more) 5 times for two driving cycles in order to detect malfunction. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0724: Stop light switch/Rationality Stop light switch, Vehicle speed sensor Continuous GO and STOP 5 times 2 driving cycles None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. See page 05-1007 Battery voltage 8 V or more Ignition switch ON Starter OFF GO (Vehicle speed is 30 km/h (18.63 mph) or more) Once STOP (Vehicle speed is less than 3 km/h (1.86 mph)) Once TYPICAL MALFUNCTION THRESHOLDS Brake switch Remain ON during GO and STOP 5 times 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1242 DIAGNOSTICS - 05-1053 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) WIRING DIAGRAM 3 4L B 1 2 ECM Passenger Side J/B S15 Stop Light SW Y 12 4M BR 19 STP E6 Instrument Panel J/B 1 1E STOP 1 1A F7 FL Block W B 1 ALT 2 FL MAIN Battery G30837 G32448 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1243 05-1054 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) INSPECTION PROCEDURE HINT: According to the DATA LIST displayed by the OBD II scan tool or hand-held tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. (a) Turn the ignition switch off. (b) Connect the OBD II scan tool or hand-held tester to the DLC3. (c) Turn the ignition switch to the ON position. (d) Push the ”ON” button of the OBD II scan tool or the hand-held tester. (e) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/DATA LIST”. (f) According to the display on tester, read the ”DATA LIST”. 1 Item Measurement Item/ Range (display) STOP LIGHT SW Stop light SW Status/ ON or OFF Normal Condition
Brake Pedal is depressed: ON
Brake Pedal is released: OFF INSPECT STOP LAMP SWITCH ASSY 2 4 1 3 Free Pushed in E65594 (a) (b) Remove the stop lamp switch assy. Measure the resistance according to the value(s) in the table below. Standard: Switch position Tester Connection Specified Condition Switch pin free 1-2 10 kΩ or higher Switch pin pushed in ↑ Below 1 Ω Switch pin free 3-4 Below 1 Ω Switch pin pushed in ↑ 10 kΩ or higher NG REPLACE STOP LAMP SWITCH ASSY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1244 DIAGNOSTICS 2 - 05-1055 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) CHECK HARNESS AND CONNECTOR(STOP LAMP SWITCH ASSY - ECM) ECM: E7 (a) (b) STP(+) E8 E9 E6 E5 G26289 Install the stop lamp switch assy. Measure the voltage according to the value(s) in the table below when the brake pedal is depressed and released. Standard: Condition Tester Connection Specified Condition Brake pedal is depressed E6 - 19 (STP) Body ground 10 to 14 V Brake pedal is released ↑ Below 1 V NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK REPLACE ECM (SEE PAGE 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1245 05-1056 DTC DIAGNOSTICS P0741 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05EKD-05 TORQUE CONVERTER CLUTCH SOLENOID PERFORMANCE (SHIFT SOLENOID VALVE DSL) SYSTEM DESCRIPTION The ECM uses the signals from the throttle position sensor, Air-flow meter, turbine (input) speed sensor, intermediate (counter) shaft speed sensor and crankshaft position sensor to monitor the engagement condition of the lock-up clutch. Then the ECM compares the engagement condition of the lock-up clutch with the lock-up schedule in the ECM memory to detect a mechanical problems of the shift solenoid valve DSL, valve body and torque converter clutch. DTC No. P0741 DTC Detection Condition Lock-up does not occur when driving in lock-up range or lockup remains ON in lock-up OFF range (2-trip detection logic) Trouble Area
Shift solenoid valve DSL remains open or closed
Valve body is blocked
Shift solenoid valve DSL
Torque converter clutch
Automatic transaxle (clutch, brake or gear etc.)
Line pressure is too low
ECM MONITOR DESCRIPTION Torque converter lock-up is controlled by the ECM based on speed sensor (NT), speed sensor (NC), engine rpm, engine load, engine temperature, vehicle speed, transmission temperature, and gear selection. The ECM determines the lock-up status of the torque converter by comparing the engine rpm (NE) to the input turbine rpm (NT). The ECM calculates the actual transmission gear by comparing input turbine rpm (NT) to counter gear rpm (NC). When conditions are appropriate, the ECM requests ”lock-up” by applying control voltage to shift solenoid DSL. When the DSL is turned on, solenoid DSL applies pressure to the lock-up relay valve and locks the torque converter clutch. If the ECM detects no lock-up after lock-up has been requested or if it detects lock-up when it is not requested, the ECM interprets this as a fault in the shift solenoid valve DSL or lock-up system performance. The ECM will turn on the MIL and store the DTC. Example: When any of the following is met, the system judges it as a malfunction. (a) There is a difference in rotation between before and after torque converters even when the ECM commands lock-up. (Engine speed is at least 75 rpm greater than input turbine speed.) (b) There is no difference in rotation between before and after torque converters even when the ECM commands lock-up off. (The difference between engine speed and input turbine speed is less than 35 rpm.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1246 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1057 MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation P0741: Shift solenoid valve DSL/OFF malfunction P0741: Shift solenoid valve DSL/ON malfunction Shift solenoid valve DSL, Speed sensor (NT), Speed sensor (NC),Crankshaft position sensor (NE), Throttle position sensor (VPA1), Mass air flow sensor (MAF), Transmission temperature sensor (THO1), Engine coolant temperature sensor (ECT) Continuous Duration OFF malfunction 3.5 sec. ON malfunction 1.8 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS ALL: Transmission range ”D” ECT (Engine coolant temperature) 10C (50F) or more TFT (Transmission fluid temperature) -20 C (-4F) or more TFT sensor circuit Not circuit malfunction ECT sensor circuit Not circuit malfunction Turbine speed sensor circuit Not circuit malfunction Intermediate shaft speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction Shift solenoid valve SL3 circuit Not circuit malfunction Shift solenoid valve S4 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve DSL circuit Not circuit malfunction OFF malfunction ECM lock-up command ON Duration time from lock-up on command 3 sec. or more ECM selected gear Vehicle speed 3rd, 4th or 5th 25 km/h (15.5 mph) or more ON malfunction ECM lock-up command OFF ECM selected gear 3rd, 4th or 5th Throttle valve opening angle Vehicle speed 10% or more 25 to 60 km/h (15.5 to 37.3 mph) TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is met: OFF malfunction or ON malfunction OFF malfunction Engine speed - Input (turbine) speed 100 rpm or more ON malfunction Diffierence between engine speed and input (turbine) speed Less than 35 rpm 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1247 05-1058 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) INSPECTION PROCEDURE HINT: Performing the ACTIVE TEST using the hand-held tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the hand-held tester to the DLC3. (d) Turn the ignition switch to the ON position. (e) Push the ”ON” button of the hand-held tester. (f) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/ACTIVE TEST”. (g) According to the display on tester, perform the ”ACTIVE TEST”. Item LOCK UP Test Details Diagnostic Note [Test Details] Control the shift solenoid DSL to set the automatic transaxle to the lock-up condition. [Vehicle Condition] Vehicle Speed: 60 km/h (37 mph) or more Possible to check the DSL operation. HINT:

(h) HINT:

This test can be conducted when the vehicle speed is 60 km/h (37 mph) or more. This test can be conducted with the 5th gear. Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. When changing the accelerator pedal opening angle while driving, if the engine speed does not change, lock-up is on. Slowly release, but not fully, the accelerator pedal in order to decelerate. (Fully releasing the pedal will close the throttle valve and lock-up may be turned off.) Accelerator Pedal Opening Angle Accelerator Pedal Fully Released Lock-up OFF Engine Speed Lock-up ON G23400 → time G29214 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1248 DIAGNOSTICS 1 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1059 CHECK OTHER DTCS OUTPUT(IN ADDITION TO DTC P0741) (a) (b) Connect the OBD II scan tool or the hand-held tester to the DLC3. Turn the ignition switch to the ON position and push the OBD II scan tool or the hand-held tester main switch ON. (c) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/DTC INFO/CURRENT CODES”. (d) Read the DTCs using the OBD II scan tool or the hand-held tester. Result: Display (DTC output) Proceed to Only ”P0741” is output A ”P0741” and other DTCs B HINT: If any other codes besides ”P0741” is output, perform the troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART (SEE PAGE 05-1034 ) A 2 INSPECT TRANSMISSION WIRE(DSL) (a) Transmission Wire Side: (Connector Front View): (b) E1 DSL G26426 Disconnect the transmission wire connector from the transaxle. Measure the resistance according to the value(s) in the table below. Standard: NG Tester Connection Specified Condition 20C (68F) 10 - Body ground 11 to 13 Ω Go to step 4 OK 3 CHECK HARNESS AND CONNECTOR(TRANSMISSION WIRE - ECM) E7 ECM: C82158 E8 E9 E6 (a) (b) (c) E5 DSL C91565 Connect the transmission wire connector. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20C (68F) E8 - 11 (DSL) - Body ground 11 to 13 Ω NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1249 05-1060 4 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) INSPECT SHIFT SOLENOID VALVE(DSL) (a) (b) Shift Solenoid Valve DSL: Tester Connection Specified Condition 20C (68F) Solenoid Connector (DSL) - Solenoid Body (DSL) 11 to 13 Ω (c) (-) (+) C90646 Remove the shift solenoid valve DSL. Measure the resistance according to the value(s) in the table below. Standard: Connect positive (+) lead to the terminal of solenoid connector, negative (-) lead to the solenoid body. OK: The solenoid valve makes an operating noise. NG REPLACE SHIFT SOLENOID VALVE(DSL) OK 5 CHECK TRANSMISSION WIRE (SEE PAGE 01-36 ) OK: The connectors and pins are securely installed. There is no open or short on the wire harness. NG REPAIR OR REPLACE TRANSMISSION WIRE (SEE PAGE 40-37 ) OK 6 INSPECT TRANSMISSION VALVE BODY ASSY(See chapter 2 in the problem symptoms table) (SEE PAGE 05-1016 ) OK: There are no foreign objects on each valve and they operate smoothly. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSY (SEE PAGE 40-44 ) OK 7 INSPECT TORQUE CONVERTER CLUTCH ASSY (SEE PAGE 40-29 ) OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSY OK REPAIR AUTOMATIC TRANSAXLE ASSY (SEE PAGE 40-18 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1250 DIAGNOSTICS DTC P0746 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1061 05C0Z-18 PRESSURE CONTROL SOLENOID ”A” PERFORMANCE (SHIFT SOLENOID VALVE SL1) SYSTEM DESCRIPTION The ECM uses signals from the vehicle speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves and valve body. DTC No. P0746 DTC Detecting Condition Trouble Area The gear required by the ECM does not match the actual gear when driving (2-trip detection logic)
Shift solenoid valve SL1 remains open or closed
Valve body is blocked
Shift solenoid valve SL1
Automatic transaxle (clutch, brake or gear etc.)
ECM MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves ”ON/OFF”. According to the input shaft revolution, intermediate (counter) shaft revolution and output shaft revolution, the ECM detects the actual gear position (1st, 2nd, 3rd, 4th or 5th gear position). When the gear position commanded by the ECM and the actual gear position are not same, the ECM illuminates the MIL. Example: When either condition (a) or (b) is met, the ECM detects a malfunction. (a) The ECM commands the 1st gear, but the actual gear is 2nd. (b) The ECM commands the 2nd gear, but the actual gear is 1st. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0746: Shift solenoid valve SL1/OFF malfunction Shift solenoid valve SL1/ON malfunction Shift solenoid valve SL1, Speed sensor (NT), Speed sensor (NC), Crankshaft position sensor (NE) Continuous 0.8 sec. 2 driving cycles None 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1251 05-1062 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) TYPICAL ENABLING CONDITIONS ALL: Transmission range ”D” ECT (Engine coolant temperature) 10C (50F) or more TFT (Transmission fluid temperature) -20 C (-4F) or more TFT sensor circuit Not circuit malfunction ECT sensor circuit Not circuit malfunction Turbine speed sensor circuit Not circuit malfunction Intermediate shaft speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction Shift solenoid valve SL3 circuit Not circuit malfunction Shift solenoid valve S4 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve DSL circuit Not circuit malfunction OFF malfunction ECM selected gear Vehicle speed Throttle valve opening angle 1st Less than 40 km/h (24.9 mph) 4.5% or more at engine speed 1,900 rpm (Varies with engine speed) ON malfunction ECM selected gear Throttle valve opening angle 2nd 4.5% or more at engine speed 1,900 rpm (Varies with engine speed) TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is met: OFF malfunction or ON malfunction OFF malfunction 2 detections are necessary per driving cycle: 1st detection; temporary flag ON 2nd detection; pending fault code ON Input (turbine) speed/Intermediate shaft speed 1.49 to 1.63 ON malfunction Input (turbine) speed/Intermediate shaft speed 2.72 to 2.86 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1252 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1063 INSPECTION PROCEDURE HINT: Performing the ACTIVE TEST using the hand-held tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Turn the ignition switch off. (b) Connect the hand-held tester to the DLC3. (c) Turn the ignition switch to the ON position. (d) Push the ”ON” button of the hand-held tester. (e) Select the item ”DIAGNOSIS/ENHANCED OBD II/ACTIVE TEST/SHIFT”. (f) According to the display on tester, perform the ”ACTIVE TEST”. HINT: While driving, the shift position can be forcibly changed with the hand-held tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem (see page 05-1030 ). Item Test Details Diagnostic Note SHIFT [Test Details] Operate the shift solenoid valve and set the each shift position by yourself. [Vehicle Condition] Less than 50 km/h (31 mph) [Others]
Press ”→” button: Shift up
Press ”←” button: Shift down Possible to check the operation of the shift solenoid valves. HINT:

This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. The shift position commanded by the ECM is shown in the DATA LIST/SHIFT display on the hand-held tester. 1 CHECK OTHER DTCS OUTPUT(IN ADDITION TO DTC P0746) (a) (b) Connect the OBD II scan tool or the hand-held tester to the DLC3. Turn the ignition switch to the ON position and push the OBD II scan tool or the hand-held tester main switch ON. (c) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/DTC INFO/CURRENT CODES”. (d) Read the DTCs using the OBD II scan tool or the hand-held tester. Result: Display (DTC output) Proceed to Only ”P0746” is output A ”P0746” and other DTCs B HINT: If any other codes besides ”P0746” is output, perform the troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART (SEE PAGE 05-1034 ) A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1253 05-1064 2 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) INSPECT SHIFT SOLENOID VALVE(SL1) (a) (b) Shift Solenoid Valve SL1: 1 2 (c) 2 1 (-) Remove the shift solenoid valve SL1. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20C (68F) 1-2 5.0 to 5.6 Ω Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating noise. (+) G20767 NG REPLACE SHIFT SOLENOID VALVE(SL1) OK 3 INSPECT TRANSMISSION VALVE BODY ASSY(See chapter 2 in the problem symptoms table) (SEE PAGE 05-1016 ) OK: There are no foreign objects on each valve and they operate smoothly. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSY (SEE PAGE 40-44 ) OK 4 INSPECT TORQUE CONVERTER CLUTCH ASSY (SEE PAGE 40-29 ) OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSY OK REPAIR OR REPLACE AUTOMATIC TRANSAXLE ASSY (SEE PAGE 40-18 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1254 DIAGNOSTICS DTC P0748 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1065 05C10-20 PRESSURE CONTROL SOLENOID ”A” ELECTRICAL (SHIFT SOLENOID VALVE SL1) CIRCUIT DESCRIPTION Shifting from 1st to 5th is performed in combination with ”ON” and ”OFF” operation of the shift solenoid valves SL1, SL2, SL3, S4 and SR which is controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly (Fail safe function). DTC No. DTC Detection Condition Trouble Area P0748 ECM checks for an open or short circuit in shift solenoid valves SL1 (1-trip detection logic)
Output signal duty equals to 100%
Open or short in shift solenoid valve SL1 circuit
Shift solenoid valve SL1
ECM MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves ”ON/OFF”. When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other shift solenoid valves in good condition ”ON/OFF” (In case of an open or short circuit, the ECM stops sending current to the circuit.) (see page 05-1030 ). MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0748: Shift solenoid valve SL1/Range check Shift solenoid valve SL1 Continuous 1 sec. Immediate None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. See page 05-1007 Battery voltage 10 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Output signal duty 100% COMPONENT OPERATING RANGE Output signal duty Less than 100% 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1255 05-1066 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) WIRING DIAGRAM E1 Electronically Controlled Transmission Solenoid W 19 E8 R-B 6 SL1+ CPU SL1+ B 18 SL1E8 B-W 13 SL1- ECM +B G31765 INSPECTION PROCEDURE 1 INSPECT TRANSMISSION WIRE(SL1) Transmission Wire Side: (Connector Front View): SL1+ SL1- (a) E1 (b) G26426 (c) Disconnect the transmission wire connector from the transaxle. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20C (68F) 6 (SL1+) - 13 (SL1-) 5.0 to 5.6 Ω Measure the resistance according to the value(s) in the table below. Standard (Check for short): NG Tester Connection Specified Condition SL1+ - Body ground 10 kΩ or higher SL1- - Body ground ↑ Go to step 3 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1256 DIAGNOSTICS 2 - 05-1067 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) CHECK HARNESS AND CONNECTOR(TRANSMISSION WIRE - ECM) E7 E8 E9 E6 (a) (b) (c) E5 Connect the transmission connector to the transaxle. Disconnect the connector from the ECM. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20C (68F) E8 - 19 (SL1+) - E8 - 18 (SL1-) 5.0 to 5.6 Ω ECM: SL1+ SL1C82158 C91565 (d) Measure the resistance according to the value(s) in the table below. Standard (Check for short): Tester Connection Specified Condition E8 - 19 (SL1+) - Body ground 10 kΩ or higher E8 - 18 (SL1-) - Body ground ↑ NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK REPLACE ECM (SEE PAGE 10-24 ) 3 INSPECT SHIFT SOLENOID VALVE(SL1) (a) (b) Shift Solenoid Valve SL1: 1 2 (c) 2 1 (-) Remove the shift solenoid valve SL1. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20C (68F) 1-2 5.0 to 5.6 Ω Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating noise. (+) G20767 NG REPLACE SHIFT SOLENOID VALVE(SL1) OK REPAIR OR REPLACE TRANSMISSION WIRE (SEE PAGE 40-37 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1257 05-1068 DIAGNOSTICS DTC P0766 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05C11-20 SHIFT SOLENOID ”D” PERFORMANCE (SHIFT SOLENOID VALVE S4) SYSTEM DESCRIPTION The ECM uses signals from the vehicle speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves and valve body. DTC No. P0766 DTC Detecting Condition Trouble Area The gear required by the ECM does not match the actual gear when driving (2-trip detection logic)
Shift solenoid valve S4 remains open or closed
Valve body is blocked
Shift solenoid valve S4
Automatic transaxle (clutch, brake or gear etc.)
ECM MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves ”ON/OFF”. According to the input shaft revolution, intermediate (counter) shaft revolution and output shaft revolution, the ECM detects the actual gear position (1st, 2nd, 3rd, 4th or 5th gear position). When the gear position commanded by the ECM and the actual gear position are not same, the ECM illuminates the MIL and stores the DTC. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0766: Shift solenoid valve S4/ON malfunction Shift solenoid valve S4/OFF malfunction Shift solenoid valve S4, Speed sensor (NT), Speed sensor (NC), Crankshaft position sensor (NE) Continuous OFF malfunction (A) and ON malfunction (B) 1 sec. OFF malfunction (B) 1.2 sec. ON malfunction (A) 0.8 sec. 2 driving cycles None 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1258 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1069 TYPICAL ENABLING CONDITIONS All: Transmission range ”D” ECT (Engine coolant temperature) 10C (50F) or more TFT (Transmission fluid temperature) -20 C (-4F) or more TFT sensor circuit Not circuit malfunction ECT sensor circuit Not circuit malfunction Turbine speed sensor circuit Not circuit malfunction Intermediate shaft speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction Shift solenoid valve SL3 circuit Not circuit malfunction Shift solenoid valve S4 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve DSL circuit Not circuit malfunction OFF malfunction (A) ECM selected gear 5th Throttle valve opening angle 5% or more Vehicle speed 10 km/h (6.2 mph) or more OFF malfunction (B) ECM lock-up command ON ECM selected gear 3rd, 4th or 5th Throttle valve opening angle 10% or more Vehicle speed 25 to 100 km/h (15.5 to 62.1 mph) ON malfunction (A) ECM selected gear Throttle valve opening angle 4th or 5th 4.5% or more at engine speed 1,900 rpm (Varies with engine speed) ON malfunction (B) ECM selected gear 4th Throttle valve opening angle 5% or more Vehicle speed 10 km/h (6.2 mph) or more TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is met: OFF malfunction (A) and (B), or ON malfunction (A) and (B) 2 detections are necessary per driving cycle: 1st detection; temporary flag ON 2nd detection; pending fault code ON OFF malfunction (A) Intermediate shaft speed/Output speed 1.44 to 1.58 OFF malfunction (B) Difference between engine speed and input (turbine) speed Less than 35 rpm ON malfunction (A) Input (turbine) speed/Intermediate shaft speed 0.64 to 0.74 ON malfunction (B) Intermediate shaft speed/Output speed 1.02 to 1.16 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1259 05-1070 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) INSPECTION PROCEDURE HINT: Performing the ACTIVE TEST using the hand-held tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Turn the ignition switch off. (b) Connect the hand-held tester to the DLC3. (c) Turn the ignition switch to the ON position. (d) Push the ”ON” button of the hand-held tester. (e) Select the item ”DIAGNOSIS/ENHANCED OBD II/ACTIVE TEST/SHIFT”. (f) According to the display on tester, perform the ”ACTIVE TEST”. HINT: While driving, the shift position can be forcibly changed with the hand-held tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem (see page 05-1030 ). Item Test Details Diagnostic Note SHIFT [Test Details] Operate the shift solenoid valve and set the each shift position by yourself. [Vehicle Condition] Less than 50 km/h (31 mph) [Others]
Press ”→” button: Shift up
Press ”←” button: Shift down Possible to check the operation of the shift solenoid valves. HINT:

This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. The shift position commanded by the ECM is shown in the DATA LIST/SHIFT display on the hand-held tester. 1 CHECK OTHER DTCS OUTPUT(IN ADDITION TO DTC P0766) (a) (b) Connect the OBD II scan tool or the hand-held tester to the DLC3. Turn the ignition switch to the ON position and push the OBD II scan tool or the hand-held tester main switch ON. (c) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/DTC INFO/CURRENT CODES”. (d) Read the DTCs using the OBD II scan tool or the hand-held tester. Result: Display (DTC output) Proceed to Only ”P0766” is output A ”P0766” and other DTCs B HINT: If any other codes besides ”P0766” is output, perform the troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART (SEE PAGE 05-1034 ) A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1260 DIAGNOSTICS 2 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1071 INSPECT SHIFT SOLENOID VALVE(S4) (-) Shift Solenoid Valve S4: (a) (b) (+) C90639 Remove the shift solenoid valve S4. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20C (68F) Solenoid Connector (S4) - Solenoid Body (S4) 11 to 15 Ω (c) Connect positive (+) lead to the terminal of solenoid connector, negative (-) lead to the solenoid body. OK: The solenoid makes an operating noise. NG REPLACE SHIFT SOLENOID VALVE(S4) OK 3 INSPECT TRANSMISSION VALVE BODY ASSY(See chapter 2 in the problem symptoms table) (SEE PAGE 05-1016 ) OK: There are no foreign objects on each valve and they operate smoothly. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSY (SEE PAGE 40-44 ) OK 4 INSPECT TORQUE CONVERTER CLUTCH ASSY (SEE PAGE 40-29 ) OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSY OK REPAIR OR REPLACE AUTOMATIC TRANSAXLE ASSY (SEE PAGE 40-18 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1261 05-1072 DIAGNOSTICS DTC P0771 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05C12-12 SHIFT SOLENOID ”E” PERFORMANCE (SHIFT SOLENOID VALVE SR) SYSTEM DESCRIPTION The ECM uses signals from the vehicle speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves and valve body. DTC No. P0771 DTC Detecting Condition Trouble Area The gear required by the ECM does not match the actual gear when driving (2-trip detection logic)
Shift solenoid valve SR remains open or closed
Valve body is blocked
Shift solenoid valve SR
Automatic transaxle (clutch, brake or gear etc.)
ECM MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves ”ON/OFF”. According to the input shaft revolution, intermediate (counter) shaft revolution and output shaft revolution, the ECM detects the actual gear position (1st, 2nd, 3rd, 4th or 5th gear position). When the gear position commanded by the ECM and the actual gear position are not same, the ECM illuminates the MIL and stores the DTC. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0771: Shift solenoid valve SR/Rationality check Shift solenoid valve SR, Speed sensor (NT), Speed sensor (NC), Crankshaft position sensor (NE) Continuous OFF malfunction (A) 1 sec. OFF malfunction (B) 3.5 sec. ON malfunction (A) Continuous ON malfunction (B) and (C) 0.8 sec. 2 driving cycles None 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1262 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1073 TYPICAL ENABLING CONDITIONS All: Transmission range ”D” ECT (Engine coolant temperature) 10C (50F) or more TFT (Transmission fluid temperature) -20 C (-4F) or more TFT sensor circuit Not circuit malfunction ECT sensor circuit Not circuit malfunction Turbine speed sensor circuit Not circuit malfunction Intermediate shaft speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction Shift solenoid valve SL3 circuit Not circuit malfunction Shift solenoid valve S4 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve DSL circuit Not circuit malfunction OFF malfunction (A) ECM selected gear 5th Throttle valve opening angle Vehicle speed 5% or more 10 km/h (6.2 mph) or more OFF malfunction (B) ECM lock-up command ON ECM selected gear Vehicle speed 3rd, 4th or 5th 25 km/h (15.5 mph) ON malfunction (A) ECM lock-up command OFF ON malfunction (B) ECM selected gear Vehicle speed Throttle valve opening angle 1st Less than 40 km/h (24.9 mph) 4.5% or more at engine speed 1,900 rpm (Varies with engine speed) ON malfunction (C) ECM selected gear Throttle valve opening angle 3rd 4.5% or more at engine speed 1,900 rpm (Varies with engine speed) ON malfunction (D) ECM selected gear 4th or 5th Duration time from shift command of ECM 15 sec. or more 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1263 05-1074 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is met: OFF malfunction (A) and (B), or ON malfunction (A), (B), (C) and (D) OFF malfunction (A) Intermediate shaft speed/Output speed 1.44 to 1.58 OFF malfunction (B) Engine speed - Input (turbine) speed When condition ”OFF malfunction (A)” of shift solenoid ”D” is detected; When condition ”OFF malfunction (A)” of shift solenoid ”D” is not detected; 75 rpm or more 100 rpm or more ON malfunction (A) Difference between engine speed and input (turbine) speed 150 rpm or more ON malfunction (B) Input (turbine) speed/Intermediate shaft speed 0.93 to 1.07 ON malfunction (C) Input (turbine) speed/Intermediate shaft speed 0.93 to 1.07 ON malfunction (D) Input (turbine) speed/Intermediate shaft speed 0.64 to 0.74 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1264 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1075 INSPECTION PROCEDURE HINT: Performing the ACTIVE TEST using the hand-held tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Turn the ignition switch off. (b) Connect the hand-held tester to the DLC3. (c) Turn the ignition switch to the ON position. (d) Push the ”ON” button of the hand-held tester. (e) Select the item ”DIAGNOSIS/ENHANCED OBD II/ACTIVE TEST/SHIFT”. (f) According to the display on tester, perform the ”ACTIVE TEST”. HINT: While driving, the shift position can be forcibly changed with the hand-held tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem (see page 05-1030 ). Item Test Details Diagnostic Note SHIFT [Test Details] Operate the shift solenoid valve and set the each shift position by yourself. [Vehicle Condition] Less than 50 km/h (31 mph) [Others]
Press ”→” button: Shift up
Press ”←” button: Shift down Possible to check the operation of the shift solenoid valves. HINT:

This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. The shift position commanded by the ECM is shown in the DATA LIST/SHIFT display on the hand-held tester. 1 CHECK OTHER DTCS OUTPUT(IN ADDITION TO DTC P0771) (a) (b) Connect the OBD II scan tool or the hand-held tester to the DLC3. Turn the ignition switch to the ON position and push the OBD II scan tool or the hand-held tester main switch ON. (c) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/DTC INFO/CURRENT CODES”. (d) Read the DTCs using the OBD II scan tool or the hand-held tester. Result: Display (DTC output) Proceed to Only ”P0771” is output A ”P0771” and other DTCs B HINT: If any other codes besides ”P0771” is output, perform the troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART (SEE PAGE 05-1034 ) A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1265 05-1076 2 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) INSPECT SHIFT SOLENOID VALVE(SR) (+) Shift Solenoid Valve SR: (a) (b) (-) C90640 Remove the shift solenoid valve SR. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20C (68F) Solenoid Connector (SR) - Solenoid Body (SR) 11 to 15 Ω (c) Connect positive (+) lead to the terminal of solenoid connector, negative (-) lead to the solenoid body. OK: The solenoid makes an operating noise. NG REPLACE SHIFT SOLENOID VALVE(SR) OK 3 INSPECT TRANSMISSION VALVE BODY ASSY(See chapter 2 in the problem symptoms table) (SEE PAGE 05-1016 ) OK: There are no foreign objects on each valve and they operate smoothly. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSY (SEE PAGE 40-44 ) OK 4 INSPECT TORQUE CONVERTER CLUTCH ASSY (SEE PAGE 40-29 ) OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSY OK REPAIR OR REPLACE AUTOMATIC TRANSAXLE ASSY (SEE PAGE 40-18 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1266 DIAGNOSTICS DTC P0776 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1077 05C13-18 PRESSURE CONTROL SOLENOID ”B” PERFORMANCE (SHIFT SOLENOID VALVE SL2) SYSTEM DESCRIPTION The ECM uses signals from the vehicle speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves and valve body. DTC No. P0776 DTC Detecting Condition Trouble Area The gear required by the ECM does not match the actual gear when driving (2-trip detection logic)
Shift solenoid valve SL2 remains open or closed
Valve body is blocked
Shift solenoid valve SL2
Automatic transaxle (clutch, brake or gear etc.)
ECM MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves ”ON/OFF”. According to the input shaft revolution, intermediate (counter) shaft revolution and output shaft revolution, the ECM detects the actual gear position (1st, 2nd, 3rd, 4th or 5th gear position). When the gear position commanded by the ECM and the actual gear position are not same, the ECM illuminates the MIL and stores the DTC. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0776: Shift solenoid valve SL2/OFF malfunction Shift solenoid valve SL2/ON malfunction Shift solenoid valve SL2, Speed sensor (NT), Speed sensor (NC), Crankshaft position sensor (NE) Continuous OFF malfunction (A) 1.8 sec. OFF malfunction (B) and (C) 0.8 sec. ON malfunction (A) and (B) 0.8 sec. ON malfunction (C) 0.4 sec. 2 driving cycles None 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1267 05-1078 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) TYPICAL ENABLING CONDITIONS All: Transmission range ”D” ECT (Engine coolant temperature) 10C (50F) or more TFT (Transmission fluid temperature) -20 C (-4F) or more TFT sensor circuit Not circuit malfunction ECT sensor circuit Not circuit malfunction Turbine speed sensor circuit Not circuit malfunction Intermediate shaft speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction Shift solenoid valve SL3 circuit Not circuit malfunction Shift solenoid valve S4 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve DSL circuit Not circuit malfunction OFF malfunction (A) ECM lock-up command Vehicle speed OFF Less than 60 km/h (37.3 mph) Throttle valve opening angle 10% or more OFF malfunction (B) ECM selected gear Vehicle speed Throttle valve opening angle 1st Less than 40 km/h (24.9 mph) 4.5% or more at engine speed 1,900 rpm (Varies with engine speed) OFF malfunction (C) ECM selected gear Throttle valve opening angle 3rd 4.5% or more at engine speed 1,900 rpm (Varies with engine speed) OFF malfunction (D) ECM select gear 4th or 5th Duration time from shift command of ECM 15 sec. or more ON malfunction (A) ECM select gear Vehicle speed Throttle valve opening angle 1st Less than 40 km/h (24.9 mph) 4.5% or more at engine speed 1,900 rpm (Varies with engine speed) ON malfunction (B) ECM selected gear Throttle valve opening angle 3rd 7.0% or more at output speed 1,400 rpm (Varies with engine speed) Malfunction of pressure control solenoid ”B” (SL2) and ”C” (SL3) Not detected ON malfunction (C) Throttle valve opening angle 7.0% or more at output speed 1,050 rpm (Varies with engine speed) Malfunction of pressure control solenoid ”B” (SL2) Not detected 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1268 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1079 TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is met: OFF malfunction (A), (B), (C) and (D), or ON malfunction (A), (B) and (C) OFF malfunction (A) Difference between engine speed and input (turbine) speed Less than 35 rpm OFF malfunction (B) Input (turbine) speed/Intermediate shaft speed 0.93 to 1.07 OFF malfunction (C) Input (turbine) speed/Intermediate shaft speed 0.93 to 1.07 OFF malfunction (D) Input (turbine) speed/Intermediate shaft speed 0.64 to 0.74 ON malfunction (A) Input (turbine) speed/Intermediate shaft speed 2.72 to 2.86 ON malfunction (B) Input (turbine) speed - Intermediate shaft speed 700 rpm or more ON malfunction (C) Input (turbine) speed - Intermediate shaft speed Less than -500 rpm or 700 rpm or more 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1269 05-1080 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) INSPECTION PROCEDURE HINT: Performing the ACTIVE TEST using the hand-held tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Turn the ignition switch off. (b) Connect the hand-held tester to the DLC3. (c) Turn the ignition switch to the ON position. (d) Push the ”ON” button of the hand-held tester. (e) Select the item ”DIAGNOSIS/ENHANCED OBD II/ACTIVE TEST/SHIFT”. (f) According to the display on tester, perform the ”ACTIVE TEST”. HINT: While driving, the shift position can be forcibly changed with the hand-held tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem (see page 05-1030 ). Item Test Details Diagnostic Note SHIFT [Test Details] Operate the shift solenoid valve and set the each shift position by yourself. [Vehicle Condition] Less than 50 km/h (31 mph) [Others]
Press ”→” button: Shift up
Press ”←” button: Shift down Possible to check the operation of the shift solenoid valves. HINT:

This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. The shift position commanded by the ECM is shown in the DATA LIST/SHIFT display on the hand-held tester. 1 CHECK OTHER DTCS OUTPUT(IN ADDITION TO DTC P0776) (a) (b) Connect the OBD II scan tool or the hand-held tester to the DLC3. Turn the ignition switch to the ON position and push the OBD II scan tool or the hand-held tester main switch ON. (c) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/DTC INFO/CURRENT CODES”. (d) Read the DTCs using the OBD II scan tool or the hand-held tester. Result: Display (DTC output) Proceed to Only ”P0776” is output A ”P0776” and other DTCs B HINT: If any other codes besides ”P0776” is output, perform the troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART (SEE PAGE 05-1034 ) A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1270 DIAGNOSTICS 2 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1081 INSPECT SHIFT SOLENOID VALVE(SL2) (a) (b) Shift Solenoid Valve SL2: 1 2 (c) 2 1 (-) Remove the shift solenoid valve SL2. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20C (68F) 1-2 5.0 to 5.6 Ω Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating noise. (+) G20767 NG REPLACE SHIFT SOLENOID VALVE(SL2) OK 3 INSPECT TRANSMISSION VALVE BODY ASSY(See chapter 2 in the problem symptoms table) (SEE PAGE 05-1016 ) OK: There are no foreign objects on each valve and they operate smoothly. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSY (SEE PAGE 40-44 ) OK 4 INSPECT TORQUE CONVERTER CLUTCH ASSY (SEE PAGE 40-29 ) OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSY OK REPAIR OR REPLACE AUTOMATIC TRANSAXLE ASSY (SEE PAGE 40-18 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1271 05-1082 DIAGNOSTICS DTC P0778 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05C14-18 PRESSURE CONTROL SOLENOID ”B” ELECTRICAL (SHIFT SOLENOID VALVE SL2) CIRCUIT DESCRIPTION Shifting from 1st to 5th is performed in combination with ”ON” and ”OFF” operation of the shift solenoid valves SL1, SL2, SL3, S4 and SR which is controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly (Fail safe function). DTC No. DTC Detection Condition Trouble Area P0778 ECM checks for an open or short circuit in shift solenoid valves SL2 (1-trip detection logic) Hybrid IC for solenoid indicates fail.
Open or short in shift solenoid valve SL2 circuit
Shift solenoid valve SL2
ECM MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves ”ON/OFF”. When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other shift solenoid valves in good condition ”ON/OFF” (In case of an open or short circuit, the ECM stops sending current to the circuit.) (see page 05-1030 ). MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0778: Shift solenoid valve SL2/Range check Shift solenoid valve SL2 Continuous 1 sec. Immediate None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. See page 05-1007 Solenoid current cut status Not cut Battery voltage 11 V or more CPU commanded duty ratio to SL2 19% or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Solenoid status from IC Fail (Open or short) COMPONENT OPERATING RANGE Output signal duty Less than 100% 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1272 DIAGNOSTICS - 05-1083 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) WIRING DIAGRAM E1 Electronically Controlled Transmission Solenoid LG 15 E8 L-Y SL2+ 5 CPU SL2+ BR 14 E8 L-R SL2- ECM +B SL2- 12 G31765 INSPECTION PROCEDURE 1 INSPECT TRANSMISSION WIRE(SL2) (a) Transmission Wire Side: (Connector Front View): SL2+ (b) E1 SL2- G26426 (c) Disconnect the transmission wire connector from the transaxle. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20C (68F) 5 (SL2+) - 12 (SL2-) 5.0 to 5.6 Ω Measure the resistance according to the value(s) in the table below. OK: Standard (Check for short): NG Tester Connection Specified Condition 5 (SL2+) - Body ground 10 kΩ or higher 12 (SL2-) - Body ground ↑ Go to step 3 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1273 05-1084 2 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) CHECK HARNESS AND CONNECTOR(TRANSMISSION WIRE - ECM) E7 E8 E9 SL2+ C82158 E6 (a) (b) (c) E5 ECM: SL2- C91565 (d) Connect the transmission connector to the transaxle. Disconnect the connector from the ECM. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20C (68F) E8 - 15 (SL2+) - E8 - 14 (SL2-) 5.0 to 5.6 Ω Measure the resistance according to the value(s) in the table below. Standard (Check for short): Tester Connection Specified Condition E8 - 15 (SL2+) - Body ground 10 kΩ or higher E8 - 14 (SL2-) - Body ground ↑ NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK REPLACE ECM (SEE PAGE 10-24 ) 3 INSPECT SHIFT SOLENOID VALVE(SL2) (a) (b) Shift Solenoid Valve SL2: 1 2 (c) 2 1 (-) Remove the shift solenoid valve SL2. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20C (68F) 1-2 5.0 to 5.6 Ω Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating noise. (+) G20767 NG REPLACE SHIFT SOLENOID VALVE(SL2) OK REPAIR OR REPLACE TRANSMISSION WIRE (SEE PAGE 40-37 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1274 DIAGNOSTICS DTC P0793 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1085 05F2R-04 INTERMEDIATE SHAFT SPEED SENSOR ”A” CIRCUIT DESCRIPTION This sensor detects the rotation speed of the counter gear. By comparing the counter gear speed signal (NC) with the direct clutch speed sensor signal (NT), the ECM detects the shift timing of the gears and appropriately controls the engine torque and hydraulic pressure according to various conditions. Thus smooth gear shifting is performed. DTC No. DTC Detection Condition Trouble Area ECM detects conditions (a), (b) and (c) continuity for 5 sec. or more: (1-trip detection logic) (a) Vehicle speed: 50 km/h (31 mph) or more (b) Park/neutral position switch (NSW) is OFF (c) Speed sensor (NC): less than 300 rpm P0793 1 V/DIV
Open or short in transmission revolution sensor NC (speed sensor NC) circuit
Transmission revolution sensor NC (speed sensor NC)
ECM Reference (Using an oscilloscope): Check the waveform between the terminals NC+ and NC- of the ECM connector. Standard: Refer to the illustration. Terminal NC+ - NC- Tool setting 1V/DIV, 1ms/DIV Vehicle condition Vehicle speed 30 km/h (19 mph): (3rd gear) Engine speed 1,400 rpm 1 ms/DIV C93866 MONITOR DESCRIPTION The NC terminal of ECM detects a revolution signal from the speed sensor (NC) (counter gear rpm). The ECM calculates a gearshift comparing the speed sensor (NT) with the speed sensor (NC). While the vehicle is operating in 2nd, 3rd, 4th or 5th gear in the shift position of D, if the counter gear revolution is less than 300 rpm*1 although the output shaft revolution is more than 1,000 rpm*2, the ECM detects the trouble, illuminates the MIL and stores the DTC. *1: Pulse is not output or is irregularly output. *2: The vehicle speed is 50 km/h (31 mph) or more. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0793: Speed sensor (NC)/Verify pulse input Speed sensor (NC), Speed sensor (NT), Park/neutral position switch Continuous 5 sec. Immediate None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. See page 05-1007 Engine Running NSW switch OFF Output shaft rpm 1,000 rpm or more 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1275 05-1086 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) TYPICAL MALFUNCTION THRESHOLDS Sensor signal rpm Less than 300 rpm COMPONENT OPERATING RANGE [HINT] 3rd when shift lever position is D position (After warming up the engine);
Intermediate shaft speed (NC) becomes close to the engine speed. Counter gear speed sensor (NC) WIRING DIAGRAM ECM C6 Counter Gear Speed Sensor 26 R 1 NC+ E8 2 5V 34 E8 W-G NCE1 G31763 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1276 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1087 INSPECTION PROCEDURE HINT: According to the DATA LIST displayed by the OBD II scan tool or hand-held tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the OBD II scan tool or hand-held tester to the DLC3. (d) Turn the ignition switch to the ON position. (e) Push the ”ON” button of the OBD II scan tool or the hand-held tester. (f) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/DATA LIST”. (g) According to the display on tester, read the ”DATA LIST”. Measurement Item/ Range (display) Item Normal Condition [HINT] 3rd when shift lever position is D position (After warming up the engine);
Intermediate shaft speed (NC) becomes close to the engine speed. Counter Gear Speed/ display: 50 r/min SPD (NC) HINT:
SPD (NC) is always 0 while driving: Open or short in the sensor or circuit. SPD (NC) is always more than 0 and less than 300 rpm while driving the vehicle at 50 km/h (31 mph) or more: Sensor trouble, improper installation, or intermittent connection trouble of the circuit.
1 INSPECT SPEED SENSOR INSTALLATION (a) OK Check the speed sensor installation. OK: The installation bolt is tightened properly and there is no clearance between the sensor and transaxle case. NG BR3795 NG REPLACE SPEED SENSOR(NC) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1277 05-1088 2 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) INSPECT SPEED SENSOR(NC) (a) Sensor Side: (Connector Front View): (b) C6 2 Disconnect the speed sensor connector from the transaxle. Measure the resistance according to the value(s) in the table below. Standard: 1 C58536 NG Tester Connection Specified Condition 20 C (68 F) 1-2 560 to 680 Ω REPLACE SPEED SENSOR(NC) OK 3 CHECK HARNESS AND CONNECTOR(SPEED SENSOR - ECM) E7 E8 E9 E6 (a) (b) (c) E5 Connect the speed sensor connector. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard: NC+ NCC82158 ECM: C91565 (d) Tester Connection Specified Condition 20 C (68 F) E8 - 26 (NC+) - E8 - 34 (NC-) 560 to 680 Ω Measure the resistance according to the value(s) in the table below. Standard (Check for short): Tester Connection Specified Condition E8 - 26 (NC+) - Body ground 10 kΩ or higher E8 - 34 (NC-) - Body ground ↑ NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK REPLACE ECM (SEE PAGE 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1278 DIAGNOSTICS DTC P0796 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1089 05C15-12 PRESSURE CONTROL SOLENOID ”C” PERFORMANCE (SHIFT SOLENOID VALVE SL3) SYSTEM DESCRIPTION The ECM uses signals from the vehicle speed sensor to detect the actual gear position (1st, 2nd, 3rd, 4th or 5th gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical troubles of the shift solenoid valves and valve body. DTC No. P0796 DTC Detecting Condition Trouble Area The gear required by the ECM does not match the actual gear when driving (2-trip detection logic)
Shift solenoid valve SL3 remains open or closed
Valve body is blocked
Shift solenoid valve SL3
Automatic transaxle (clutch, brake or gear etc.)
ECM MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves ”ON/OFF”. According to the input shaft revolution, intermediate (counter) shaft revolution and output shaft revolution, the ECM detects the actual gear position (1st, 2nd, 3rd, 4th or 5th gear position). When the gear position commanded by the ECM and the actual gear position are not same, the ECM illuminates the MIL and stores the DTC. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0796: Shift solenoid valve SL3/OFF malfunction Shift solenoid valve SL3/ON malfunction Shift solenoid valve SL3, Speed sensor (NT), Speed sensor (NC), Crankshaft position sensor (NE) Continuous OFF malfunction (A) 0.8 sec. OFF malfunction (B) 1 sec. ON malfunction (A) and (B) 0.8 sec. ON malfunction (C) 0.4 sec. 2 driving cycles None 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1279 05-1090 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) TYPICAL ENABLING CONDITIONS All: Transmission range ”D” ECT (Engine coolant temperature) 10C (50F) or more TFT (Transmission fluid temperature) -20 C (-4F) or more TFT sensor circuit Not circuit malfunction ECT sensor circuit Not circuit malfunction Turbine speed sensor circuit Not circuit malfunction Intermediate shaft speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction Shift solenoid valve SL3 circuit Not circuit malfunction Shift solenoid valve S4 circuit Not circuit malfunction Shift solenoid valve SR circuit Not circuit malfunction Shift solenoid valve DSL circuit Not circuit malfunction OFF malfunction (A) ECM selected gear Throttle valve opening angle 4th or 5th 4.5% or more at engine speed 1,900 rpm (Varies with engine speed) OFF malfunction (B) ECM selected gear 4th Throttle valve opening angle Vehicle speed 5% or more 10 km/h (6.2 mph) or more ON malfunction (A) ECM selected gear Vehicle speed Throttle valve opening angle 1st Less than 40 km/h (24.9 mph) 4.5% or more at engine speed 1,900 rpm (Varies with engine speed) ON malfunction (B) ECM selected gear Throttle valve opening angle 3rd 7.0% or more at output speed 1,400 rpm (Varies with engine speed) Malfunction of pressure control solenoid ”B” (SL2) and ”C” (SL3) Not detected ON malfunction (C) Throttle valve opening angle 7.0% or more at output speed 1,050 rpm (Varies with engine speed) Malfunction of pressure control solenoid ”B” (SL2) Not detected 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1280 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1091 TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is met: OFF malfunction (A) and (B), or ON malfunctions (A), (B) and (C) 2 detections are necessary per driving cycle: 1st detection; temporary flag ON 2nd detection; pending fault code ON OFF malfunction (A) Input (turbine) speed/Intermediate shaft speed 0.93 to 1.07 OFF malfunction (B) Intermediate shaft speed/Output speed 1.02 to 1.16 ON malfunction (A) Input (turbine) speed/Intermediate shaft speed 0.93 to 1.07 ON malfunction (B) Input (turbine) speed - Intermediate shaft speed 700 rpm or more ON malfunction (C) Input (turbine) speed - Intermediate shaft speed Less than -500 rpm or 700 rpm or more 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1281 05-1092 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) INSPECTION PROCEDURE HINT: Performing the ACTIVE TEST using the hand-held tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Turn the ignition switch off. (b) Connect the hand-held tester to the DLC3. (c) Turn the ignition switch to the ON position. (d) Push the ”ON” button of the hand-held tester. (e) Select the item ”DIAGNOSIS/ENHANCED OBD II/ACTIVE TEST/SHIFT”. (f) According to the display on tester, perform the ”ACTIVE TEST”. HINT: While driving, the shift position can be forcibly changed with the hand-held tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem (see page 05-1030 ). Item Test Details Diagnostic Note SHIFT [Test Details] Operate the shift solenoid valve and set the each shift position by yourself. [Vehicle Condition] Less than 50 km/h (31 mph) [Others]
Press ”→” button: Shift up
Press ”←” button: Shift down Possible to check the operation of the shift solenoid valves. HINT:

This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. The shift position commanded by the ECM is shown in the DATA LIST/SHIFT display on the hand-held tester. 1 CHECK OTHER DTCS OUTPUT(IN ADDITION TO DTC P0796) (a) (b) Connect the OBD II scan tool or the hand-held tester to the DLC3. Turn the ignition switch to the ON position and push the OBD II scan tool or the hand-held tester main switch ON. (c) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/DTC INFO/CURRENT CODES”. (d) Read the DTCs using the OBD II scan tool or the hand-held tester. Result: Display (DTC output) Proceed to Only ”P0796” is output A ”P0796” and other DTCs B HINT: If any other codes besides ”P0796” is output, perform the troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART (SEE PAGE 05-1034 ) A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1282 DIAGNOSTICS 2 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1093 INSPECT SHIFT SOLENOID VALVE(SL3) (a) (b) Shift Solenoid Valve SL3: 1 2 (c) 2 1 (-) Remove the shift solenoid valve SL3. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20C (68F) 1-2 5.0 to 5.6 Ω Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating noise. (+) G20767 NG REPLACE SHIFT SOLENOID VALVE(SL3) OK 3 INSPECT TRANSMISSION VALVE BODY ASSY(See chapter 2 in the problem symptoms table) (SEE PAGE 05-1016 ) OK: There are no foreign objects on each valve and they operate smoothly. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSY (SEE PAGE 40-44 ) OK 4 INSPECT TORQUE CONVERTER CLUTCH ASSY (SEE PAGE 40-29 ) OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSY OK REPAIR OR REPLACE AUTOMATIC TRANSAXLE ASSY (SEE PAGE 40-18 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1283 05-1094 DIAGNOSTICS DTC P0798 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05C16-22 PRESSURE CONTROL SOLENOID ”C” ELECTRICAL (SHIFT SOLENOID VALVE SL3) CIRCUIT DESCRIPTION Shifting from 1st to 5th is performed in combination with ”ON” and ”OFF” operation of the shift solenoid valves SL1, SL2, SL3, S4 and SR which is controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly (Fail safe function). DTC No. DTC Detection Condition Trouble Area P0798 ECM checks for an open or short circuit in shift solenoid valves SL3 (1-trip detection logic)
Output signal duty equals to 100%
Open or short in shift solenoid valve SL3 circuit
Shift solenoid valve SL3
ECM MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves ”ON/OFF”. When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other shift solenoid valves in good condition ”ON/OFF” (In case of an open or short circuit, the ECM stops sending current to the circuit.) (see page 05-1030 ). MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0798: Shift solenoid valve SL3/Range check Shift solenoid valve SL3 Continuous 1 sec. Immediate None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. See page 05-1007 Battery voltage 10 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Output signal duty 100% COMPONENT OPERATING RANGE Output signal duty Less than 100% 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1284 DIAGNOSTICS - 05-1095 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) WIRING DIAGRAM E1 Electronically Controlled Transmission Solenoid R 17 E8 G-B SL3+ 4 CPU SL3+ L 16 E8 G-R 11 SL3- ECM +B SL3- G31765 INSPECTION PROCEDURE 1 INSPECT TRANSMISSION WIRE(SL3) (a) Transmission Wire Side: (Connector Front View): SL3+ E1 SL3- (b) G26426 (c) Disconnect the transmission wire connector from the transaxle. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20C (68F) 4 (SL3+) - 11 (SL3-) 5.0 to 5.6 Ω Measure the resistance according to the value(s) in the table below. Standard (Check for short): NG Tester Connection Specified Condition 4 (SL3+) - Body ground 10 kΩ or higher 11 (SL3-) - Body ground ↑ Go to step 3 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1285 05-1096 2 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) CHECK HARNESS AND CONNECTOR(TRANSMISSION WIRE - ECM) E7 E8 E9 E6 (a) (b) (c) E5 ECM: SL3+ C82158 SL3- C91565 (d) Connect the transmission connector to the transaxle. Disconnect the connector from the ECM. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20C (68F) E8 - 17 (SL3+) - E8 - 16 (SL3-) 5.0 to 5.6 Ω Measure the resistance according to the value(s) in the table below. Standard (Check for short): Tester Connection Specified Condition E8 - 17 (SL3+) - Body ground 10 kΩ or higher E8 - 16 (SL3-) - Body ground ↑ NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK REPLACE ECM (SEE PAGE 10-24 ) 3 INSPECT SHIFT SOLENOID VALVE(SL3) (a) (b) Shift Solenoid Valve SL3: 1 2 (c) 2 1 (-) Remove the shift solenoid valve SL3. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20C (68F) 1-2 5.0 to 5.6 Ω Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating noise. (+) G20767 NG REPLACE SHIFT SOLENOID VALVE(SL3) OK REPAIR OR REPLACE TRANSMISSION WIRE (SEE PAGE 40-37 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1286 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1097 05C17-24 DTC P0982 SHIFT SOLENOID ”D” CONTROL CIRCUIT LOW (SHIFT SOLENOID VALVE S4) DTC P0983 SHIFT SOLENOID ”D” CONTROL CIRCUIT HIGH (SHIFT SOLENOID VALVE S4) CIRCUIT DESCRIPTION Shifting from 1st to 5th is performed in combination with ”ON” and ”OFF” operation of the shift solenoid valves SL1, SL2, SL3, S4 and SR which is controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly (Fail safe function). DTC No. DTC Detection Condition Trouble Area P0982 ECM detects short in solenoid valve S4 circuit 2 times when solenoid valve S4 is operated (1-trip detection logic)
Short in shift solenoid valve S4 circuit
Shift solenoid valve S4
ECM P0983 ECM detects open in solenoid valve S4 circuit 2 times when solenoid valve S4 is not operated (1-trip detection logic)
Open in shift solenoid valve S4 circuit
Shift solenoid valve S4
ECM MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves ”ON/OFF”. When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other shift solenoid valves in good condition ”ON/OFF” (In case of an open or short circuit, the ECM stops sending current to the circuit.) (see page 05-1030 ). MONITOR STRATEGY Related DTCs Required sensors/Components P0982: Shift solenoid valve S4/Range check (Low resistance) P0983: Shift solenoid valve S4/Range check (High resistance) Shift solenoid valve S4 Frequency of operation Continuous Duration 0.064 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS P0982: Range check (Low resistance) The monitor will run whenever this DTC is not present. See page 05-1007 Shift solenoid valve S4 ON Battery voltage 8 V or more Ignition switch ON Starter OFF P0983: Range check (High resistance) The monitor will run whenever this DTC is not present. See page 05-1007 Shift solenoid valve S4 OFF Battery voltage 8 V or more Ignition switch ON Starter OFF 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1287 05-1098 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) TYPICAL MALFUNCTION THRESHOLDS P0982: Range check (Low resistance) 8 Ω or less Shift solenoid valve S4 resistance P0983: Range check (High resistance) Shift solenoid valve S4 resistance 100 kΩ or more COMPONENT OPERATING RANGE Resistance: 11 to 15 Ω at 20C (68F) Shift solenoid valve S4 WIRING DIAGRAM E1 Electronically Controlled Transmission Solenoid ECM +B 10 S4 E8 L-W Y S4 3 CPU G31165 INSPECTION PROCEDURE 1 INSPECT TRANSMISSION WIRE(S4) Transmission Wire Side: (Connector Front View): (a) S4 (b) E1 G26426 Disconnect the transmission wire connector from the transaxle. Measure the resistance according to the value(s) in the table below. Standard: NG Tester Connection Specified Condition 20C (68F) 3 - Body ground 11 to 15 Ω Go to step 3 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1288 DIAGNOSTICS 2 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1099 CHECK HARNESS AND CONNECTOR(TRANSMISSION WIRE - ECM) E7 E8 E9 E6 S4 (a) (b) (c) E5 Connect the transmission connector to the transaxle. Disconnect the connector from the ECM. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20C (68F) E8 - 10 (S4) - Body ground 11 to 15 Ω ECM: C82158 C91565 NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK REPLACE ECM (SEE PAGE 10-24 ) 3 INSPECT SHIFT SOLENOID VALVE(S4) (-) Shift Solenoid Valve S4: (a) (b) (+) C90639 Remove the shift solenoid valve S4. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20C (68F) Solenoid Connector (S4) - Solenoid Body (S4) 11 to 15 Ω (c) Connect positive (+) lead to the terminal of solenoid connector, negative (-) lead to the solenoid body. OK: The solenoid makes an operating noise. NG REPLACE SHIFT SOLENOID VALVE(S4) OK REPAIR OR REPLACE TRANSMISSION WIRE (SEE PAGE 40-37 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1289 05-1 100 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05C18-12 DTC P0985 SHIFT SOLENOID ”E” CONTROL CIRCUIT LOW (SHIFT SOLENOID VALVE SR) DTC P0986 SHIFT SOLENOID ”E” CONTROL CIRCUIT HIGH (SHIFT SOLENOID VALVE SR) CIRCUIT DESCRIPTION Shifting from 1st to 5th is performed in combination with ”ON” and ”OFF” operation of the shift solenoid valves SL1, SL2, SL3, S4 and SR which is controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly (Fail safe function). DTC No. DTC Detection Condition Trouble Area P0985 ECM detects short in solenoid valve SR circuit 2 times when solenoid valve SR is operated (1-trip detection logic)
Short in shift solenoid valve SR circuit
Shift solenoid valve SR
ECM P0986 ECM detects open in solenoid valve SR circuit 2 times when solenoid valve SR is not operated (1-trip detection logic)
Open in shift solenoid valve SR circuit
Shift solenoid valve SR
ECM MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves ”ON/OFF”. When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other shift solenoid valves in good condition ”ON/OFF” (In case of an open or short circuit, the ECM stops sending current to the circuit.) (see page 05-1030 ). MONITOR STRATEGY Related DTCs Required sensors/Components P0985: Shift solenoid valve SR/Range check (Low resistance) P0986: Shift solenoid valve SR/Range check (High resistance) Shift solenoid valve SR Frequency of operation Continuous Duration 0.064 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS P0985: Range check (Low resistance) The monitor will run whenever this DTC is not present. See page 05-1007 Shift solenoid valve SR ON Battery voltage 8 V or more Ignition switch ON Starter OFF P0986: Range check (High resistance) The monitor will run whenever this DTC is not present. See page 05-1007 Shift solenoid valve SR OFF Battery voltage 8 V or more Ignition switch ON Starter OFF 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1290 DIAGNOSTICS - 05-1 101 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) TYPICAL MALFUNCTION THRESHOLDS P0985: Range check (Low resistance) 8 Ω or less Shift solenoid valve SR resistance P0986: Range check (High resistance) Shift solenoid valve SR resistance 100 kΩ or more COMPONENT OPERATING RANGE Resistance: 11 to 15 Ω at 20C (68F) Shift solenoid valve SR WIRING DIAGRAM E1 Electronically Controlled Transmission Solenoid ECM +B 9 SR E8 L-B V SR 9 CPU G31165 INSPECTION PROCEDURE 1 INSPECT TRANSMISSION WIRE(SR) (a) Transmission Wire Side: (Connector Front View): (b) E1 SR G26426 Disconnect the transmission wire connector from the transaxle. Measure the resistance according to the value(s) in the table below. Standard: NG Tester Connection Specified Condition 20C (68F) 9 - Body ground 11 to 15 Ω Go to step 3 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1291 05-1 102 2 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) CHECK HARNESS AND CONNECTOR(TRANSMISSION WIRE - ECM) E7 E8 E9 E6 (a) (b) (c) E5 Connect the transmission connector to the transaxle. Disconnect the connector from the ECM. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20C (68F) E8 - 9 (SR) - Body ground 11 to 15 Ω SR ECM: C82158 C91565 NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK REPLACE ECM (SEE PAGE 10-24 ) 3 INSPECT SHIFT SOLENOID VALVE(SR) (+) Shift Solenoid Valve SR: (a) (b) (-) C90640 Remove the shift solenoid valve SR. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20C (68F) Solenoid Connector (SR) - Solenoid Body (SR) 11 to 15 Ω (c) Connect positive (+) lead to the terminal of solenoid connector, negative (-) lead to the solenoid body. OK: The solenoid makes an operating noise. NG REPLACE SHIFT SOLENOID VALVE(SR) OK REPAIR OR REPLACE TRANSMISSION WIRE (SEE PAGE 40-37 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1292 DIAGNOSTICS DTC P2716 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1 103 05C19-27 PRESSURE CONTROL SOLENOID ”D” ELECTRICAL (SHIFT SOLENOID SLT) CIRCUIT DESCRIPTION Line Pressure Control Pressure Current Flow to Solenoid D02290 ON OFF The linear solenoid valve (SLT) controls the transmission line pressure for smooth transmission operation based on signals from the throttle position sensor and the vehicle speed sensor. The ECM adjusts the duty cycle of the SLT solenoid valve to control hydraulic line pressure coming from the primary regulator valve. Appropriate line pressure assures smooth shifting with varying engine outputs. (*): Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity in one cycle, and B is the period of non-continuity, then Duty Ratio=A/(A+B) x 100 (%) 1 cycle BE4056 DTC No. DTC Detection Condition Trouble Area Condition (a) or (b) below is detected 1 sec. or more: (1-trip detection logic) (a) SLT- terminal: 0V (b) SLT- terminal: 12V P2716
Open or short in shift solenoid valve SLT circuit
Shift solenoid valve SLT
ECM MONITOR DESCRIPTION When an open or short in the linear solenoid valve (SLT) circuit is detected, the ECM interprets this as a fault. The ECM will turn ON the MIL and store the DTC. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P2716: Shift solenoid valve SLT/Range check Shift solenoid valve SLT Continuous 1 sec. Immediate None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. See page 05-1007 Solenoid current cut status Not cut Battery voltage 11 V or more CPU commanded duty ratio to SLT 19% or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Solenoid status from IC Fail (Open or short) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1293 05-1 104 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) COMPONENT OPERATING RANGE Resistance: 5.0 to 5.6 Ω at 20C (68F) Shift solenoid valve SLT WIRING DIAGRAM E1 Electronically Controlled Transmission Solenoid G SLT+ Y-R 2 ECM +B 13 E8 SLT+ GR 8 Y-B SLT- 12 SLTE8 G31770 INSPECTION PROCEDURE 1 INSPECT TRANSMISSION WIRE(SLT) Transmission Wire Side: (Connector Front View): (a) SLT+ (b) E1 SLT- G26426 (c) Disconnect the transmission wire connector from the transaxle. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20C (68F) 2 (SLT+) - 8 (SLT-) 5.0 to 5.6 Ω Measure the resistance according to the value(s) in the table below. Standard (Check for short): NG Tester Connection Specified Condition 2 (SLT+) - Body ground 10 kΩ or higher 8 (SLT-) - Body ground ↑ Go to step 3 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1294 DIAGNOSTICS 2 - 05-1 105 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) CHECK HARNESS AND CONNECTOR(TRANSMISSION WIRE - ECM) E8 E7 SLT+ E9 E6 (a) (b) (c) E5 ECM: SLT- C82158 C91565 (d) Connect the transmission wire connector to the transaxle. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20C (68F) E8 - 13 (SLT+) - E8 - 12 (SLT-) 5.0 to 5.6 Ω Measure the resistance according to the value(s) in the table below. Standard (Check for short): Tester Connection Specified Condition E8 - 13 (SLT+) - Body ground 10 kΩ or higher E8 - 12 (SLT-) - Body ground ↑ NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK REPLACE ECM (SEE PAGE 10-24 ) 3 INSPECT SHIFT SOLENOID VALVE(SLT) (a) (b) Shift Solenoid Valve SLT: 1 2 (c) 2 1 (-) Remove the shift solenoid valve (SLT). Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20C (68F) 1-2 5.0 to 5.6 Ω Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating noise. (+) G20767 NG REPLACE SHIFT SOLENOID VALVE(SLT) OK REPAIR OR REPLACE TRANSMISSION WIRE (SEE PAGE 40-37 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1295 05-1 106 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 0527R-38 DTC P2769 TORQUE CONVERTER CLUTCH SOLENOID CIRCUIT LOW (SHIFT SOLENOID VALVE DSL) DTC P2770 TORQUE CONVERTER CLUTCH SOLENOID CIRCUIT HIGH (SHIFT SOLENOID VALVE DSL) CIRCUIT DESCRIPTION The shift solenoid valve DSL is turned ”ON” and ”OFF” by signals from the ECM in order to control the hydraulic pressure operation, the lock-up relay valve, which then the controls operation of the lock-up clutch. DTC No. DTC Detection Condition Trouble Area P2769 ECM detects short in solenoid valve DSL circuit (0.1 sec.) when solenoid valve DSL is operated (2-trip detection logic)
Short in shift solenoid valve DSL circuit
Shift solenoid valve DSL
ECM P2770 ECM detects open in solenoid valve DSL circuit (0.1 sec.) when solenoid valve DSL is not operated (2-trip detection logic)
Open in shift solenoid valve DSL circuit
Shift solenoid valve DSL
ECM MONITOR DESCRIPTION Torque converter lock-up is controlled by the ECM based on engine rpm, engine load, engine temperature, vehicle speed, transmission temperature, and shift range selection. The ECM determines the lock-up status of the torque converter by comparing the engine rpm (NE) to the input turbine rpm (NT). The ECM calculates the actual transmission gear by comparing input turbine rpm (NT) to counter gear rpm (NC). When conditions are appropriate, the ECM requests ”lock-up” by applying control voltage to shift solenoid DSL. When the DSL is opened, solenoid DSL applies pressure to the lock-up relay valve and locks the torque converter clutch. If the ECM detects an open or short in the DSL solenoid circuit, the ECM interprets this as a fault in the DSL solenoid or circuit. The ECM will turn on the MIL and store the DTC. MONITOR STRATEGY Related DTCs Required sensors/Components P2769: Shift solenoid valve DSL/Range check (Low resistance) P2770: Shift solenoid valve DSL/Range check (High resistance) Shift solenoid valve DSL Frequency of operation Continuous Duration 0.064 sec. MIL operation Sequence of operation 2 driving cycles None TYPICAL ENABLING CONDITIONS P2769: Range check (Low resistance) The monitor will run whenever this DTC is not present. See page 05-1007 Shift solenoid valve DSL ON Solenoid current cut status Not cut Battery voltage 8 V or more Ignition switch ON Starter OFF 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1296 DIAGNOSTICS - 05-1 107 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) P2770: Range check (High resistance) The monitor will run whenever this DTC is not present. See page 05-1007 Shift solenoid valve DSL ON Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS P2769: Range check (Low resistance) 8 Ω or less Shift solenoid valve DSL resistance P2770: Range check (High resistance) Shift solenoid valve DSL resistance 100 kΩ or more COMPONENT OPERATING RANGE Resistance: 11 to 13 Ω at 20C (68F) Shift solenoid valve DSL WIRING DIAGRAM ECM E1 Electronically Controlled Transmission Solenoid +B SB Y-G 10 11 DSL E8 CPU DSL G31165 INSPECTION PROCEDURE 1 INSPECT TRANSMISSION WIRE(DSL) (a) Transmission Wire Side: (Connector Front View): (b) E1 DSL G26426 Disconnect the transmission wire connector from the transaxle. Measure the resistance according to the value(s) in the table below. Standard: NG Tester Connection Specified Condition 20C (68F) 10 - Body ground 11 to 13 Ω Go to step 3 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1297 05-1 108 2 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) CHECK HARNESS AND CONNECTOR(TRANSMISSION WIRE - ECM) E7 E8 ECM: E9 E6 (a) (b) (c) E5 DSL C82158 C91565 Connect the transmission wire connector. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20C (68F) E8 - 11 (DSL) - Body ground 11 to 13 Ω NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK REPLACE ECM (SEE PAGE 10-24 ) 3 INSPECT SHIFT SOLENOID VALVE(DSL) (a) (b) Shift Solenoid Valve DSL: Tester Connection Specified Condition 20C (68F) Solenoid Connector (DSL) - Solenoid Body (DSL) 11 to 13 Ω (c) (-) (+) C90646 Remove the shift solenoid valve DSL. Measure the resistance according to the value(s) in the table below. Standard: Connect positive (+) lead to the terminal of solenoid connector, negative (-) lead to the solenoid body. OK: The solenoid valve makes an operating noise. NG REPLACE SHIFT SOLENOID VALVE(DSL) OK REPAIR OR REPLACE TRANSMISSION WIRE (SEE PAGE 40-37 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1298 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-997 05EJV-07 ROAD TEST 1. (a) PROBLEM SYMPTOM CONFIRMATION Based on the result of the customer problem analysis, try to reproduce the symptoms. If the problem is that the transaxle does not shift up, shift down, or the shift point is too high or too low, conduct the following road test referring to the automatic shift schedule and simulate the problem symptoms. 2. ROAD TEST NOTICE: Perform the test at the ATF (Automatic Transmission Fluid) temperature 50 to 80°C (122 to 176°F) in the normal operation. (a) D position test: Shift into the D position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that 1 → 2, 2 → 3, 3 → 4 and 4 → 5th up-shifts take place, and that the shift points conform to the automatic shift schedule (see page 03-51 ). HINT: 5th Gear Up-shift Prohibition Control
Engine coolant temperature is 68 °C (154 °F) or less and vehicle speed is at 70 km/h (43 mph) or less.
ATF temperature is -2 °C (28 °F) or less. 4th Gear Up-shift Prohibition Control
Engine coolant temperature is 65 °C (149 °F) or less and vehicle speed is at 55 km/h (34 mph) or less. 5th and 4th Gear Lock-up Prohibition Control
Brake pedal is depressed.
Accelerator pedal is released.
Engine coolant temperature is 60 °C (140 °F) or less. (2) (3) Check for shift shock and slip. Check for shock and slip at the 1 → 2, 2 → 3, 3 → 4 and 4 → 5th up-shifts. Check for abnormal noise and vibration. Check for abnormal noise and vibration when up-shifting from 1 → 2, 2 → 3, 3 → 4 and 4 → 5 while driving with the shift lever in the D position, and check while driving in the lock-up condition. HINT: The check for the cause of abnormal noise and vibration must be done thoroughly as it could also be due to loss of balance in the differential, torque converter clutch, etc. (4) Check kick-down operation. Check vehicle speeds when the 2nd to 1st, 3rd to 2nd, 4th to 3rd, and 5th to 4th kick-downs take place while driving with the shift lever in the D position. Confirm that each speed is within the applicable vehicle speed range indicated in the automatic shift schedule (see page 03-51 ). (5) Check abnormal shock and slip at kick-down. (6) Check the lock-up mechanism.
Drive in D position (5th gear), at a steady speed (lock-up ON).
Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. HINT:
There is no lock-up function in the 1st, 2nd and 3rd gear.
4th lock-up operates while uphill-downhill control is active in the D position.
If there is a big jump in engine speed, there is no lock-up. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1187 05-998 (b) DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 4 position (O/D OFF) test: Shift into the 4 position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2, 2 → 3 and 3 → 4 up-shift takes place and that the shift point conforms to the automatic shift schedule (see page 03-51 ). HINT: There is no 5th up-shift in the 4 position. (2) Check engine braking. While driving in the 4 position and 4th gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration, and for shock at up-shift and down-shift. (c) 3 position test: Shift into the 3 position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2 and 2 → 3 up-shift takes place and that the shift point conforms to the automatic shift schedule (see page 03-51 ). HINT: There is no 4th up-shift and lock-up in the 3 position. (2) Check engine braking. While running in the 3 position and 3rd gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration, and for shock at up-shift and down-shift. (d) 2 position test: Shift into the 2 position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2 up-shift takes place and that the shift point conforms to the automatic shift schedule (see page 03-51 ). HINT: There is no 3rd up-shift and lock-up in the 2 position. (2) Check engine braking. While running in the 2 position and 2nd gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration, and for shock at up-shift and down-shift. (e) L position test: Shift into the L position and fully depress the accelerator pedal and check the following points. (1) Check no up-shift. While running in the L position, check that there is no up-shift to 2nd gear. HINT: There is no lock-up in the L position. (2) Check engine braking. While running in the L position, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1188 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-999 (f) R position test: Shift into the R position, lightly depress the accelerator pedal, and check that the vehicle moves backward without any abnormal noise or vibration. CAUTION: Before conducting this test ensure that the test area is free from people and obstruction. (g) P position test: Stop the vehicle on a grade (more than 5°) and after shifting into the P position, release the parking brake. Then, check that the parking lock pawl holds the vehicle in place. (h) Uphill/downhill control function test: (1) Check that the gear does not up-shift to the 4th or 5th gear while the vehicle is driving uphill. (2) Check that the gear automatically down-shifts from the 5th to 4th or from the 4th to 3rd gear when brake is applied while the vehicle is driving downhill. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1189 05-992 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05EJU-06 SYSTEM DESCRIPTION 1. (a) SYSTEM DESCRIPTION The ECT (Electronic controlled automatic transmission/transaxle) is an automatic transmission/transaxle that electronically controls shift timing using the ECM. The ECM detects electrical signals that indicate engine and driving conditions, controls the shift point, and selects the appropriate shift pattern based on driver habits and road conditions. As a result, fuel efficiency and power transmission/transaxle performance are improved. Shift shock has been reduced by controlling the engine and transmission/transaxle simultaneously. In addition, the ECT has the following features:
Diagnostic function.
Fail-safe function when a malfunction occurs. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1182 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-991 05EJT-05 SYSTEM DIAGRAM The configuration of the electronic control system in the U151E/U151F automatic transaxles is as shown in the following chart. NE Crankshaft Position Sensor SL1 Engine Coolant Temperature Sensor Throttle Position Sensor THW SL2 VTA1, 2 Shift Solenoid Valve SL1 Shift Solenoid Valve SL2 VC Transmission Control Switch (2 ⇔ L Position) L SL3 Park/Neutral Position Switch Shift Solenoid Valve SL3 NSW R, D, 3, 2 SLT Transmission Control Switch (O/D Main Switch) ODMS ECM Speed Sensor S4 Shift Solenoid Valve SLT Shift Solenoid Valve S4 Skid Control ECU DSL Combination Meter SPD SR Counter Gear Speed Sensor (Speed Sensor NC) NC Input Turbine Speed Sensor (Speed Sensor NT) NT Stop Lamp Switch Assy Shift Solenoid Valve SR W MIL (Malfunction Indicator Lamp) SIL DLC3 (Data Link Connector 3) STP TC ATF (Automatic Transmission Fluid) Temperature Sensor Shift Solenoid Valve DSL THO1 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1181 05-988 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05EK8-06 PART AND SYSTEM NAME LIST This reference list indicates the part names used in this manual along with their definitions. Part and system name Definition Toyota HCAC system, Hydrocarbon adsorptive Catalyst (HCAC) system, HC adsorptive three-way catalyst HC adsorptive three-way catalytic converter Variable Valve Timing sensor, VVT sensor Camshaft position sensor Variable valve timing system, VVT system Camshaft timing control system Camshaft timing oil control valve, Oil control valve OCV, VVT, VSV Camshaft timing oil control valve Variable timing and lift, VVTL Camshaft timing and lift control Crankshaft position sensor ”A” Crankshaft position sensor Engine speed sensor Crankshaft position sensor THA Intake air temperature Knock control module Engine knock control module Knock sensor Engine knock sensor Mass or volume air flow circuit Mass air flow sensor circuit Vacuum sensor Manifold air pressure sensor Internal control module, Control module, Engine control ECU, PCM Power train control module FC idle Deceleration fuel cut Idle air control valve Idle speed control VSV for CCV, Canister close valve VSV for canister control Evaporative emissions canister vent valve VSV for EVAP, Vacuum switching valve assembly No. 1, EVAP VAV, Purge VSV Evaporative emissions canister purge valve VSV for pressure switching valve, Bypass VSV Evaporative emission pressure switching valve Vapor pressure sensor, EVAP pressure sensor, Evaporative emission control system pressure sensor Fuel tank pressure sensor Charcoal canister Evaporative emissions canister ORVR system On-boad refueling vapor recovery system Intake manifold runner control Intake manifold tuning system Intake manifold runner valve, IMRV, IACV (runner valve) Intake manifold tuning valve Intake control VSV Intake manifold tuning solenoid valve AFS Air fuel ratio sensor O2 sensor Heater oxygen sensor Oxygen sensor pumping current circuit Oxygen sensor output signal Oxygen sensor reference ground circuit Oxygen sensor signal ground Accel position sensor Accelerator pedal position sensor Throttle actuator control motor, Actuator control motor, Electronic throttle motor, Throttle control motor Electronic throttle actuator Electronic throttle control system, Throttle actuator control system Electronic throttle control system Throttle/pedal position sensor, Throttle/pedal position switch, Throttle position sensor/switch Throttle position sensor Turbo press sensor Turbocharger pressure sensor Turbo VSV Turbocharger pressure control solenoid valve P/S pressure switch Power-steering pressure switch VSV for ACM Active control engine mount Speed sensor, Vehicle speed sensor ”A”, Speed sensor for skid control ECU Vehicle speed sensor ATF temperature sensor, Trans. fluid temp. sensor, ATF temperature sensor ”A” Transmission fluid temperature sensor Electronic controlled automatic transmission, ECT Electronically controlled automatic Intermediate shaft speed sensor ”A” Counter gear speed sensor 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1178 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) Part and system name 05-989 Definition Output speed sensor Output shaft speed sensor Input speed sensor, Input turbine speed sensor ”A”, Speed sensor (NT), Turbine speed sensor Input turbine speed sensor PNP switch, NSW Park/neutral position switch Pressure control solenoid Transmission pressure control solenoid Shift solenoid Transmission shift solenoid valve Transmission control switch, Shift lock control unit Shift lock control module Engine immobilizer system, Immobilizer system Vehicle anti-theft system 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1179 05-996 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 0527I-44 CUSTOMER PROBLEM ANALYSIS CHECK Automatic Transaxle System Check Sheet Inspector’s Name : VIN Production Date Customer’s Name / / Licence plate No. Date Vehicle Brought In / Date Problem Occurred / How Often Does Problem Occur? / Intermittent ( Continuous Vehicle does not move ( No up-shift No down-shift Any position 1st → 2nd ( km mile Odometer Reading / ( 5th → 4th times a day) particular position) 2nd → 3rd 3rd → 4th 4th → 3rd 4th → 5th) 3rd → 2nd 2nd → 1st) Lock-up malfunction Shift point too high or too low Symptoms Harsh engagement ( N→D Lock-up Any drive position) Slip or shudder No kick-down Others Check Item Malfunction Indicator Lamp Normal 1st Time Normal code Malfunction code (DTC ) 2nd Time Normal code Malfunction code (DTC ) Remains ON DTC Check 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1186 05-1034 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 0527K-49 DIAGNOSTIC TROUBLE CODE CHART If a DTC is displayed during the DTC check, check the parts listed in the table below and proceed to the page given. HINT:  *1 :
... MIL (Malfunction Indicator Lamp) light up  *2 :  ... Mark means ECM memorizes the malfunction code if the ECM detects the DTC detection condition.  This DTC may be output when the clutch, brake and gear components etc. inside the automatic transaxle are damaged. DTC No. (See Page) Detection Item Trouble Area MIL *1 Memory *2
 P0500 (05-578 ) Vehicle Speed Sensor ”A”  Combination meter  Open or short in vehicle speed sensor circuit  Vehicle speed sensor  ECM P0705 (05-1036 ) Transmission Range Sensor Circuit Malfunction (PRNDL Input)  Open or short in park/neutral position switch circuit  Park/neutral position switch  ECM
 P0710 (05-1042 ) Transmission Fluid Temperature Sensor ”A” Circuit  Open or short in ATF temperature sensor circuit  Transmission wire (ATF temperature sensor)  ECM
 P0711 (05-1046 ) Transmission Fluid Temperature Sensor ”A” Performance  Open or short in ATF temperature sensor circuit  Transmission wire (ATF temperature sensor)  ECM
 P0712 (05-1042 ) Transmission Fluid Temperature Sensor ”A” Circuit Low Input  Short in ATF temperature sensor circuit  Transmission wire (ATF temperature sensor)  ECM
 P0713 (05-1042 ) Transmission Fluid Temperature Sensor ”A” Circuit High Input  Open in ATF temperature sensor circuit  Transmission wire (ATF temperature sensor)  ECM
 Turbine Speed Sensor Circuit No Signal  Open or short in transmission revolution sensor NT (speed sensor NT) circuit  Transmission revolution sensor NT (speed sensor NT)  ECM  Automatic transaxle assembly
 Brake Switch ”B” Circuit High  Short in stop light switch signal circuit  Stop light switch  ECM
 P0741 (05-1056 ) Torque Converter Clutch Solenoid Performance (Shift Solenoid Valve DSL)  Shift solenoid valve DSL remains open or closed  Valve body is blocked  Shift solenoid valve DSL  Torque converter clutch  Automatic transaxle (clutch, brake or gear etc.)  Line pressure is too low  ECM
 P0746 (05-1061 ) Pressure Control Solenoid ”A” Performance (Shift Solenoid Valve SL1)  Shift solenoid valve SL1 remains open or closed  Valve body is blocked  Shift solenoid valve SL1  Automatic transaxle (clutch, brake or gear etc.)  ECM
 P0748 (05-1065 ) Pressure Control Solenoid ”A” Electrical (Shift Solenoid Valve SL1)  Open or short in shift solenoid valve SL1 circuit  Shift solenoid valve SL1  ECM
 P0717 (05-1049 ) P0724 (05-1052 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1224 DIAGNOSTICS - 05-1035 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) Shift Solenoid ”D” Performance (Shift Solenoid Valve S4)  Shift solenoid valve S4 remains open or closed  Valve body is blocked  Shift solenoid valve S4  Automatic transaxle (clutch, brake or gear etc.)  ECM
 P0771 (05-1072 ) Shift Solenoid ”E” Performance (Shift Solenoid Valve SR)  Shift solenoid valve SR remains open or closed  Valve body is blocked  Shift solenoid valve SR  Automatic transaxle (clutch, brake or gear etc.)  ECM
 P0776 (05-1077 ) Pressure Control Solenoid ”B” Performance (Shift Solenoid Valve SL2)  Shift solenoid valve SL2 remains open or closed  Valve body is blocked  Shift solenoid valve SL2  Automatic transaxle (clutch, brake or gear etc.)  ECM
 P0778 (05-1082 ) Pressure Control Solenoid ”B” Electrical (Shift Solenoid Valve SL2)  Open or short in shift solenoid valve SL2 circuit  Shift solenoid valve SL2  ECM
 P0793 (05-1085 ) Intermediate Shaft Speed Sensor ”A”  Open or short in transmission revolution sensor NC (speed sensor NC) circuit  Transmission revolution sensor NC (speed sensor NC)  ECM
 P0796 (05-1089 ) Pressure Control Solenoid ”C” Performance (Shift Solenoid Valve SL3)  Shift solenoid valve SL3 remains open or closed  Valve body is blocked  Shift solenoid valve SL3  Automatic transaxle (clutch, brake or gear etc.)  ECM
 P0798 (05-1094 ) Pressure Control Solenoid ”C” Electrical (Shift Solenoid Valve SL3)  Open or short in shift solenoid valve SL3 circuit  Shift solenoid valve SL3  ECM
 P0982 (05-1097 ) Shift Solenoid ”D” Control Circuit Low (Shift Solenoid Valve S4)  Short in shift solenoid valve S4 circuit  Shift solenoid valve S4  ECM
 P0983 (05-1097 ) Shift Solenoid ”D” Control Circuit High (Shift Solenoid Valve S4)  Open in shift solenoid valve S4 circuit  Shift solenoid valve S4  ECM
 P0985 (05-1100) Shift Solenoid ”E” Control Circuit Low (Shift Solenoid Valve SR)  Short in shift solenoid valve SR circuit  Shift solenoid valve SR  ECM
 P0986 (05-1100) Shift Solenoid ”E” Control Circuit High (Shift Solenoid Valve SR)  Open in shift solenoid valve SR circuit  Shift solenoid valve SR  ECM
 P2716 (05-1103) Pressure Control Solenoid ”D” Electrical (Shift Solenoid Valve SLT)  Open or short in shift solenoid valve SLT circuit  Shift solenoid valve SLT  ECM
 P2769 (05-1106) Torque Converter Clutch Solenoid Circuit Low (Shift Solenoid Valve DSL)  Short in shift solenoid valve DSL circuit  Shift solenoid valve DSL  ECM
 P2770 (05-1106) Torque Converter Clutch Solenoid Circuit High (Shift Solenoid Valve DSL)  Open in shift solenoid valve DSL circuit  Shift solenoid valve DSL  ECM
 P0766 (05-1068 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1225 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-993 0527H-45 HOW TO PROCEED WITH TROUBLESHOOTING HINT:
The ECM of this system is connected to the multiplex communication system. Therefore, before starting troubleshooting, make sure to check that there is no trouble in the multiplex communication system. The hand-held tester can be used at steps 3, 4, 6, and 9.
1 Vehicle Brought to Workshop 2 Customer Problem Analysis (SEE PAGE 05-996 ) 3 Connect the OBD II scan tool or hand-held tester to DLC3 4 Check and Clear DTC and Freeze Frame Data (SEE PAGE 05-1026 ) 5 Visual Inspection 6 Setting the Check Mode Diagnosis (SEE PAGE 05-1028 ) 7 Problem Symptom Confirmation (SEE PAGE 05-997 ) Symptom does not occur: Go to step 8 Symptom occur: Go to step 9 8 Symptom Simulation (SEE PAGE 01-26 ) 9 DTC Check (SEE PAGE 05-1026 ) DTC is not output: Go to step 10 DTC is output: Go to step 17 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1183 05-994 10 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) Basic Inspection (SEE PAGE 40-2 , 40-1 1 and 40-71 ) NG Go to step 19 OK 11 Mechanical System Test (SEE PAGE 05-1000 ) NG Go to step 16 OK 12 Hydraulic Test (SEE PAGE 05-1002 ) NG Go to step 16 OK 13 Manual Shifting Test (SEE PAGE 05-1004 ) NG Go to step 15 OK 14 Problem Symptoms Table Chapter 1 (SEE PAGE 05-1016 ) NG Go to step 18 OK 15 Problem Symptoms Table Chapter 2 (SEE PAGE 05-1016 ) 16 Part Inspection Go to step 19 17 DTC Chart (SEE PAGE 05-1034 ) 18 Circuit Inspection 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1184 DIAGNOSTICS 19 Repair or Replace 20 Confirmation Test - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-995 End 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1185 05-990 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 0527L-45 LOCATION Combination Meter
MIL (Malfunction Indicator Lamp) ECM Transmission Control Switch (O/D Main Switch) Pattern Select Switch (ECT SNOW Switch) Stop Lamp Switch Assy DLC3 (Data Link Connector 3) Transmission Control Switch (2 ⇔ L Position) Transmission Revolution Sensor NT (Speed Sensor NT) Shift Solenoid Valve SL1 Transmission Revolution Sensor NC (Speed Sensor NC) Shift Solenoid Valve SLT Shift Solenoid Valve SL3 Shift Solenoid Valve SR Transmission Wire (ATF Temperature Sensor) Park/neutral Position Switch Assy Shift Solenoid Valve DSL Shift Solenoid Valve S4 Shift Solenoid Valve SL2 G32074 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1180 05-986 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05C0T-30 PRECAUTION NOTICE: Perform the RESET MEMORY (AT initialization) when replacing the automatic transaxle assy, engine assy or ECM (see page 05-1005 ). HINT: Initialization can not be completed by only disconnecting the battery terminal. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1176 05-1016 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 0527M-48 PROBLEM SYMPTOMS TABLE HINT: If a normal code is displayed during the diagnostic trouble code check although the trouble still occurs, check the electrical circuits for each symptom in the order given in the charts on the following pages and proceed to the page given for troubleshooting. The Matrix Chart is divided into 2 chapters. 1. Chapter 1: Electronic Circuit Matrix Chart  Refer to the table below when the trouble cause is considered to be electrical.  If the instruction ”Proceed to next circuit inspection shown on matrix chart” is given in the flow chart of each circuit, proceed to the circuit with the next highest number in the table to continue the check.  If the trouble still occurs even though there are no abnormalities in any of the other circuits, check and replace the ECM. HINT: *1: When the circuit on which mark *1 is attached is a malfunction, DTC could be output (see page 05-1026 ). Symptom Suspect Area See page No down-shift (A particular gear, from 1st to 4th gear, is not down-shifted) 1. Shift solenoid valve (SL1) circuit *1 2. Shift solenoid valve (SL2) circuit *1 3. Shift solenoid valve (SL3) circuit *1 4. Shift solenoid valve (SR) circuit *1 5. ECM 05-1061 05-1077 05-1089 05-1072 01-36 No down-shift (5th → 4th) 1. Transmission control switch (O/D OFF) circuit 2. Shift solenoid valve (S4) circuit *1 3. ECM 05-1109 05-1068 01-36 No up-shift (A particular gear, from 1st to 4th gear, is not up-shifted) 1. Shift solenoid valve (SL1) circuit *1 2. Shift solenoid valve (SL2) circuit *1 3. ECM 05-1061 05-1077 01-36 No up-shift (4th → 5th) 1. Transmission control switch (O/D OFF) circuit 2. Shift solenoid valve (S4) circuit *1 3. ECM 05-1109 05-1068 01-36 No lock-up 1. Shift solenoid valve (DSL) circuit *1 2. Stop light switch circuit *1 3. Engine coolant temp. sensor circuit *1 4. ECM 05-1056 05-1052 05-412 01-36 No lock-up off 1. Shift solenoid valve (DSL) circuit *1 2. ECM 05-1056 01-36 Shift point too high or too low 1. Throttle position sensor circuit *1 2. Shift solenoid valve (SLT) circuit *1 3. ECM 05-412 05-1103 01-36 Up-shift to 5th from 4th while shift lever is D (O/D OFF) position 1. Transmission control switch (O/D OFF) circuit 2. ECM 05-1109 01-36 Up-shift to 5th from 4th while engine is cold 1. Engine coolant temp. sensor circuit *1 2. ECM 05-412 01-36 Up-shift to 2nd from 1st while shift lever is L position 1. Transmission control switch (2 ⇔ L position) circuit *1 2. ECM 05-1036 01-36 Harsh engagement (N → D) 1. Shift solenoid valve (SL1) circuit *1 2. ECM 05-1061 01-36 Harsh engagement (Lock-up) 1. Shift solenoid valve (SL2) circuit *1 2. ECM 05-1077 01-36 Harsh engagement (Any driving position) 1. Shift solenoid valve (SLT) circuit *1 2. ECM 05-1103 01-36 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1206 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) Poor acceleration 1. Shift solenoid valve (SLT) circuit *1 2. ECM No kick-down ECM 05-1017 05-1103 01-36 01-36 *1 05-1056 01-36 Engine stalls when starting off or stopping 1. Shift solenoid valve (DSL) circuit 2. ECM Malfunction in shifting 1. Park/neutral position switch circuit *1 2. Transmission control switch (O/D OFF) circuit 3. ECM 05-1036 05-1109 01-36 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1207 05-1018 2. DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) Chapter 2: On-Vehicle Repair and Off-Vehicle Repair (
: U151E, U151F AUTOMATIC TRANSAXLE Repair Manual Pub. No. RM1021U) Symptom Suspect Area See page Vehicle does not move in forward position and in reverse positions 1. Valve body assy 2. U/D brake (B3) 3. Torque converter clutch 40-44
40-29 Vehicle does not move in R position 1. Valve body assy 2. Reverse clutch (C2) 3. 1st & reverse brake (B2) 40-44

No up-shift (1st → 2nd) 1. Valve body assy 2. 2nd & O/D brake (B1) 40-44
No up-shift (2nd → 3rd) 1. Valve body assy 2. Direct and O/D clutch (C0) 40-44
No up-shift (3rd → 4th) 1. Valve body assy 2. 2nd & O/D brake (B1) 40-44
No up-shift (4th → 5th) 1. Valve body assy 2. U/D clutch (C3) 40-44
No down-shift (5th → 4th) Valve body assy 40-44 No down-shift (4th → 3rd) Valve body assy 40-44 No down-shift (3rd → 2nd) Valve body assy 40-44 No down-shift (2nd → 1st) Valve body assy 40-44 No lock-up or No lock-up off 1. Valve body assy 2. Torque converter clutch 40-44 40-29 Harsh engagement (N → D) 1. 2. 3. 4. 5. 40-44



Harsh engagement (Lock-up) 1. Valve body assy 2. Torque converter clutch 40-44 40-29 Harsh engagement (N → R) 1. 2. 3. 4. 40-44


Harsh engagement (1st →2nd → 3rd → 4th → 5th) Valve body assy 40-44 Harsh engagement (1st → 2nd) 1. Valve body assy 2. 2nd & O/D brake (B1) 40-44
Harsh engagement (2nd → 3rd) 1. Valve body assy 2. C0 accumulator 3. Direct and O/D clutch (C0) 40-44

Harsh engagement (3rd → 4th) 1. Valve body assy 2. 2nd & O/D brake (B1) 40-44
Harsh engagement (4th → 5th) 1. Valve body assy 2. C3 accumulator 3. U/D clutch (C3) 40-44

Harsh engagement (5th → 4th) 1. Valve body assy 2. B3 accumulator 40-44
Valve body assy C1 accumulator Forward clutch (C1) One-way clutch No.1 (F1) U/D one-way clutch (F2) Valve body assy C2 accumulator Reverse clutch (C2) 1st & reverse brake (B2) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1208 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1019 Slip or shudder (Forward and reverse: After warm-up) 1. Valve body assy 2. Oil strainer 3. Direct and O/D clutch (C0) 4. Forward clutch (C1) 5. U/D clutch (C3) 6. 2nd & O/D brake (B1) 7. U/D brake (B3) 8. One-way clutch No.1 (F1) 9. U/D one-way clutch (F2) 10.Torque converter clutch 40-44 40-44






40-29 Slip or shudder (Particular position: Just after engine starts) Torque converter clutch 40-29 Slip or shudder (R position) 1. Reverse clutch (C2) 2. 1st & reverse brake (B2)

Slip or shudder (1st) 1. Forward clutch (C1) 2. One-way clutch No.1 (F1) 3. U/D one-way clutch (F2)

Slip or shudder (2nd) 2nd & O/D brake (B1)
Slip or shudder (3rd) Direct and O/D clutch (C0)
Slip or shudder (4th) 2nd & O/D brake (B1)
Slip or shudder (5th) U/D clutch (C3)
No engine braking (1st − 4th: D position) U/D brake (B3)
No engine braking (1st: L (1) position) 1. Valve body assy 2. 1st & reverse brake (B2) 40-44
No engine braking (2nd: 2 position) 1. Valve body assy 2. 2nd & O/D brake (B1) 40-44
No engine braking (3rd: 3 position) U/D brake (B3) Poor acceleration (All positions) Torque converter clutch Poor acceleration (5th) 1. U/D clutch (C3) 2. U/D planetary gear unit Engine stalls when starting off or stopping Torque converter clutch 40-29 No kick-down Valve body assy 40-44
40-29

2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1209 05-1020 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05EK6-06 TERMINALS OF ECM 1. ECM E7 E8 E9 E6 E5 C80654 C91969 HINT: Each ECM terminal’s standard voltage is shown in the table below. In the table, first follow the information under ”Condition”. Look under ”Symbols (Terminal No.)” for the terminals to be inspected. The standard voltage between the terminals is shown under ”Specific Condition”. Use the illustration above as a reference for the ECM terminals. Symbols (Terminals No.) P (E5-6) (E5 6) - E1 (E9-1) (E9 1) N (E5-7) (E5 7) - E1 (E9-1) (E9 1) L (E6-8) (E6 8) - E1 (E9-1) (E9 1) 2 (E6-9) (E6 9) - E1 (E9-1) (E9 1) D (E6-10) (E6 10) - E1 (E9-1) (E9 1) R (E6-11) (E6 11) - E1 (E9-1) (E9 1) Wiring Color V - BR GR - BR R - BR G - BR Y - BR L - BR SPD (E6-17) - E1 (E9-1) Y - BR STP (E6-19) (E6 19) - E1 (E9-1) (E9 1) BR - BR 3 (E6-20) (E6 20) - E1 (E9-1) (E9 1) P - BR Terminal Description P shift position osition switch sig signal N shift position osition switch sig signal L shift position osition switch sigsig nal 2 shift position osition switch sigsig nal D shift position osition switch sig signal R shift position osition switch sig signal Speed signal St lamp Stop l switch it h signal i l 3 shift position osition switch sigsig nal Condition Specified Condition IG switch ON and shift lever P position 10 to 14 V IG switch ON and shift lever except P position Below 1 V IG switch ON and shift lever N position 10 to 14 V IG switch ON and shift lever except N position Below 1 V IG switch ON and shift lever L position 10 to 14 V IG switch ON and shift lever except L position Below 1 V IG switch ON and shift lever 2 and L position 10 to 14 V IG switch ON and shift lever except 2 and L position Below 1 V IG switch ON and shift lever D position 10 to 14 V IG switch ON and shift lever except D position Below 1 V IG switch ON and shift lever R position 10 to 14 V IG switch ON and shift lever except R position Below 1 V Vehicle speed 20 km/h (12 mph) Pulse generation (See waveform 8) Brake pedal is depressed 7.5 to 14 V Brake pedal is released Below 1.5 V IG switch ON and shift lever 3 position 10 to 14 V IG switch ON and shift lever except 3 position Below 1 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1210 DIAGNOSTICS NSW (E7-16) (E7 16) - E1 (E9-1) (E9 1) DSL (E8-11) - E1 (E9-1) B R - BR B-R - P k neutral Park t l switch it h signal i l Y-G - BR DSL solenoid signal SR (E8 (E8-9) 9) - E1 (E9 (E9-1) 1) L-B L B - BR SR solenoid signal ODMS (E5-16) - E1 (E9-1) GR - BR O/D main switch ↑ ↑ S4 (E8 (E8-10) 10) - E1 (E9 (E9-1) 1) ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) ↑ L-W L W - BR S4 solenoid signal 05-1021 IG switch ON and shift lever P and N position Below 1 V IG switch ON and shift lever except P and N position 10 to 14 V Vehicle speed 65 km/h (40 mph), lock-up (ON to OFF) Pulse generation (See waveform 2) IG switch ON Below 1 V 3rd, 4th or 5th gear 10 to 14 V 1st or 2nd gear Below 1 V IG switch ON 10 to 14 V IG switch ON and press continuously O/D main switch Below 1 V IG switch ON Below 1 V 5th gear 10 to 14 V Except 5th gear Below 1 V SL3+ (E8-17) - SL3- (E8-16) G-B - G-R SL3 solenoid signal Engine idle speed Pulse generation (See waveform 3) SL2+ (E8-15) - SL2- (E8-14) L-Y - L-R SL2 solenoid signal Engine idle speed Pulse generation (See waveform 4) SL1+ (E8-19) - SL1- (E8-18) R-B - B-W SL1 solenoid signal Engine idle speed Pulse generation (See waveform 5) NC+ (E8-26) - NC- (E8-34) R - W-G Speed sensor (NC) signal Vehicle speed 30 km/h (19 mph): (3rd gear) Engine speed 1,400 rpm Pulse generation (See waveform 6) NT+ (E8-27) - NT- (E8-35) W - R-W Speed sensor (NT) signal Vehicle speed 20 km/h (12 mph) Pulse generation (See waveform 7) SLT+ (E8-13) - SLT- (E8-12) Y-R - Y-B SLT solenoid signal Engine idle speed Pulse generation (See waveform 1) THO1 (E8-32) - E2 (E7-28) G-Y - BR ATF temperature sensor signal ATF temperature: 115
C (239
F) or more 5 V/DIV Below 1.5 V Waveform 1 Reference: Terminal SLT+ - SLT- Tool setting 5V/DIV, 1ms/DIV Vehicle condition Engine idle speed GND 1 ms/DIV G23426 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1211 05-1022 DIAGNOSTICS 10 V/DIV - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) Waveform 2 Reference: Terminal DSL - E1 Tool setting 10V/DIV, 100ms/DIV Vehicle condition Vehicle speed 65 km/h (40 mph), lock-up (ON to OFF) 100 ms/DIV C53420 C42677 5 V/DIV Waveform 3 Reference: Terminal SL3+ - SL3- Tool setting 5V/DIV, 1ms/DIV Vehicle condition Engine idle speed GND 1 ms/DIV G23426 5 V/DIV Waveform 4 Reference: Terminal SL2+ - SL2- Tool setting 5V/DIV, 1ms/DIV Vehicle condition Engine idle speed GND 1 ms/DIV G23426 5 V/DIV Waveform 5 Reference: Terminal SL1+ - SL1- Tool setting 5V/DIV, 1ms/DIV Vehicle condition Engine idle speed GND 1 ms/DIV G23426 1 V/DIV Waveform 6 Reference: Terminal NC+ - NC- Tool setting 1V/DIV, 1ms/DIV Vehicle condition Vehicle speed 30 km/h (19 mph): (3rd gear) Engine speed 1,400 rpm 1 ms/DIV C93866 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1212 DIAGNOSTICS 5 V/DIV - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E/U151F) 05-1023 Waveform 7 Reference: Terminal NT+ - NT- Tool setting 5V/DIV, 0.5ms/DIV Vehicle condition Vehicle speed 20 km/h (12 mph) 0.5 ms/DIV C53419 C42920 5 V/DIV Waveform 8 Reference: Terminal SPD - E1 Tool setting 5V/DIV, 20ms/DIV Vehicle condition Vehicle speed 20 km/h (12 mph) 20 ms/DIV A05135 C53421 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1213 05-914 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05F33-05 CHECK MODE PROCEDURE 1. DTC CHECK (CHECK MODE) HINT: Hand-held tester only: Compared to the normal mode, the check mode has more sensing ability to detect malfunctions. Furthermore, the same diagnostic items which are detected in the normal mode can also be detected in the check mode. Hand-Held Tester DLC3 G30830 0.13 sec. 0.13 sec. ON OFF BR3904 (a) Procedure for Check Mode using the hand-held tester. (1) Check the initial conditions.
Battery positive voltage 11 V or more
Throttle valve fully closed
Transaxle in the P or N position
A/C switch is off (2) Turn the ignition switch off. (3) Connect the hand-held tester to the DLC3. (4) Turn the ignition switch to the ON position and push the hand-held tester main switch on. (5) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/ CHECK MODE” (Check that the MIL flashes). NOTICE: All DTCs and freeze frame data recorded will be erased if: 1) the hand-held tester is used to change the ECM from normal mode to check mode or vice-versa; or 2) during check mode, the ignition switch is turned from ON to ACC or OFF. (6) Start the engine (MIL goes off after the engine starts). (7) Perform ”MONITOR DRIVE PATTERN” for the ECT test (see page 05-902 ). (Or, simulate the conditions of the malfunction described by the customer). NOTICE: Leave the ignition switch in the ON position until you have checked the DTCs, etc. (8) After simulating malfunction conditions, use the hand-held tester diagnosis selector to check the DTCs and freeze frame data, etc. (9) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/ DTC INFO/CURRENT CODES”. (10) After checking the DTC, inspect the applicable circuit. (11) See page 05- 920 to confirm the details of the DTCs. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1104 DIAGNOSTICS 2. (a) - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-915 DTC CLEAR When using the OBD II scan tool or hand-held tester: Clearing the DTCs. (1) Connect the OBD II scan tool or hand-held tester to the DLC3. (2) Turn the ignition switch to the ON position and push the OBD II scan tool or the hand-held tester main switch on. (3) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/ DTC INFO/CLEAR CODES [YES] button”. HINT: When operating the OBD II scan tool (complying with SAE J1978) or hand-held tester to erase the codes, the DTCs and freeze frame data will be erased. (See the OBD II scan tool’s instruction book for operating instructions.) (b) When not using the OBD II scan tool or hand-held tester: Clearing the DTCs. (1) Disconnecting the battery terminal or remove the EFI and ETCS fuses from the engine room J/B for 60 seconds or more. But if you disconnect the battery terminal, you should do the ”INITIALIZE” procedure. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1105 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-877 05F37-05 DEFINITION OF TERMS Term Definition Monitor description Description of what the ECM monitors and how it detects malfunctions (monitoring purpose and its details). Related DTCs A group of diagnostic trouble codes that are output by the ECM based on the same malfunction detection logic. Typical enabling condition Preconditions that allow the ECM to detect malfunctions. With all preconditions satisfied, the ECM sets the DTC when the monitored value(s) exceeds the malfunction threshold(s). Sequence of operation The priority order that is applied to monitoring, if multiple sensors and components are used to detect the malfunction. While another sensor is being monitored, the next sensor or component will not be monitored until the previous monitoring has concluded. Required sensor/components The sensors and components that are used by the ECM to detect malfunctions. Frequency of operation The number of times that the ECM checks for malfunctions per driving cycle. ”Once per driving cycle” means that the ECM detects malfunction only one time during a single driving cycle. ”Continuous” means that the ECM detects malfunction every time when enabling condition is met. Duration The minimum time that the ECM must sense a continuous deviation in the monitored value(s) before setting a DTC. This timing begins after the ”typical enabling conditions” are met. Malfunction thresholds Beyond this value, the ECM will conclude that there is a malfunction and set a DTC. MIL operation MIL illumination timing after a defect is detected. ”Immediately” means that the ECM illuminates MIL the instant the ECM determines that there is a malfunction. ”2 driving cycle” means that the ECM illuminates MIL if the same malfunction is detected again in the 2nd driving cycle. Component operating range Normal operation range of sensors and solenoids under normal driving conditions. Use these ranges as a reference. They cannot be used to judge if a sensor or solenoid is defective or not. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1067 05-910 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05F30-05 DIAGNOSIS SYSTEM 1. (a) DIAGNOSIS SYSTEM Description (1) When troubleshooting OBD II vehicles, the only difference from the usual troubleshooting procedure is that you need to connect an OBD II scan tool complying with SAE J1987 or a hand-held tester to the vehicle, and read off various data output from the vehicle’s ECM. (2) FI0534 OBD II regulations require that the vehicle’s onboard computer illuminate the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in the computer itself or in the drive system components which affect the vehicle emissions. In addition to the MIL illuminating when a malfunction is detected, the applicable DTCs prescribed by SAE J2012 are recorded in the ECM memory (see page 05-920 ). If the malfunction does not occur in 3 consecutive trips, the MIL goes off but the DTCs remain in the ECM memory. (3) To check the DTCs, connect the OBD II scan tool or hand-held tester to the DLC3 of the vehicle. The OBD II scan tool or hand-held tester also enables you to erase the DTCs and check freeze frame data and various forms of engine data (For instruction book). (4) The DTCs include SAE controlled codes and Manufacturer controlled codes. SAE controlled codes must be set as prescribed by the SAE, while Manufacturer controlled codes can be set freely by a manufacturer within the prescribed limits (see the DTC chart on page 05-920 ). (5) The diagnosis system operates in the normal mode during the normal vehicle use, and also has a check mode for technicians to simulate malfunction symptoms and perform troubleshooting. Most DTCs use 2 trip detection logic(*) to prevent erroneous detection. By switching the ECM to the check mode when troubleshooting, the technician can cause the MIL to illuminate for a malfunction that is only detected once or momentarily (hand-held tester). (6) *2 trip detection logic: When a malfunction is first detected, the malfunction is temporarily stored in the ECM memory. If the same malfunction is detected again during the second test drive, this second detection causes the MIL to illuminate. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1100 DIAGNOSTICS (b) D1 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-91 1 Inspect the DLC3. The vehicle’s ECM uses ISO 9141-2 for communication. The terminal arrangement of DLC3 complies with SAE J1962 and matches the ISO 9141-2 format. 1 23 4 5 6 78 9 10111213141516 DLC3 A04550 Tester connection 7 (Bus
Line) - 5 (Signal ground) Condition Specified condition During communication Pulse generation 4 (Chassis Ground) - Body Always 1 Ω or less 5 (Signal Ground) - Body Always 1 Ω or less 16 (B+) - Body Always 9 to 14 V HINT: If your display shows UNABLE TO CONNECT TO VEHICLE when you have connected the cable of the OBD II scan tool or hand-held tester to the DLC3, turned the ignition switch to the ON position and operated the scan tool, there is a problem on the vehicle side or tool side.
If the communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle.
If the communication is still impossible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool’s instruction manual. (c) Measure the battery voltage. Battery Voltage: 11 to 14 V If voltage is below 11 V, recharge the battery before proceeding. (d) Check the MIL. (1) The MIL comes on when the ignition switch is turned to the ON position and the engine is not running. HINT: If the MIL does not light up, troubleshoot the combination meter. (2) When the engine is started, the MIL should go off. If the lamp remains on, it means that the diagnosis system has detected a malfunction or abnormality in the system. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1101 05-918 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05F35-05 DATA LIST/ACTIVE TEST 1. DATA LIST HINT: According to the DATA LIST displayed by the OBD II scan tool or hand-held tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the OBD II scan tool or hand-held tester to the DLC3. (d) Turn the ignition switch to the ON position. (e) Push the ”ON” button of the OBD II scan tool or the hand-held tester. (f) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/DATA LIST”. (g) According to the display on tester, read the ”DATA LIST”. Item Measurement Item/ Range (display) STOP LIGHT SW Stop light SW Status/ ON or OFF Normal Condition Diagnostic Note
Brake Pedal is depressed: ON
Brake Pedal is released: OFF - PNP SW [NSW] PNP SW Status/ ON or OFF Shift lever position is; P and N: ON Except P and N: OFF When the shift lever position displayed on the hand-held tester differs from the actual position, adjustment of the PNP switch or the shift cable may be incorrect. HINT: When the failure still occurs even after adjusting these parts, see page 05-922 . LOW PNP SW Status/ ON or OFF Shift lever position is; L: ON Except L: OFF ↑ 2ND PNP SW Status/ ON or OFF Shift lever position is; 2: ON Except 2: OFF ↑ REVERSE PNP SW Status/ ON or OFF Shift lever position is; R: ON Except R: OFF ↑ 4TH/DRIVE PNP SW Status/ ON or OFF Shift lever position is; D: ON Except D: OFF ↑ O/D SW Status/ ON or OFF
IG SW ON: ON ↓
O/D SW Push: OFF ↓
O/D SW Push: ON - Shift lever position is;
L: 1st
2: 1st or 2nd
3: 1st, 2nd or 3rd
D(O/D ON): 1st, 2nd, 3rd or 4th (O/D) - OVERDRV CUT SW1 SHIFT Actual Gear position/ 1st, 2nd, 3rd, 4th (O/D) LOCK UP SOL Lock Up Solenoid Status/ ON or OFF
Lock Up: ON
Except Lock Up: OFF - SOLENOID (SLT) Shift Solenoid SLT Status/ ON or OFF
Accelerator pedal is depressed: OFF
Accelerator pedal is released: ON - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1108 DIAGNOSTICS AT FLUID TEMP SPD (NC) ATF Temp. Sensor Value/ min.: -40C (-40F) max.: 215C (419F) Counter Gear Speed/ display: 50 r/min - 05-919 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F)
After Stall Test; Approx. 80C (176F)
Equal to ambient temperature when the engine is cold If the value is ”-40C (-40F)” or ”215C (419F)”, ATF temp. sensor circuit is opened or shorten. [HINT] 4th (O/D) when shift lever position is D position (After warming up the engine);
Intermediate shaft speed (NC) becomes close to the engine speed. - 2. ACTIVE TEST HINT: Performing the ACTIVE TEST using the hand-held tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the hand-held tester to the DLC3. (d) Turn the ignition switch to the ON position. (e) Push the ”ON” button of the hand-held tester. (f) Select the item ”DIAGNOSIS/ENHANCED OBD II/ACTIVE TEST”. (g) According to the display on tester, perform the ”ACTIVE TEST”. Item Test Details Diagnostic Note SHIFT [Test Details] Operate the shift solenoid valve and set the each shift position by yourself. [Vehicle Condition] Less than 50 km/h (31 mph) [Others]
Press ”→” button: Shift up
Press ”←” button: Shift down Possible to check the operation of the shift solenoid valves. [Test Details] Control the shift solenoid DSL to set the automatic transaxle to the lock-up condition. [Vehicle Condition] Vehicle Speed: 58 km/h (36 mph) or more Possible to check the DSL operation. LOCK UP LINE PRESS UP * [Test Details] Operate the shift solenoid SLT and raise the line pressure. [Vehicle Condition]
Vehicle Stopped.
IDL: ON [HINT] OFF: Line pressure up (When the active test of ”LINE PRESS UP” is performed, the ECM commands the SLT solenoid to turn off). ON: No action (normal operation) - *: ”LINE PRESS UP” in the ACTIVE TEST is performed to check the line pressure changes by connecting the SST to the automatic transaxle, which is used in the HYDRAULIC TEST (see page 05-891 ) as well. HINT: The pressure values in ACTIVE TEST and HYDRAULIC TEST are different from each other. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1109 05-912 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05F31-05 DTC CHECK/CLEAR 1. DTC CHECK (NORMAL MODE) NOTICE: When the diagnostic system is switched from the normal mode to the check mode, all the DTCs and freeze frame data recorded in the normal mode will be erased. So before switching modes, always check the DTCs and freeze frame data, and note them down. Hand-Held Tester DLC3 G30830 (a) Checking DTCs using the OBD II scan tool or hand-held tester. (1) Turn the ignition switch off. (2) Connect the OBD II scan tool or hand-held tester to DLC3. (3) Turn the ignition switch to the ON position and push the OBD II scan tool or the hand-held tester main switch on. (4) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/ DTC INFO/CURRENT CODES”. (5) Use the OBD II scan tool or hand-held tester to check the DTCs and freeze frame data and note them down (For operating instructions, see the OBD II scan tool’s instruction book). (6) See page 05-920 to confirm the details of the DTCs. NOTICE: When simulating symptoms with an OBD II scan tool (excluding hand-held tester) to check the DTCs, use the normal mode. For codes on the DTCs chart subject to ”2 trip detection logic”, turn the ignition switch off after the symptom is simulated once. Then repeat the simulation process again. When the problem has been simulated twice, the MIL is indicated on the instrument panel and DTCs are recorded in the ECM. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1102 DIAGNOSTICS 2. (a) - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-913 DTC CLEAR When using the OBD II scan tool or hand-held tester: Clearing the DTCs. (1) Connect the OBD II scan tool or hand-held tester to the DLC3. (2) Turn the ignition switch to the ON position and push the OBD II scan tool or the hand-held tester main switch on. (3) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/ DTC INFO/CLEAR CODES [YES] button”. HINT: When operating the OBD II scan tool (complying with SAE J1978) or hand-held tester to erase the codes, the DTCs and freeze frame data will be erased. (See the OBD II scan tool’s instruction book for operating instructions.) (b) When not using the OBD II scan tool or hand-held tester: Clearing the DTCs. (1) Disconnecting the battery terminal or remove the EFI and ETCS fuses from the engine room J/B for 60 seconds or more. But if you disconnect the battery terminal, you should do the ”INITIALIZE” procedure. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1103 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-983 05ITR-02 PATTERN SELECT SWITCH CIRCUIT CIRCUIT DESCRIPTION Multiplex network body ECU receives pattern select switch information, and sends it through the multiplex communication system to the ECM. ECT SNOW is the system that operates the throttle motor to control engine output to reduce skidding of the driving wheels, guarantee takeoff acceleration, driving straightness and turning stability. WIRING DIAGRAM E4 Electronically Controlled Transmission Pattern Select SW * Center J/B W-B 13 3F 8 3D W-B Y 4 3 Multiplex Network Body ECU 15 B9 SNOW IB (*) Pattern Select Switch (ECT SNOW Switch) When the ECT SNOW switch is pushed, the switch contact is made and the ECT SNOW mode is selected. To cancel the ECT SNOW mode, push the ECT SNOW switch once again. The ECT SNOW mode is automatically cancelled when the ignition switch is turned ”OFF”. G30835 G32449 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1173 05-984 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) INSPECTION PROCEDURE 1 (a) (b) (c) (d) DRIVING TEST Start the engine. Turn the ECT SNOW switch ”OFF” (Normal drive mode). Confirm vehicle response by driving from a parked position to fully depressing the accelerator pedal. Turn the ECT SNOW switch ”ON” and perform the same check as (c). Confirm that there is a difference between ECT SNOW switch ”ON” and ”OFF”. HINT:

Driving test should be done on a paved road (a nonskid road). Make sure not to use the TRAC system when testing a vehicle equipped with one. OK: There is a difference in acceleration between ”ON” and ”OFF”. NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-904 ) 2 CHECK HARNESS AND CONNECTOR(PATTERN SELECT SWITCH ASSY NO.1 BODY GROUND) (a) Wire Harness Side: (Connector Front View): (b) Disconnect the connector of pattern select switch (ECT SNOW switch). Measure the resistance according to the value(s) in the table below. Standard: E4 NG G23382 Tester Connection Specified Condition 4 - Body ground Below 1 Ω REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK 3 INSPECT PATTERN SELECT SWITCH ASSY NO.1 (a) Switch Side: (Connector Front View): Measure the resistance according to the value(s) in the table below. Standard: Switch Condition E4 Tester Connection Press continuously Pattern select switch Below 1 Ω 3-4 Release Pattern select switch C82813 Specified Condition D25463 NG 10 kΩ or higher REPLACE PATTERN SELECT SWITCH ASSY NO.1 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1174 DIAGNOSTICS 4 - 05-985 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) CHECK HARNESS AND CONNECTOR(PATTERN SELECT SWITCH ASSY NO.1 MULTIPLEX NETWORK BODY ECU) (a) (b) (c) Connect the connector of pattern select switch (ECT SNOW switch). Disconnect the multiplex network body ECU connector. Measure the resistance between terminals SNOW of multiplex network body ECU and body ground. Standard: Switch Condition Tester Connection Press continuously Pattern select switch Release Pattern select switch Multiplex Network Body ECU: Back Side: Specified Condition Below 1 Ω B9 - 15 (SNOW) Body ground 10 kΩ or higher B9 B9 SNOW G32072 NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-904 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1175 05-916 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05F32-05 FAIL-SAFE CHART 1. FAIL-SAFE This function minimizes the loss of the ECT functions when any malfunction occurs in each sensor or solenoid. (a) ATF (Automatic Transmission Fluid) temperature sensor: When the ATF temperature sensor has a malfunction, O/D upshift is prohibited. (b) Counter gear speed sensor NC (Speed sensor NC): When the counter gear speed sensor has a malfunction, O/D upshift is prohibited. (c) Shift solenoid valve DSL: When the solenoid valve DSL has a malfunction, the current to the solenoid valve is stopped. This stops lock-up control, then fuel economy decreases. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1106 DIAGNOSTICS - 05-917 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) (d) Shift solenoid valve SL1, SL2 and S4: Fail safe function: If either of the shift solenoid valve circuits develops an open or short, the ECM turns the other shift solenoid ”ON” and ”OFF” in order to shift into the gear positions shown in the table below. Manual shifting as shown in the following table must be done (In case of a short circuit, the ECM stops sending the current to the short circuit solenoid). Even if starting the engine in the fail-safe mode, the gear position remain in the same position. SHIFT SOLENOID SL1 MALFUNCTIONING NORMAL Solenoid Valve Gear Solenoid Valve SL1 SL2 S4 ON ON OFF 1st X ON OFF 2nd OFF ON OFF 2nd X ON OFF 2nd OFF X OFF OFF OFF OFF 3rd X 3rd OFF X 3rd OFF X SL1 SL2 S4 Gear SHIFT SOLENOID SL2 MALFUNCTIONING Solenoid Valve Gear SL1 SL2 S4 ON X OFF 3rd OFF OFF OFF ON O/D X ON ON ON SHIFT SOLENOID SL1 AND SL2 MALFUNCTIONING Solenoid Valve Gear SL1 SL2 S4 SHIFT SOLENOID SL1 AND S4 MALFUNCTIONING Solenoid Valve Gear SL1 SL2 S4 X 1st 3rd OFF ON X 2nd OFF 3rd OFF OFF X 3rd ON O/D OFF OFF X 3rd SHIFT SOLENOID SL2 AND S4 MALFUNCTIONING Solenoid Valve Gear SL1 SL2 S4 ON X 3rd X OFF X OFF 3rd X ON X 2nd X X OFF 3rd X ON X 2nd OFF X X X X OFF 3rd X X 2nd OFF X X 2nd OFF X ON OFF X X ON O/D X Gear ON X OFF Solenoid Valve SL1 SL2 S4 ON OFF OFF ON OFF SHIFT SOLENOID S4 MALFUNCTIONING SHIFT SOLENOID SL1, SL2 AND S4 MALFUNCTIONING Solenoid Valve Gear SL1 SL2 S4 X X X 3rd 3rd X X X 3rd X 3rd X X X 3rd X 3rd X X X 3rd ON : Condition in the normal operation is shown on the up of ” ”. Condition in the fail-safe mode is shown on the down of ” ”. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1107 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-891 05F2X-05 HYDRAULIC TEST 1. PERFORM HYDRAULIC TEST (a) Measure the line pressure. NOTICE:
Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature 50 to 80°C (122 to 176°F).
The line pressure test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stopper outside the vehicle while the other is doing the test.
Be careful to prevent SST’s hose from interfering with the exhaust pipe. (1) (2) SST SST C81121 D25472 Warm up the ATF. Remove the test plug on the front side of the transaxle case and connect SST. SST 09992-00095 (09992- 00231, 09992-00271) (3) Fully apply the parking brake and chock the 4 wheels. (4) Connect an OBD II scan tool or hand-held tester to the DLC3. (5) Start the engine and check idling speed. (6) Keep your left foot pressing firmly on the brake pedal and shift into D position. (7) Measure the line pressure when the engine is idling. (8) Depress the accelerator pedal all the way down. Quickly read the highest line pressure when engine speed reaches stall speed. (9) In the same way, do the test in R position. Specified line pressure: Condition D position kPa (kgf / cm2, psi) R position kPa (kgf / cm2, psi) Idling 372 to 412 kPa (3.8 to 4.2 kgf/cm2, 54 to 60 psi) 672 to 742 kPa (6.9 to 7.6 kgf/cm2, 97 to 108 psi) Stall test 931 to 1,031 kPa (9.5 to 10.5 kgf/cm2, 135 to 150 psi) 1,768 to 1,968 kPa (18.0 to 20.0 kgf/cm2, 256 to 285 psi) Evaluation: Problem Possible cause If the measured values at all positions are higher
Line pressure control solenoid (SLT) defective
Regulator valve detective If the measured values at all positions are lower
Line pressure control solenoid (SLT) defective
Regulator valve detective
Oil pump defective
U/D (Underdrive) direct clutch defective If pressure is low in the D position only
D position circuit fluid leak
Forward clutch defective If pressure is low in the R position only
R position circuit fluid leak
Direct clutch defective
1st and reverse brake defective 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1081 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-893 05F2Z-05 INITIALIZATION 1. RESET MEMORY CAUTION: Perform the RESET MEMORY (AT initialization) when replacing the automatic transaxle assy, engine assy or ECM. NOTICE: Hand-held tester only HINT: The ECM memorizes the condition that the ECT controls the automatic transaxle assy and engine assy according to those characteristics. Therefore, when the automatic transaxle assy, engine assy, or ECM has been replaced, it is necessary to reset the memory so that the ECM can memorize the new information. Reset procedure is as follows. (a) Turn the ignition switch off. (b) Connect the hand-held tester to the DLC3. (c) Turn the ignition switch to the ON position and push the hand-held tester main switch on. (d) Select the item ”DIAGNOSIS/ENHANCED OBD II”. (e) Perform the reset memory procedure from the ENGINE menu. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1083 05-894 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) CAUTION: After performing the RESET MEMORY, be sure to perform the ROAD TEST (see page 05-887 ) described earlier. HINT: The ECM is learned by performing the ROAD TEST. Tester menu flow: G23367 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1084 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-895 05ITI-02 LIST OF DISABLE A MONITOR HINT: This table indicates ECM monitoring status for the items in the upper columns if the DTCs in each line on the left are being set. As for the ”X” mark, when the DTC on the left is stored, detection of the DTC in the upper column is not performed. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1085 05-896 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) A98648 A92385 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1086 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-897 A92386 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1087 05-898 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) A98729 A92387 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1088 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-899 A92388 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1089 05-900 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) A92389 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1090 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-901 A92390 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1091 05-902 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05F3E-05 MONITOR DRIVE PATTERN 1. (a) MONITOR DRIVE PATTERN FOR ECT TEST Perform this drive pattern as one method to simulate the detection conditions of the ECT malfunctions. (The DTCs may not be detected due the actual driving conditions. And some codes may not be detected through this drive pattern). HINT: Preparation for driving
Warm up the engine sufficiently. (Engine coolant temperature is 60 °C (140 °F) or higher)
Drive the vehicle when the atmospheric temperature is -10 °C (14 °F) or higher. (Malfunction is not detected when the atmospheric temperature is -10 °C (14 °F) or less) Driving note
Drive the vehicle through all gears. Stop → 1st → 2nd → 3rd → O/D → O/D (lock-up ON).
Repeat the above driving pattern three times or more. NOTICE:
The monitor status can be checked using the OBD II scan tool. When using the hand-held tester, monitor status can be found in the ”ENHANCED OBD II/DATA LIST” or under ”CARB OBD II”.
In the event that the drive pattern must be interrupted (possibly due to traffic conditions or other factors) the drive pattern can be resumed and, in most cases, the monitor can be completed. CAUTION: Perform this drive pattern on a level road as much as possible and strictly observe the posted speed limits and traffic laws while driving. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1092 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-903 Vehicle Speed Maintain a constant speed or gradual acceleration (with the throttle open) for 3 minutes or more.*1 Lock-up ON Vehicle Speed Approx.100 km/h (62 mph) Approx. 80 km/h (50 mph) 0 Warmed up sufficiently Stop (Idling) Normal acceleration through all the gears from 1st to 4th(O/D) G31593 HINT: *1: Drive at such a speed in the uppermost gear, to engage lock-up. The vehicle can be driven at a speed lower than that in the above diagram under the lock-up condition. NOTICE: It is necessary to drive the vehicle for approximately 30 minutes to detect DTC P0711 (ATF temperature sensor malfunction). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1093 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-889 05F2W-05 MECHANICAL SYSTEM TESTS 1. (a) PERFORM MECHANICAL SYSTEM TESTS Measure the stall speed. The object of this test is to check the overall performance of the transaxle and engine by measuring the stall speeds in the D and R positions. NOTICE:
Perform the test at the normal operating ATF (Automatic Transmission Fluid) temperature 50 to 80°C (122 to 176°F).
Do not continuously run this test for longer than 10 seconds.
To ensure safety, do this test in a wide, clear level area which provides good traction.
The stall test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test. (1) Chock the 4 wheels. (2) Connect an OBD II scan tool or hand-held tester to the DLC3. (3) Fully apply the parking brake. (4) Keep your left foot pressed firmly on the brake pedal. (5) Start the engine. (6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot. (7) Quickly read the stall speed at this time. Stall speed: 2,250
150 rpm (8) Do the same test in the R position. Stall speed: 2,250
150 rpm Evaluation: Problem Possible cause (a) Stall engine speed is low in D and R positions
Engine power output may be insufficient
Stator one-way clutch not operating properly HINT: If the value is less than the specified value by 600 rpm or more, the torque converter could be faulty. (b) Stall engine speed is high in D position
Line pressure is too low
Forward clutch slipping
No. 2 one-way clutch not operating properly
U/D (Underdrive) clutch slipping (c) Stall engine speed is high in R position
Line pressure is too low
Direct clutch slipping
1st and reverse brake slipping
U/D (Underdrive) clutch slipping (d) Stall engine speed is high in D and R positions
Line pressure is too low
Improper fluid level
U/D (Underdrive) one-way clutch not operating properly 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1079 05-890 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) (b) Measure the time lag. (1) When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before the shock can be felt. This is used for checking the condition of the direct clutch, forward clutch, and 1st and reverse brake. NOTICE:
Perform the test at the normal operating ATF temperature 50 to 80 °C (122 to 176 °F).
Be sure to allow 1 minute interval between tests.
Perform the test three times, and measure the time lags. Calculate the average value of the three time lags. (2) Connect an OBD II scan tool or hand-held tester to the DLC3. (3) Fully apply the parking brake. (4) Start and warm up the engine and check idle speed. Idle speed: approx. 700 rpm (In N position and A/C OFF) (5) Shift the lever from N to D position. Using a stop watch, measure the time from when the lever is shifted until the shock is felt. Time lag: N → D less than 1.2 seconds (6) In the same way, measure the time lag for N → R. Time lag: N → R less than 1.5 seconds Evaluation (If N → D or N → R time lag is longer than the specified): Problem Possible cause N → D time lag is longer
Line pressure is too low
Forward clutch worn
U/D (Underdrive) one-way clutch not operating N → R time lag is longer
Line pressure is too low
Direct clutch worn
1st and reverse brake worn
U/D (Underdrive) one-way clutch not operating properly 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1080 05-892 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05F2Y-05 MANUAL SHIFTING TEST 1. PERFORM MANUAL SHIFTING TEST HINT: By this test, it can be determined whether the trouble is within the electrical circuit or is a mechanical problem in the transaxle. (a) (b) D09299 Disconnect the transmission wire connector. Inspect the manual driving operation. Check that the shift and gear positions correspond to the table below. While driving, shift through the L, 2 and D positions. Check that the gear change corresponds to the shift position. Shift Position Gear Position D 3rd 2 3rd L 3rd R Reverse P Pawl Lock HINT: If the gear positions of the L, 2 and D are difficult to distinguish, do the following road test (see page 05-887 ). If any abnormality is found in the above test, the problem is in the transaxle itself. (c) Connect the transmission wire connector. (d) Clear the DTC (see page 05-912 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1082 DIAGNOSTICS - 05-981 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05ITQ-02 O/D MAIN SWITCH CIRCUIT CIRCUIT DESCRIPTION The O/D main switch (transmission control switch) is a momentary type switch. When pressing the O/D main switch, the O/D OFF indicator light lights up and the ECM prohibits shifting into O/D, and when pressing it once again, the O/D OFF indicator light goes off and the ECM allows shifting into O/D. Turning the IG switch OFF will reset the O/D OFF indicator light. WIRING DIAGRAM Center J/B W-B 13 3F T16 Transmission Control SW and Transmission Shift Main SW 2 8 L 3H IF3 W-B 6 2 ECM GR 16 E5 ODMS IB G30835 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1171 05-982 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(TRANSMISSION CONTROL SWITCH-BODY GROUND) (a) (b) Wire Harness Side: (Connector Front View) Disconnect the transmission control switch connector. Measure the resistance according to the value(s) in the table below. Standard: T16 NG Tester Connection Specified Condition 6 - Body ground Below 1 Ω REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR G23398 OK 2 INSPECT TRANSMISSION CONTROL SWITCH (a) Switch Side: (Connector Front View): T16 G28380 Measure the resistance according to the value(s) in the table below. Standard: Switch Condition Tester Connection Specified Condition Press continuously transmission control switch 2-6 Below 1 Ω Release transmission control switch ↑ 10 kΩ or higher NG REPLACE TRANSMISSION CONTROL SWITCH (SEE PAGE 40-61 ) OK 3 CHECK HARNESS AND CONNECTOR(TRANSMISSION CONTROL SWITCH-ECM) E7 E8 E9 E6 (a) (b) (c) E5 ODMS G25190 Connect the transmission control switch connector. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard: Switch Condition Tester Connection Specified Condition Press continuously transmission control switch E5 - 16 (ODMS) Body ground Below 1 Ω Release transmission control switch ↑ 10 kΩ or higher NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-904 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1172 05-922 DIAGNOSTICS DTC P0705 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05ITL-02 TRANSMISSION RANGE SENSOR CIRCUIT MALFUNCTION (PRNDL INPUT) CIRCUIT DESCRIPTION The park/neutral position switch detects the shift lever position and sends signals to the ECM. DTC No. DTC Detection Condition Trouble Area (A) Any 2 or more signals of the following are ON simultaneously (2-trip detection logic)
NSW input signal is ON.
R input signal is ON.
D input signal is ON.
2 input signal is ON.
L input signal is ON. (B) Any 2 or more signals of the following are ON simultaneously (2-trip detection logic)
P input signal is ON.
R input signal is ON.
N input signal is ON.
D input signal is ON.
2 input signal is ON.
L input signal is ON. P0705
Open or short in park/neutral position switch circuit
Park/neutral position switch
ECM MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0705: Park/neutral position switch/Verify switch input Park/neutral position switch Continuous 2 sec. 2 driving cycles None TYPICAL ENABLING CONDITIONS Condition (A) and (B) The monitor will run whenever this DTC is not present. See page 05-895 Ignition switch ON Battery voltage 10.5 V or more 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1112 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-923 TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is met: Condition (A) or (B) Condition (A) Number of the following signal input at the same time 2 or more NSW switch ON R switch ON D switch ON 2 switch ON L switch ON Condition (B) Number of the following signal input at the same time 2 or more P switch ON R switch ON N switch ON D switch ON 2 switch ON L switch ON COMPONENT OPERATING RANGE Park/neutral position switch The park/neutral position switch sends only one signal to the ECM. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1113 05-924 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) WIRING DIAGRAM ECM 17 STA E7 B 4 EB2 B To STARTER Relay L-W P1 Park/Neutral Position SW 5 P N 4 NSW 8 L E6 Y-G 7 IM1 R G 18 IM1 P 9 2 E6 L-W 8 IM1 Y 10 D E6 LL 8 2L 3 DL 7 2 RB Passenger Side J/B 20 IM1 R-B RL 1 L 6 4A 5 4K 9 IM1 L-Y PL 6 V NL 9 R F7 FL Block W 1 FL MAIN B ALT 2 E6 J6 J/C GR C C 2 1G IG1 1 1A AM1 1 R 6 P E5 B V B Instrument Panel J/B 10 IM1 11 L J6 J/C 19 IM1 Y-R R +B 16 E7 B-R 7 N E5 GR I15 Ignition SW 7 1C G 6 1C 4 IG1 AM1 2 W 2 Battery G30838 G32478 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1114 DIAGNOSTICS - 05-925 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) INSPECTION PROCEDURE HINT: According to the DATA LIST displayed by the OBD II scan tool or hand-held tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. (a) Turn the ignition switch off. (b) Connect the OBD II scan tool or hand-held tester to the DLC3. (c) Turn the ignition switch to the ON position. (d) Push the ”ON” button of the OBD II scan tool or the hand-held tester. (e) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/DATA LIST”. (f) According to the display on tester, read the ”DATA LIST”. Item Measurement Item/ Range (display) Normal Condition Diagnostic Note When the shift lever position displayed on the hand-held tester differs from the actual position, adjustment of the PNP switch or the shift cable may be incorrect. PNP SW [NSW] PNP SW Status/ ON or OFF Shift lever position is; P or N: ON Except P or N: OFF LOW PNP SW Status/ ON or OFF Shift lever position is; L: ON Except L: OFF ↑ 2ND PNP SW Status/ ON or OFF Shift lever position is; 2: ON Except 2: OFF ↑ REVERSE PNP SW Status/ ON or OFF Shift lever position is; R: ON Except R: OFF ↑ 4TH/DRIVE PNP SW Status/ ON or OFF Shift lever position is; D: ON Except D: OFF ↑ 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1115 05-926 1 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) INSPECT PARK/NEUTRAL POSITION SWITCH ASSY (a) (b) Switch Side: (Connector Front View): Disconnect the park/neutral position switch connector. Measure resistance according to the value(s) in the table below when the shift lever is moved to each position. Standard: Shift Position Tester Connection Specified Condition P 2 - 6 and 4 - 5 Below 1 Ω Except P ↑ 10 kΩ or higher R 2-1 Below 1 Ω Except R ↑ 10 kΩ or higher N 2 - 9 and 4 - 5 Below 1 Ω Except N ↑ 10 kΩ or higher D 2-7 Below 1 Ω Except D ↑ 10 kΩ or higher 2 2-3 Below 1 Ω Except 2 ↑ 10 kΩ or higher L 2-8 Below 1 Ω Except L ↑ 10 kΩ or higher P1 G26080 NG REPLACE PARK/NEUTRAL POSITION SWITCH ASSY (SEE PAGE 40-3 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1116 DIAGNOSTICS 2 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-927 CHECK HARNESS AND CONNECTOR(PARK/NEUTRAL POSITION SWITCH ECM) NSW(+) L(+) D(+) N(+) R(+) 2(+) P(+) E7 E9 ON E8 ECM: E6 (a) (b) Connect the transmission control switch connector of shift lock control unit assy. Turn the ignition switch to the ON position, and measure the voltage according to the value(s) in the table below when the shift lever is moved to each position. E5 G26425 Standard: Shift Position Tester Connection Specified condition P and N E7 - 16 (NSW) - Body ground Below 1 V Except P and N ↑ 10 to 14 V P E5 - 6 (P) - Body ground 10 to 14 V Except P ↑ Below 1 V N E5 - 7 (N) - Body ground 10 to 14 V Except N ↑ Below 1 V R E6 - 11 (R) - Body ground 10 to 14 V* Except R ↑ Below 1 V D E6 - 10 (D) - Body ground 10 to 14 V Except D ↑ Below 1 V 2 E6 - 9 (2) - Body ground 10 to 14 V Except 2 ↑ Below 1 V L E6 - 8 (L) - Body ground 10 to 14 V Except L ↑ Below 1 V HINT: *: The voltage will drop slightly due to lighting up of the back up light. NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK REPLACE ECM (SEE PAGE 10-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1117 05-928 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) DTC P0710 TRANSMISSION FLUID TEMPERATURE SENSOR ”A” CIRCUIT DTC P0712 TRANSMISSION FLUID TEMPERATURE SENSOR ”A” CIRCUIT LOW INPUT DTC P0713 TRANSMISSION FLUID TEMPERATURE SENSOR ”A” CIRCUIT HIGH INPUT 0527N-31 CIRCUIT DESCRIPTION The ATF (Automatic Transmission Fluid) temperature sensor converts the fluid temperature into a resistance value which is input into the ECM. The ECM applies a voltage to the temperature sensor through ECM terminal THO1 (THO). The sensor resistance changes with the transmission fluid temperature. As the temperature becomes higher, the sensor resistance decreases. One terminal of the sensor is grounded so that the sensor resistance decreases and the voltage goes down as the temperature becomes higher. The ECM calculates the fluid temperature based on the voltage signal. DTC No. DTC Detection Condition Trouble Area P0710 (a) and (b) is detected momentary within 0.5 sec. when neither P0712 or P0713 is not detected (1-trip detection logic) (a) ATF temperature sensor resistance is less than 79 Ω. (b) ATF temperature sensor resistance is more than 156 kΩ. HINT: Within 0.5 sec., the malfunction switches from (a) to (b) or from (b) to (a)
Open or short in ATF temperature sensor circuit
Transmission wire (ATF temperature sensor)
ECM P0712 ATF temperature sensor resistance is less than 79 Ω for 0.5 sec. or more (1-trip detection logic)
Short in ATF temperature sensor circuit
Transmission wire (ATF temperature sensor)
ECM P0713 ATF temperature sensor resistance is more than 156 kΩ when 15 minutes or more after the engine start DTC is detected for 0.5 sec. or more (1-trip detection logic)
Open in ATF temperature sensor circuit
Transmission wire (ATF temperature sensor)
ECM MONITOR DESCRIPTION The automatic transmission fluid (ATF) temperature sensor converts ATF temperature to an electrical resistance value. Based on the resistance, the ECM determines the ATF temperature, and the ECM detects an opens or shorts in the ATF temperature circuit. If the resistance value of the ATF temperature is less than 79 Ω*1 or more than 156 kΩ*2, the ECM interprets this as a fault in the ATF sensor or wiring. The ECM will turn on the MIL and store the DTC. *1: 150C (302F) or more is indicated regardless of the actual ATF temperature. *2: -40C (-40F) is indicated regardless of the actual ATF temperature. HINT: The ATF temperature can be checked on the OBD II scan tool or hand-held tester display. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1118 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-929 MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0710: ATF temperature sensor/Range check (Fluttering) P0712: ATF temperature sensor/Range check (Low resistance) P0713: ATF temperature sensor/Range check (High resistance) ATF temperature sensor (TFT sensor) Continuous 0.5 sec. Immediate None TYPICAL ENABLING CONDITIONS P0710: Range check (Fluttering) P0712: Range check (Low resistance) The monitor will run whenever these DTCs are not present. See page 05-895 The typical enabling condition is not available. - P0713: Range check (High resistance) The monitor will run whenever this DTC is not present. See page 05-895 Time after engine start 15 min. or more TYPICAL MALFUNCTION THRESHOLDS P0710: Range check (Fluttering) Less than 79 Ω or More than 156 kΩ TFT (transmission fluid temperature) sensor P0712: Range check (Low resistance) Less than 79 Ω TFT (transmission fluid temperature) sensor P0713: Range check (High resistance) TFT (transmission fluid temperature) sensor More than 156 kΩ COMPONENT OPERATING RANGE TFT (transmission fluid temperature) Atmospheric temperature - approx. 130C (266F) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1119 05-930 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) WIRING DIAGRAM E10 Electronically Controlled Transmission Solenoid ECM O BR E2 O 6 THO 1 Short Connector 5 5 S28 S29 BR 28 E7 E2 5V 32 E8 G-Y THO G30836 G32447 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1120 DIAGNOSTICS - 05-931 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) INSPECTION PROCEDURE HINT: According to the DATA LIST displayed by the OBD II scan tool or hand-held tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the OBD II scan tool or hand-held tester to the DLC3. (d) Turn the ignition switch to the ON position. (e) Push the ”ON” button of the OBD II scan tool or the hand-held tester. (f) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/DATA LIST”. (g) According to the display on tester, read the ”DATA LIST”. Measurement Item/ Range (display) Item Normal Condition ATF Temp. Sensor Value/ min.: -40C (-40F) AT FLUID TEMP Approx. 80C (176F) (After Stall Test) max.: 215C (419F) HINT: When DTC P0712 is output and OBD II scan tool or hand-held tester output is 150C (302F), there is a short circuit. When DTC P0713 is output and OBD II scan tool or hand-held tester output is -40C (-40F), there is an open circuit. Measure the resistance between terminal THO1 (THO) and body ground. 1 Temperature Displayed Malfunction -40 °C (-40°F) Open circuit 150°C (302°F) or more Short circuit INSPECT TRANSMISSION WIRE(ATF TEMPERATURE SENSOR) Transmission Wire Side: (Connector Front View): THO (a) (b) E10 E2 C54864 (c) Disconnect the transmission wire connector from the transaxle. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 1 (THO) - 6 (E2) 79 Ω to 156 kΩ Measure the resistance according to the value(s) in the table below. Standard (Check for short): NG Tester Connection Specified Condition 1 (THO) - Body ground 10 kΩ or higher 6 (E2) - Body ground ↑ REPAIR OR REPLACE TRANSMISSION WIRE (SEE PAGE 40-34 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1121 05-932 2 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) CHECK HARNESS AND CONNECTOR(TRANSMISSION WIRE - ECM) E7 E8 E9 E6 (a) (b) (c) E5 THO ECM: E2 (d) G20668 Connect the transmission wire connector to the transaxle. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition E8 - 32 (THO) - E7 - 28 (E2) 79 Ω to 156 kΩ Measure the resistance according to the value(s) in the table below. Standard (Check for short): Tester Connection Specified Condition E8 - 32 (THO) - Body ground 10 kΩ or higher E7 - 28 (E2) - Body ground ↑ NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK REPLACE ECM (SEE PAGE 10-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1122 DIAGNOSTICS DTC P0711 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-933 05F3A-05 TRANSMISSION FLUID TEMPERATURE SENSOR ”A” PERFORMANCE CIRCUIT DESCRIPTION The ATF (Automatic Transmission Fluid) temperature sensor converts the fluid temperature into a resistance value which is input into the ECM. DTC No. P0711 DTC Detection Condition Trouble Area Both (a) and (b) are detected: (2-trip detection logic) (a) Intake air and engine coolant temperatures are more than -10°C (14F) at engine start (b) After normal driving for over 18 min. and 9 km (6 mile) or more, ATF temp. is less than 10°C (50F)
Open or short in ATF temperature sensor circuit
Transmission wire (ATF temperature sensor)
ECM MONITOR DESCRIPTION The ATF temperature sensor converts the ATF temperature to an electrical resistance value. Based on the resistance, the ECM determines the ATF temperature and detects an opens or shorts in the ATF temperature circuit or a fault of the ATF temperature sensor. After running the vehicle for a certain period, the ATF temperature should increase. If the ATF temperature is below 10C (50F) after running the vehicle for a certain period, the ECM interprets this as a fault, and turns on the MIL. When the ATF temperature is 110C (230F) or more after 17 minutes of engine cold start, the ECM also determines this as a fault, turns on the MIL, and stores the DTC. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0711: ATF temperature sensor/Rationality check ATF temperature sensor (TFT sensor) Continuous 3 sec. 2 driving cycles None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. Time after engine start See page 05-895 16 min.and 40 sec. or more ECT (Engine coolant temperature) -15 C (5F) or more TFT (transmission fluid temperature) sensor circuit Not circuit malfunction ECT sensor circuit Not circuit malfunction IAT (Intake air temperature) sensor circuit Not circuit malfunction Time after engine start 18 min. and 20 sec. Driving distance after engine start 9 km/h (5.6 mph) IAT (12 sec. after engine start) -10 C (14F) or more ECT (12 sec. after engine start) -10 C (14F) or more TYPICAL MALFUNCTION THRESHOLDS TFT (transmission fluid temperature) Less than 10C (50F) COMPONENT OPERATING RANGE TFT (transmission fluid temperature) Atmospheric temperature - approx. 130C (266F) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1123 05-934 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) WIRING DIAGRAM E10 Electronically Controlled Transmission Solenoid ECM O BR E2 O 6 THO 1 Short Connector 5 5 S28 S29 BR 28 E7 E2 5V 32 E8 G-Y THO G30836 G32447 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1124 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-935 INSPECTION PROCEDURE HINT: According to the DATA LIST displayed by the OBD II scan tool or hand-held tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the OBD II scan tool or hand-held tester to the DLC3. (d) Turn the ignition switch to the ON position. (e) Push the ”ON” button of the OBD II scan tool or the hand-held tester. (f) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/DATA LIST”. (g) According to the display on tester, read the ”DATA LIST”. Measurement Item/ Range (display) Item Normal Condition ATF Temp. Sensor Value/ min.: -40C (-40F) AT FLUID TEMP Approx. 80C (176F) (After Stall Test) max.: 215C (419F) HINT: When DTC P0712 is output and OBD II scan tool or hand-held tester output is 150C (302F), there is a short circuit. When DTC P0713 is output and OBD II scan tool or hand-held tester output is -40C (-40F), there is an open circuit. Measure the resistance between terminal THO1 (THO) and body ground. Temperature Displayed Malfunction -40 °C (-40°F) Open circuit 150°C (302°F) or more Short circuit HINT: If a circuit related to the ATF temperature sensor becomes open, P0713 is immediately set (in 0.5 second). When P0713 is set, P0711 cannot be detected. It is not necessary to inspect the circuit when P0711 is set. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1125 05-936 1 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) CHECK OTHER DTCS OUTPUT(IN ADDITION TO DTC P0711) (a) (b) Connect the OBD II scan tool or the hand-held tester to the DLC3. Turn the ignition switch to the ON position and push the OBD II scan tool or the hand-held tester main switch ON. (c) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/DTC INFO/CURRENT CODES”. (d) Read the DTCs using the OBD II scan tool or the hand-held tester. Result: Display (DTC output) Proceed to Only ”P0711” is output A ”P0711” and other DTCs B HINT: If any other codes besides ”P0711” is output, perform the troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART (SEE PAGE 05-920 ) A 2 CHECK TRANSAXLE FLUID LEVEL (SEE PAGE 40-2 ) OK: Automatic transaxle fluid level is correct. NG ADD FLUID OK REPLACE TRANSMISSION WIRE (SEE PAGE 40-34 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1126 DIAGNOSTICS DTC P0717 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-937 05F3B-05 TURBINE SPEED SENSOR CIRCUIT NO SIGNAL CIRCUIT DESCRIPTION This sensor detects the rotation speed of the input turbine. By comparing the input turbine speed signal (NT) with the counter gear speed sensor signal (NC), the ECM detects the shift timing of the gears and appropriately controls the engine torque and hydraulic pressure according to various conditions. Thus, providing smooth gear shift. DTC No. P0717 DTC Detection Condition Trouble Area ECM detects conditions (a), (b) and (c) continuity for 5 sec. or more: (1-trip detection logic) (a) Vehicle speed: 50 km/h (31 mph) or more (b) Park/neutral position switch (NSW, R and L) is OFF (c) Speed sensor (NT): less than 300 rpm 5 V/DIV GND
Open or short in transmission revolution sensor NT (speed sensor NT) circuit
Transmission revolution sensor NT (speed sensor NT)
ECM
Automatic transaxle assembly Reference (Using an oscilloscope): Check the waveform between the terminals NT+ and NTof the ECM connector. Standard: Refer to the illustration. Terminal NT+ - NT- Tool setting 5V/DIV, 0.5ms/DIV Vehicle condition Vehicle speed 20 km/h (12 mph) 0.5 ms/DIV C53419 C42920 MONITOR DESCRIPTION The NT terminal of the ECM detects a revolution signal from the speed sensor (NT) (input RPM). The ECM calculates a gearshift comparing the speed sensor (NT) with the speed sensor (NC). While the vehicle is operating in 2nd, 3rd or O/D gear in the shift position of D, if the input shaft revolution is less than 300 rpm*1 although the output shaft revolution is more than 1,000 rpm*2, the ECM detects the trouble, illuminates the MIL and stores the DTC. *1: Pulse is not output or is irregularly output. *2: The vehicle speed is 50 km/h (31 mph) or more. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0717: Speed sensor (NT)/Verify pulse input Speed sensor (NT), Speed sensor (NC) Continuous 5 sec. Immediate None 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1127 05-938 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. See page 05-895 Shift change Shift change is completed and before starting next shift change operation ECM selected gear 2nd, 3rd or 4th Output shaft rpm 1,000 rpm or more NSW switch OFF R switch OFF L switch OFF Engine Running TYPICAL MALFUNCTION THRESHOLDS Sensor signal rpm Less than 300 rpm COMPONENT OPERATING RANGE Speed sensor (NT) Turbine speed is equal to engine speed when lock-up ON WIRING DIAGRAM ECM T3 Turbine Speed Sensor 27 E8 W 1 2 NT+ 5V 35 E8 R-W NTE1 G31763 INSPECTION PROCEDURE 1 INSPECT SPEED SENSOR INSTALLATION (a) OK NG Check the speed sensor installation. OK: The installation bolt is tightened properly and there is no clearance between the sensor and transaxle case. NG REPLACE SPEED SENSOR(NT) BR3795 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1128 DIAGNOSTICS 2 - 05-939 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) INSPECT SPEED SENSOR(NT) (a) Sensor Side: (Connector Front View): (b) T3 2 Disconnect the speed sensor connector from the transaxle. Measure the resistance according to the value(s) in the table below. Standard: TOYOTA made: 1 C58536 Tester Connection Specified Condition 20 C (68 F) 1-2 500 to 620 Ω Standard: AISIN made: NG Tester Connection Specified Condition 20 C (68 F) 1-2 560 to 680 Ω REPLACE SPEED SENSOR(NT) OK 3 CHECK HARNESS AND CONNECTOR(SPEED SENSOR - ECM) E7 E8 E9 E6 (a) (b) (c) E5 NT+ Connect the speed sensor connector. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard: TOYOTA made: Tester Connection Specified Condition 20 C (68 F) E8 - 27 (NT+) - E8 - 35 (NT-) 500 to 620 Ω NTECM: C82158 C91565 Standard: AISIN made: (d) Tester Connection Specified Condition 20 C (68 F) E8 - 27 (NT+) - E8 - 35 (NT-) 560 to 680 Ω Measure the resistance according to the value(s) in the table below. Standard (Check for short): Tester Connection Specified Condition E8 - 27 (NT+) - Body ground 10 kΩ or higher E8 - 35 (NT-) - Body ground ↑ NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK REPLACE ECM (SEE PAGE 10-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1129 05-940 DIAGNOSTICS DTC P0724 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05F3C-05 BRAKE SWITCH ”B” CIRCUIT HIGH CIRCUIT DESCRIPTION The purpose of this circuit is to prevent the engine from stalling while driving in lock-up condition, when brakes are suddenly applied. When the brake pedal is depressed, this switch sends a signals to the ECM. Then the ECM cancels the operation of the lock-up clutch while braking is in progress. DTC No. DTC Detecting Condition Trouble Area The stop light switch remains ON even when the vehicle is driven in a GO (30 km/h) and STOP (3 km/h) fashion 5 times. (2-trip detection logic). P0724
Short in stop light switch signal circuit
Stop light switch
ECM MONITOR DESCRIPTION This DTC indicates that the stop light switch remains on. When the stop light switch remains ON during ”stop and go” driving, the ECM interprets this as a fault in the stop light switch and the MIL comes on and the ECM stores the DTC. The vehicle must stop (less than 3 km/h (2 mph)) and go (30 km/h (19 mph) or more) 5 times for two driving cycles in order to detect malfunction. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0724: Stop light switch/Range check/Rationality Stop light switch, Vehicle speed sensor Continuous GO and STOP 5 times 2 driving cycles None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. See page 05-895 Battery voltage 8 V or more Ignition switch ON Starter OFF GO (Vehicle speed is 30 km/h (18.63 mph) or more) Once STOP (Vehicle speed is less than 3 km/h (1.86 mph)) Once TYPICAL MALFUNCTION THRESHOLDS Brake switch Remain ON during GO and STOP 5 times 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1130 DIAGNOSTICS - 05-941 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) WIRING DIAGRAM 3 4L B 1 2 ECM Passenger Side J/B S15 Stop Light SW Y 12 4M BR 19 STP E6 Instrument Panel J/B 1 1E STOP 1 1A F7 FL Block W B 1 ALT 2 FL MAIN Battery G30837 G32448 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1131 05-942 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) INSPECTION PROCEDURE HINT: According to the DATA LIST displayed by the OBD II scan tool or hand-held tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. (a) Turn the ignition switch off. (b) Connect the OBD II scan tool or hand-held tester to the DLC3. (c) Turn the ignition switch to the ON position. (d) Push the ”ON” button of the OBD II scan tool or the hand-held tester. (e) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/DATA LIST”. (f) According to the display on tester, read the ”DATA LIST”. 1 Item Measurement Item/ Range (display) STOP LIGHT SW Stop light SW Status/ ON or OFF Normal Condition
Brake Pedal is depressed: ON
Brake Pedal is released: OFF INSPECT STOP LAMP SWITCH ASSY 2 4 1 3 Free Pushed in E65594 (a) (b) Remove the stop lamp switch assy. Measure the resistance according to the value(s) in the table below. Standard: Switch position Tester Connection Specified Condition Switch pin free 1-2 10 kΩ or higher Switch pin pushed in ↑ Below 1 Ω Switch pin free 3-4 Below 1 Ω Switch pin pushed in ↑ 10 kΩ or higher NG REPLACE STOP LAMP SWITCH ASSY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1132 DIAGNOSTICS 2 - 05-943 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) CHECK HARNESS AND CONNECTOR(STOP LAMP SWITCH ASSY - ECM) ECM: E7 (a) (b) STP(+) E8 E9 E6 E5 G26289 Connect the stop lamp switch assy connector. Measure the voltage according to the value(s) in the table below when the brake pedal is depressed and released. Standard: Condition Tester Connection Specified Condition Brake pedal is depressed E6 - 19 (STP) Body ground 10 to 14 V Brake pedal is released ↑ Below 1 V NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK REPLACE ECM (SEE PAGE 10-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1133 05-944 DTC DIAGNOSTICS P0741 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05F3F-05 TORQUE CONVERTER CLUTCH SOLENOID PERFORMANCE (SHIFT SOLENOID VALVE DSL) SYSTEM DESCRIPTION The ECM uses the signals from the throttle position sensor, Air-flow meter, turbine (input) speed sensor, intermediate (counter) shaft speed sensor and crankshaft position sensor to monitor the engagement condition of the lock-up clutch. Then the ECM compares the engagement condition of the lock-up clutch with the lock-up schedule in the ECM memory to detect a mechanical problems of the shift solenoid valve DSL, valve body and torque converter clutch. DTC No. P0741 DTC Detection Condition Lock-up does not occur when driving in lock-up range (normal driving at 85 km/h [53 mph]), or lock-up remains ON in lockup OFF range (2-trip detection logic) Trouble Area
Shift solenoid valve DSL remains open or closed
Valve body is blocked
Shift solenoid valve DSL
Torque converter clutch
Automatic transaxle (clutch, brake or gear etc.)
Line pressure is too low
ECM MONITOR DESCRIPTION Torque converter lock-up is controlled by the ECM based on speed sensor (NT), speed sensor (NC), engine rpm, engine load, engine temperature, vehicle speed, transmission temperature, and gear selection. The ECM determines the lock-up status of the torque converter by comparing the engine rpm (NE) to the input turbine rpm (NT). The ECM calculates the actual transmission gear by comparing input turbine rpm (NT) to counter gear rpm (NC). When conditions are appropriate, the ECM requests ”lock-up” by applying control voltage to shift solenoid DSL. When the DSL is turned on, solenoid DSL applies pressure to the lock-up relay valve and locks the torque converter clutch. If the ECM detects no lock-up after lock-up has been requested or if it detects lock-up when it is not requested, the ECM interprets this as a fault in the shift solenoid valve DSL or lock-up system performance. The ECM will turn on the MIL and store the DTC. Example: When any of the following is met, the system judges it as a malfunction. (a) There is a difference in rotation between before and after torque converters even when the ECM commands lock-up. (Engine speed is at least 75 rpm greater than input turbine speed.) (b) There is no difference in rotation between before and after torque converters even when the ECM commands lock-up off. (The difference between engine speed and input turbine speed is less than 35 rpm.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1134 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-945 MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation P0741: Shift solenoid valve DSL/OFF malfunction Shift solenoid valve DSL/ON malfunction Shift solenoid valve DSL, Speed sensor (NT), Speed sensor (NC),Crankshaft position sensor (NE), Throttle position sensor (VPA1), Mass air flow sensor (MAF), Transmission temperature sensor (THO1), Engine coolant temperature sensor (ECT) Continuous Duration OFF malfunction 3.5 sec. ON malfunction 1.8 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS ALL: Transmission range ”D” ECT (Engine coolant temperature) 60°C (140°F) or more TFT (Transmission fluid temperature) -20 C (-4F) or more TFT sensor circuit Not circuit malfunction ECT sensor circuit Not circuit malfunction Turbine speed sensor circuit Not circuit malfunction Intermediate shaft speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction Shift solenoid valve S4 circuit Not circuit malfunction Shift solenoid valve DSL circuit Not circuit malfunction Electronic throttle system Not circuit malfunction OFF malfunction ECM lock-up command ON ECM selected gear Vehicle speed 3rd or 4th 25 km/h (15.5 mph) or more ON malfunction ECM lock-up command OFF ECM selected gear 3rd or 4th Throttle valve opening angle Vehicle speed 8% or more 25 to 60 km/h (15.5 to 37.2 mph) TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is met: OFF malfunction or ON malfunction OFF malfunction Engine speed - Input (turbine) speed 100 rpm or more ON malfunction 2 detections are necessary per driving cycle: 1st detection; temporary flag ON 2nd detection; pending fault code ON Vehicle speed must be under 10 km/h (6.2 mph) once before 2nd detection Diffierence between engine speed and input (turbine) speed Less than 35 rpm 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1135 05-946 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) INSPECTION PROCEDURE HINT: Performing the ACTIVE TEST using the hand-held tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the hand-held tester to the DLC3. (d) Turn the ignition switch to the ON position. (e) Push the ”ON” button of the hand-held tester. (f) Select the item ”DIAGNOSIS/ENHANCED OBD II/ACTIVE TEST”. (g) According to the display on tester, perform the ”ACTIVE TEST”. Item LOCK UP Test Details Diagnostic Note [Test Details] Control the shift solenoid DSL to set the automatic transaxle to the lock-up condition. [Vehicle Condition] Vehicle Speed: 58 km/h (36 mph) or more Possible to check the DSL operation. HINT:

(h) HINT:

This test can be conducted when the vehicle speed is 58 km/h (36 mph) or more. This test can be conducted with the 3rd or O/D gear. Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. When changing the accelerator pedal opening angle while driving, if the engine speed does not change, lock-up is on. Slowly release, but not fully, the accelerator pedal in order to decelerate. (Fully releasing the pedal will close the throttle valve and lock-up may be turned off.) Accelerator Pedal Opening Angle Accelerator Pedal Fully Released Lock-up OFF Engine Speed Lock-up ON G23400 → time G29214 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1136 DIAGNOSTICS 1 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-947 CHECK OTHER DTCS OUTPUT(IN ADDITION TO DTC P0741) (a) (b) Connect the OBD II scan tool or the hand-held tester to the DLC3. Turn the ignition switch to the ON position and push the OBD II scan tool or the hand-held tester main switch ON. (c) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/DTC INFO/CURRENT CODES”. (d) Read the DTCs using the OBD II scan tool or the hand-held tester. Result: Display (DTC output) Proceed to Only ”P0741” is output A ”P0741” and other DTCs B HINT: If any other codes besides ”P0741” is output, perform the troubleshooting for those DTCs first. NG GO TO RELEVANT DTC CHART (SEE PAGE 05-920 ) A 2 INSPECT TRANSMISSION WIRE(DSL) Transmission Wire Side: (Connector Front View): (a) DSL (b) E10 C54864 Disconnect the transmission wire connector from the transaxle. Measure the resistance according to the value(s) in the table below. Standard: NG Tester Connection Specified Condition 20 C (68 F) 3 - Body ground 11 to 13 Ω Go to step 4 OK 3 CHECK HARNESS AND CONNECTOR(TRANSMISSION WIRE - ECM) E7 ECM: C82158 E8 E9 E6 (a) (b) (c) E5 DSL C91565 Connect the transmission wire connector. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20 C (68 F) E8 - 9 (DSL) - Body ground 11 to 13 Ω NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1137 05-948 4 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) INSPECT SHIFT SOLENOID VALVE(DSL) (a) (b) Shift Solenoid Valve DSL: (-) Remove the shift solenoid valve DSL. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20 C (68 F) Solenoid Connector (DSL) - Solenoid Body (DSL) 11 to 13 Ω (+) (c) G28385 Connect positive (+) lead to the terminal of solenoid connector, negative (-) lead to the solenoid body. OK: The solenoid valve makes an operating noise. NG REPLACE SHIFT SOLENOID VALVE(DSL) OK 5 CHECK TRANSMISSION WIRE (SEE PAGE 01-36 ) OK: The connectors and pins are securely installed. There is no open or short on the wire harness. NG REPAIR OR REPLACE TRANSMISSION WIRE (SEE PAGE 40-34 ) OK 6 INSPECT TRANSMISSION VALVE BODY ASSY(See chapter 2 in the problem symptoms table) (SEE PAGE 05-904 ) OK: There are no foreign objects on each valve and they operate smoothly. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSY (SEE PAGE 40-40 ) OK 7 INSPECT TORQUE CONVERTER CLUTCH ASSY (SEE PAGE 40-29 ) OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSY OK REPAIR AUTOMATIC TRANSAXLE ASSY (SEE PAGE 40-12 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1138 DIAGNOSTICS DTC P0746 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-949 05C0Z-17 PRESSURE CONTROL SOLENOID ”A” PERFORMANCE (SHIFT SOLENOID VALVE SL1) SYSTEM DESCRIPTION The ECM uses signals from the vehicle speed sensor to detect the actual gear position (1st, 2nd, 3rd or O/D gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves and valve body. DTC No. P0746 DTC Detecting Condition Trouble Area The gear required by the ECM does not match the actual gear when driving (2-trip detection logic)
Shift solenoid valve SL1 remains open or closed
Valve body is blocked
Shift solenoid valve SL1
Automatic transaxle (clutch, brake or gear etc.)
ECM MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves ”ON/OFF”. According to the input shaft revolution, intermediate (counter) shaft revolution and output shaft revolution, the ECM detects the actual gear position (1st, 2nd, 3rd or O/D gear position). When the gear position commanded by the ECM and the actual gear position are not same, the ECM illuminates the MIL. Example: When either condition (a) or (b) is met, the ECM detects a malfunction. (a) The ECM commands the 1st gear, but the actual gear is 2nd. (b) The ECM commands the 2nd gear, but the actual gear is 1st. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0746: Shift solenoid valve SL1/OFF malfunction Shift solenoid valve SL1/ON malfunction Shift solenoid valve SL1, Speed sensor (NT), Speed sensor (NC), Crankshaft position sensor (NE) Continuous OFF malfunction, ON malfunction (A) 0.8 sec. ON malfunction (B) 1 sec. 2 driving cycles None 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1139 05-950 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) TYPICAL ENABLING CONDITIONS ALL: Transmission range ”D” ECT (Engine coolant temperature) 60°C (140°F) or more TFT (Transmission fluid temperature) -20 C (-4F) or more TFT sensor circuit Not circuit malfunction ECT sensor circuit Not circuit malfunction Turbine speed sensor circuit Not circuit malfunction Intermediate shaft speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction Shift solenoid valve S4 circuit Not circuit malfunction Electronic throttle system Not circuit malfunction OFF malfunction ECM selected gear Vehicle speed Throttle valve opening angle 1st 10 to 40 km/h (6.2 to 24.9 mph) 4.5% or more at engine speed 1,900 rpm (Varies with engine speed) ON malfunction (A) ECM selected gear Vehicle speed Throttle valve opening angle 2nd 10 km/h (6.2 mph) or more 4.5% or more at engine speed 1,900 rpm (Varies with engine speed) ON malfunction (B) ECM lock-up command OFF ECM selected gear 3rd or 4th TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is met: OFF malfunction, or ON malfunction (A) and (B) 2 detections are necessary per driving cycle: 1st detection; temporary flag ON 2nd detection; pending fault code ON OFF malfunction Input (turbine) speed/Intermediate shaft speed 1.49 to 1.63 ON malfunction (A) Input (turbine) speed/Intermediate shaft speed 2.72 to 2.86 ON malfunction (B) Engine speed - Input (tubine) speed 250 rpm or more 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1140 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-951 INSPECTION PROCEDURE HINT: Performing the ACTIVE TEST using the hand-held tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Turn the ignition switch off. (b) Connect the hand-held tester to the DLC3. (c) Turn the ignition switch to the ON position. (d) Push the ”ON” button of the hand-held tester. (e) Select the item ”DIAGNOSIS/ENHANCED OBD II/ACTIVE TEST/SHIFT”. (f) According to the display on tester, perform the ”ACTIVE TEST”. HINT: While driving, the shift position can be forcibly changed with the hand-held tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem (see page 05-916 ). Item Test Details Diagnostic Note SHIFT [Test Details] Operate the shift solenoid valve and set the each shift position by yourself. [Vehicle Condition] Less than 50 km/h (31 mph) [Others]
Press ”→” button: Shift up
Press ”←” button: Shift down Possible to check the operation of the shift solenoid valves. HINT:

This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. The shift position commanded by the ECM is shown in the DATA LIST/SHIFT display on the hand-held tester. 1 CHECK OTHER DTCS OUTPUT(IN ADDITION TO DTC P0746) (a) (b) Connect the OBD II scan tool or the hand-held tester to the DLC3. Turn the ignition switch to the ON position and push the OBD II scan tool or the hand-held tester main switch ON. (c) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/DTC INFO/CURRENT CODES”. (d) Read the DTCs using the OBD II scan tool or the hand-held tester. Result: Display (DTC output) Proceed to Only ”P0746” is output A ”P0746” and other DTCs B HINT: If any other codes besides ”P0746” is output, perform the troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART (SEE PAGE 05-920 ) A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1141 05-952 2 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) INSPECT SHIFT SOLENOID VALVE(SL1) (a) (b) Shift Solenoid Valve SL1: 1 2 (c) 1 2 (-) Remove the shift solenoid valve SL1. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20 C (68 F) 1-2 5.0 to 5.6 Ω Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating noise. (+) D25466 NG REPLACE SHIFT SOLENOID VALVE(SL1) OK 3 INSPECT TRANSMISSION VALVE BODY ASSY(See chapter 2 in the problem symptoms table) (SEE PAGE 05-904 ) OK: There are no foreign objects on each valve and they operate smoothly. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSY (SEE PAGE 40-40 ) OK 4 INSPECT TORQUE CONVERTER CLUTCH ASSY (SEE PAGE 40-29 ) OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSY OK REPAIR OR REPLACE AUTOMATIC TRANSAXLE ASSY (SEE PAGE 40-12 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1142 DIAGNOSTICS DTC P0748 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-953 05C10-19 PRESSURE CONTROL SOLENOID ”A” ELECTRICAL (SHIFT SOLENOID VALVE SL1) CIRCUIT DESCRIPTION Shifting from 1st to O/D is performed in combination with ”ON” and ”OFF” operation of the shift solenoid valves SL1 and SL2 which is controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly (Fail safe function). DTC No. DTC Detection Condition Trouble Area P0748 ECM checks for an open or short circuit in shift solenoid valves SL1 (1-trip detection logic)
Output signal duty equals to 100%
Open or short in shift solenoid valve SL1 circuit
Shift solenoid valve SL1
ECM MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves ”ON/OFF”. When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other shift solenoid valves in good condition ”ON/OFF” (In case of an open or short circuit, the ECM stops sending current to the circuit.) (see page 05-916 ). MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0748: Shift solenoid valve SL1/Range check Shift solenoid valve SL1 Continuous 1 sec. Immediate None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. See page 05-895 Battery voltage 10 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Output signal duty 100% COMPONENT OPERATING RANGE Output signal duty Less than 100% 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1143 05-954 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) WIRING DIAGRAM E10 Electronically Controlled Transmission Solenoid W 19 E8 R-B 5 SL1+ CPU SL1+ B 18 SL1E8 B-W SL1- ECM +B 10 G31765 INSPECTION PROCEDURE 1 INSPECT TRANSMISSION WIRE(SL1) Transmission Wire Side: (Connector Front View): (a) E10 (b) SL1+ SL1D25234 (c) Disconnect the transmission wire connector from the transaxle. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20 C (68 F) 5 (SL1+) - 10 (SL1-) 5.0 to 5.6 Ω Measure the resistance according to the value(s) in the table below. Standard (Check for short): NG Tester Connection Specified Condition SL1+ - Body ground 10 kΩ or higher SL1- - Body ground ↑ Go to step 3 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1144 DIAGNOSTICS 2 - 05-955 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) CHECK HARNESS AND CONNECTOR(TRANSMISSION WIRE - ECM) E7 E8 E9 E6 (a) (b) (c) E5 Connect the transmission connector to the transaxle. Disconnect the connector from the ECM. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20 C (68 F) E8 - 19 (SL1+) - E8 - 18 (SL1-) 5.0 to 5.6 Ω ECM: SL1+ SL1C82158 C91565 (d) Measure the resistance according to the value(s) in the table below. Standard (Check for short): Tester Connection Specified Condition E8 - 19 (SL1+) - Body ground 10 kΩ or higher E8 - 18 (SL1-) - Body ground ↑ NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK REPLACE ECM (SEE PAGE 10-9 ) 3 INSPECT SHIFT SOLENOID VALVE(SL1) (a) (b) Shift Solenoid Valve SL1: 1 2 (c) 1 2 (-) Remove the shift solenoid valve SL1. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20 C (68 F) 1-2 5.0 to 5.6 Ω Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating noise. (+) D25466 NG REPLACE SHIFT SOLENOID VALVE(SL1) OK REPAIR OR REPLACE TRANSMISSION WIRE (SEE PAGE 40-34 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1145 05-956 DIAGNOSTICS DTC P0766 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05C11-19 SHIFT SOLENOID ”D” PERFORMANCE (SHIFT SOLENOID VALVE S4) SYSTEM DESCRIPTION The ECM uses signals from the vehicle speed sensor to detect the actual gear position (1st, 2nd, 3rd or O/D gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves and valve body. DTC No. P0766 DTC Detecting Condition Trouble Area The gear required by the ECM does not match the actual gear when driving (2-trip detection logic)
Shift solenoid valve S4 remains open or closed
Valve body is blocked
Shift solenoid valve S4
Automatic transaxle (clutch, brake or gear etc.)
ECM MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves ”ON/OFF”. According to the input shaft revolution, intermediate (counter) shaft revolution and output shaft revolution, the ECM detects the actual gear position (1st, 2nd, 3rd or O/D gear position). When the gear position commanded by the ECM and the actual gear position are not same, the ECM illuminates the MIL and stores the DTC. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0766: Shift solenoid valve S4/ON malfunction Shift solenoid valve S4/OFF malfunction Shift solenoid valve S4, Speed sensor (NT), Speed sensor (NC), Crankshaft position sensor (NE) Continuous 1 sec. 2 driving cycles None TYPICAL ENABLING CONDITIONS All: Transmission range ”D” ECT (Engine coolant temperature) 60°C (140°F) or more TFT (Transmission fluid temperature) -20 C (-4F) or more TFT sensor circuit Not circuit malfunction ECT sensor circuit Not circuit malfunction Turbine speed sensor circuit Not circuit malfunction Intermediate shaft speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction Shift solenoid valve S4 circuit Not circuit malfunction Electronic throttle system Not circuit malfunction 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1146 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-957 OFF malfunction ECM selected gear 4th Throttle valve opening angle Vehicle speed 5% or more 10 km/h (6.2 mph) or more ON malfunction ECM selected gear 3rd Throttle valve opening angle Vehicle speed 5% or more 10 km/h (6.2 mph) or more TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is met: OFF malfunction or ON malfunction 2 detections are necessary per driving cycle: 1st detection; temporary flag ON 2nd detection; pending fault code ON OFF malfunction Intermediate shaft speed/Output speed 1.34 to 1.48 ON malfunction Intermediate shaft speed/Output speed 0.95 to 1.09 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1147 05-958 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) INSPECTION PROCEDURE HINT: Performing the ACTIVE TEST using the hand-held tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Turn the ignition switch off. (b) Connect the hand-held tester to the DLC3. (c) Turn the ignition switch to the ON position. (d) Push the ”ON” button of the hand-held tester. (e) Select the item ”DIAGNOSIS/ENHANCED OBD II/ACTIVE TEST/SHIFT”. (f) According to the display on tester, perform the ”ACTIVE TEST”. HINT: While driving, the shift position can be forcibly changed with the hand-held tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem (see page 05-916 ). Item Test Details Diagnostic Note SHIFT [Test Details] Operate the shift solenoid valve and set the each shift position by yourself. [Vehicle Condition] Less than 50 km/h (31 mph) [Others]
Press ”→” button: Shift up
Press ”←” button: Shift down Possible to check the operation of the shift solenoid valves. HINT:

This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. The shift position commanded by the ECM is shown in the DATA LIST/SHIFT display on the hand-held tester. 1 CHECK OTHER DTCS OUTPUT(IN ADDITION TO DTC P0766) (a) (b) Connect the OBD II scan tool or the hand-held tester to the DLC3. Turn the ignition switch to the ON position and push the OBD II scan tool or the hand-held tester main switch ON. (c) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/DTC INFO/CURRENT CODES”. (d) Read the DTCs using the OBD II scan tool or the hand-held tester. Result: Display (DTC output) Proceed to Only ”P0766” is output A ”P0766” and other DTCs B HINT: If any other codes besides ”P0766” is output, perform the troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART (SEE PAGE 05-920 ) A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1148 DIAGNOSTICS 2 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-959 INSPECT SHIFT SOLENOID VALVE(S4) Shift Solenoid Valve S4: (+) (-) G28386 (a) (b) Remove the shift solenoid valve S4. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20 C (68 F) Solenoid Connector (S4) - Solenoid Body (S4) 11 to 15 Ω (c) Connect positive (+) lead to the terminal of solenoid connector, negative (-) lead to the solenoid body. OK: The solenoid makes an operating noise. NG REPLACE SHIFT SOLENOID VALVE(S4) OK 3 INSPECT TRANSMISSION VALVE BODY ASSY(See chapter 2 in the problem symptoms table) (SEE PAGE 05-904 ) OK: There are no foreign objects on each valve and they operate smoothly. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSY (SEE PAGE 40-40 ) OK 4 INSPECT TORQUE CONVERTER CLUTCH ASSY (SEE PAGE 40-29 ) OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSY OK REPAIR OR REPLACE AUTOMATIC TRANSAXLE ASSY (SEE PAGE 40-12 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1149 05-960 DIAGNOSTICS DTC P0776 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05C13-17 PRESSURE CONTROL SOLENOID ”B” PERFORMANCE (SHIFT SOLENOID VALVE SL2) SYSTEM DESCRIPTION The ECM uses signals from the vehicle speed sensor to detect the actual gear position (1st, 2nd, 3rd or O/D gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical problems of the shift solenoid valves and valve body. DTC No. P0776 DTC Detecting Condition Trouble Area The gear required by the ECM does not match the actual gear when driving (2-trip detection logic)
Shift solenoid valve SL2 remains open or closed
Valve body is blocked
Shift solenoid valve SL2
Automatic transaxle (clutch, brake or gear etc.)
ECM MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves ”ON/OFF”. According to the input shaft revolution, intermediate (counter) shaft revolution and output shaft revolution, the ECM detects the actual gear position (1st, 2nd, 3rd or O/D gear position). When the gear position commanded by the ECM and the actual gear position are not same, the ECM illuminates the MIL and stores the DTC. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0776: Shift solenoid valve SL2/OFF malfunction Shift solenoid valve SL2/ON malfunction Shift solenoid valve SL2, Speed sensor (NT), Speed sensor (NC), Crankshaft position sensor (NE) Continuous 0.8 sec. 2 driving cycles None TYPICAL ENABLING CONDITIONS All: Transmission range ”D” ECT (Engine coolant temperature) 60°C (140°F) or more TFT (Transmission fluid temperature) -20 C (-4F) or more TFT sensor circuit Not circuit malfunction ECT sensor circuit Not circuit malfunction Turbine speed sensor circuit Not circuit malfunction Intermediate shaft speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction Shift solenoid valve S4 circuit Not circuit malfunction Electronic throttle system Not circuit malfunction 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1150 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-961 OFF malfunction ECM selected gear Vehicle speed Throttle valve opening angle 1st 10 km/h (6.2 mph) or more 15% or more 4.5% or more at engine speed 1,900 rpm (vary with engine speed) ON malfunction ECM selected gear Vehicle speed Throttle valve opening angle 3rd or 4th 10 km/h (6.2 mph) or more 4.5% or more at engine speed 1,900 rpm (Varies with engine speed) TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is met: OFF malfunction or ON malfunction 2 detections are necessary per driving cycle: 1st detection; temporary flag ON 2nd detection; pending fault code ON OFF malfunction Input (turbine) speed/Intermediate shaft speed 0.93 to 1.07 ON malfunction Input (turbine) speed/Intermediate shaft speed 1.49 to 1.63 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1151 05-962 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) INSPECTION PROCEDURE HINT: Performing the ACTIVE TEST using the hand-held tester allows the relay, VSV, actuator and so on to operate without parts removal. Performing the ACTIVE TEST as the first step of troubleshooting is one method to shorten labor time. It is possible to display the DATA LIST during the ACTIVE TEST. (a) Turn the ignition switch off. (b) Connect the hand-held tester to the DLC3. (c) Turn the ignition switch to the ON position. (d) Push the ”ON” button of the hand-held tester. (e) Select the item ”DIAGNOSIS/ENHANCED OBD II/ACTIVE TEST/SHIFT”. (f) According to the display on tester, perform the ”ACTIVE TEST”. HINT: While driving, the shift position can be forcibly changed with the hand-held tester. Comparing the shift position commanded by the ACTIVE TEST with the actual shift position enables you to confirm the problem (see page 05-916 ). Item Test Details Diagnostic Note SHIFT [Test Details] Operate the shift solenoid valve and set the each shift position by yourself. [Vehicle Condition] Less than 50 km/h (31 mph) [Others]
Press ”→” button: Shift up
Press ”←” button: Shift down Possible to check the operation of the shift solenoid valves. HINT:

This test can be conducted when the vehicle speed is 50 km/h (31 mph) or less. The shift position commanded by the ECM is shown in the DATA LIST/SHIFT display on the hand-held tester. 1 CHECK OTHER DTCS OUTPUT(IN ADDITION TO DTC P0776) (a) (b) Connect the OBD II scan tool or the hand-held tester to the DLC3. Turn the ignition switch to the ON position and push the OBD II scan tool or the hand-held tester main switch ON. (c) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/DTC INFO/CURRENT CODES”. (d) Read the DTCs using the OBD II scan tool or the hand-held tester. Result: Display (DTC output) Proceed to Only ”P0776” is output A ”P0776” and other DTCs B HINT: If any other codes besides ”P0776” is output, perform the troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART (SEE PAGE 05-920 ) A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1152 DIAGNOSTICS 2 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-963 INSPECT SHIFT SOLENOID VALVE(SL2) (a) (b) Shift Solenoid Valve SL2: 1 2 (c) 1 2 (-) Remove the shift solenoid valve SL2. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20 C (68 F) 1-2 5.0 to 5.6 Ω Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating noise. (+) D25466 NG REPLACE SHIFT SOLENOID VALVE(SL2) OK 3 INSPECT TRANSMISSION VALVE BODY ASSY(See chapter 2 in the problem symptoms table) (SEE PAGE 05-904 ) OK: There are no foreign objects on each valve and they operate smoothly. NG REPAIR OR REPLACE TRANSMISSION VALVE BODY ASSY (SEE PAGE 40-40 ) OK 4 INSPECT TORQUE CONVERTER CLUTCH ASSY (SEE PAGE 40-29 ) OK: The torque converter clutch operates normally. NG REPLACE TORQUE CONVERTER CLUTCH ASSY OK REPAIR OR REPLACE AUTOMATIC TRANSAXLE ASSY (SEE PAGE 40-12 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1153 05-964 DIAGNOSTICS DTC P0778 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05C14-17 PRESSURE CONTROL SOLENOID ”B” ELECTRICAL (SHIFT SOLENOID VALVE SL2) CIRCUIT DESCRIPTION Shifting from 1st to O/D is performed in combination with ”ON” and ”OFF” operation of the shift solenoid valves SL1 and SL2 which is controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly (Fail safe function). DTC No. DTC Detection Condition Trouble Area P0778 ECM checks for an open or short circuit in shift solenoid valves SL2 (1-trip detection logic)
Output signal duty equals to 100%
Open or short in shift solenoid valve SL2 circuit
Shift solenoid valve SL2
ECM MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves ”ON/OFF”. When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other shift solenoid valves in good condition ”ON/OFF” (In case of an open or short circuit, the ECM stops sending current to the circuit.) (see page 05-916 ). MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0778: Shift solenoid valve SL2/Range check Shift solenoid valve SL2 Continuous 1 sec. Immediate None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. See page 05-895 Battery voltage 10 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Output signal duty 100% COMPONENT OPERATING RANGE Output signal duty Less than 100% 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1154 DIAGNOSTICS - 05-965 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) WIRING DIAGRAM E10 Electronically Controlled Transmission Solenoid ECM Y 15 E8 L-Y SL2+ 4 SL2+ BR 14 SL2E8 L-R SL2- 9 G31765 INSPECTION PROCEDURE 1 INSPECT TRANSMISSION WIRE(SL2) Transmission Wire Side: (Connector Front View): SL2+ (a) E10 (b) SL2D25234 (c) Disconnect the transmission wire connector from the transaxle. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20 C (68 F) 4 (SL2+) - 9 (SL2-) 5.0 to 5.6 Ω Measure the resistance according to the value(s) in the table below. Standard (Check for short): NG Tester Connection Specified Condition 4 (SL2+) - Body ground 10 kΩ or higher 9 (SL2-) - Body ground ↑ Go to step 3 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1155 05-966 DIAGNOSTICS 2 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) CHECK HARNESS AND CONNECTOR(TRANSMISSION WIRE - ECM) E7 E8 E9 E6 (a) (b) (c) E5 ECM: C82158 SL2+ SL2C91565 (d) Connect the transmission connector to the transaxle. Disconnect the connector from the ECM. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20 C (68 F) E8 - 15 (SL2+) - E8 - 14 (SL2-) 5.0 to 5.6 Ω Measure the resistance according to the value(s) in the table below. Standard (Check for short): Tester Connection Specified Condition E8 - 15 (SL2+) - Body ground 10 kΩ or higher E8 - 14 (SL2-) - Body ground ↑ NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK REPLACE ECM (SEE PAGE 10-9 ) 3 INSPECT SHIFT SOLENOID VALVE(SL2) (a) (b) Shift Solenoid Valve SL2: 1 2 (c) 1 2 (-) Remove the shift solenoid valve SL2. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20 C (68 F) 1-2 5.0 to 5.6 Ω Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating noise. (+) D25466 NG REPLACE SHIFT SOLENOID VALVE(SL2) OK REPAIR OR REPLACE TRANSMISSION WIRE (SEE PAGE 40-34 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1156 DIAGNOSTICS DTC P0793 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-967 05F3D-05 INTERMEDIATE SHAFT SPEED SENSOR ”A” CIRCUIT DESCRIPTION This sensor detects the rotation speed of the counter gear. By comparing the counter gear speed signal (NC) with the direct clutch speed sensor signal (NT), the ECM detects the shift timing of the gears and appropriately controls the engine torque and hydraulic pressure according to various conditions. Thus smooth gear shifting is performed. DTC No. DTC Detection Condition Trouble Area ECM detects conditions (a), (b) and (c) continuity for 5 sec. or more: (1-trip detection logic) (a) Vehicle speed: 50 km/h (31 mph) or more (b) Park/neutral position switch (NSW) is OFF (c) Speed sensor (NC): less than 300 rpm P0793 1 V/DIV GND
Open or short in transmission revolution sensor NC (speed sensor NC) circuit
Transmission revolution sensor NC (speed sensor NC)
ECM Reference (Using an oscilloscope): Check the waveform between the terminals NC+ and NC- of the ECM connector. Standard: Refer to the illustration. Terminal NC+ - NC- Tool setting 1V/DIV, 1ms/DIV Vehicle condition Vehicle speed 30 km/h (19 mph): (3rd gear) Engine speed 1,400 rpm 1 ms/DIV C93866 MONITOR DESCRIPTION The NC terminal of ECM detects a revolution signal from the speed sensor (NC) (counter gear rpm). The ECM calculates a gearshift comparing the speed sensor (NT) with the speed sensor (NC). While the vehicle is operating in 2nd, 3rd or O/D gear in the shift position of D, if the counter gear revolution is less than 300 rpm*1 although the output shaft revolution is more than 1,000 rpm*2, the ECM detects the trouble, illuminates the MIL and stores the DTC. *1: Pulse is not output or is irregularly output. *2: The vehicle speed is 50 km/h (31 mph) or more. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P0793: Speed sensor (NC)/Verify pulse input Speed sensor (NC), Speed sensor (NT), NSW switch Continuous 5 sec. Immediate None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. See page 05-895 Engine Running NSW switch OFF Output shaft rpm 1,000 rpm or more 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1157 05-968 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) TYPICAL MALFUNCTION THRESHOLDS Sensor signal rpm Less than 300 rpm COMPONENT OPERATING RANGE [HINT] 4th (O/D) when shift lever position is D position (After warming up the engine);
Intermediate shaft speed (NC) becomes close to the engine speed. Counter gear speed sensor (NC) WIRING DIAGRAM ECM C6 Counter Gear Speed Sensor 26 E8 Y 1 2 NC+ 5V 34 E8 W-G NCE1 G31763 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1158 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-969 INSPECTION PROCEDURE HINT: According to the DATA LIST displayed by the OBD II scan tool or hand-held tester, you can read the value of the switch, sensor, actuator and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is one method to shorten labor time. (a) Warm up the engine. (b) Turn the ignition switch off. (c) Connect the OBD II scan tool or hand-held tester to the DLC3. (d) Turn the ignition switch to the ON position. (e) Push the ”ON” button of the OBD II scan tool or the hand-held tester. (f) When you use hand-held tester: Select the item ”DIAGNOSIS/ENHANCED OBD II/DATA LIST”. (g) According to the display on tester, read the ”DATA LIST”. Measurement Item/ Range (display) Item Normal Condition [HINT] 4th (O/D) when shift lever position is D position (After warming up the engine);
Intermediate shaft speed (NC) becomes close to the engine speed. Counter Gear Speed/ display: 50 r/min SPD (NC) HINT:
SPD (NC) is always 0 while driving: Open or short in the sensor or circuit. SPD (NC) is always more than 0 and less than 300 rpm while driving the vehicle at 50 km/h (31 mph) or more: Sensor trouble, improper installation, or intermittent connection trouble of the circuit.
1 INSPECT SPEED SENSOR INSTALLATION (a) OK Check the speed sensor installation. OK: The installation bolt is tightened properly and there is no clearance between the sensor and transaxle case. NG BR3795 NG REPLACE SPEED SENSOR(NC) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1159 05-970 DIAGNOSTICS 2 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) INSPECT SPEED SENSOR(NC) (a) Sensor Side: (Connector Front View): (b) C6 2 Disconnect the speed sensor connector from the transaxle. Measure the resistance according to the value(s) in the table below. Standard: TOYOTA made: 1 C58536 Tester Connection Specified Condition 20 C (68 F) 1-2 500 to 620 Ω Standard: AISIN made: NG Tester Connection Specified Condition 20 C (68 F) 1-2 560 to 680 Ω REPLACE SPEED SENSOR(NC) OK 3 CHECK HARNESS AND CONNECTOR(SPEED SENSOR - ECM) E7 E8 E9 E6 (a) (b) (c) E5 NC+ NCC82158 Connect the speed sensor connector. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard: TOYOTA made: Tester Connection Specified Condition 20 C (68 F) E8 - 26 (NC+) - E8 - 34 (NC-) 500 to 620 Ω ECM: C91565 Standard: AISIN made: (d) Tester Connection Specified Condition 20 C (68 F) E8 - 26 (NC+) - E8 - 34 (NC-) 560 to 680 Ω Measure the resistance according to the value(s) in the table below. Standard (Check for short): Tester Connection Specified Condition E8 - 26 (NC+) - Body ground 10 kΩ or higher E8 - 34 (NC-) - Body ground ↑ NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK REPLACE ECM (SEE PAGE 10-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1160 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-971 05C17-23 DTC P0982 SHIFT SOLENOID ”D” CONTROL CIRCUIT LOW (SHIFT SOLENOID VALVE S4) DTC P0983 SHIFT SOLENOID ”D” CONTROL CIRCUIT HIGH (SHIFT SOLENOID VALVE S4) CIRCUIT DESCRIPTION Shifting from 1st to O/D is performed in combination with ”ON” and ”OFF” operation of the shift solenoid valves SL1 and SL2 which is controlled by the ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly (Fail safe function). DTC No. DTC Detection Condition Trouble Area P0982 ECM detects short in solenoid valve S4 circuit 2 times when solenoid valve S4 is operated (1-trip detection logic)
Short in shift solenoid valve S4 circuit
Shift solenoid valve S4
ECM P0983 ECM detects open in solenoid valve S4 circuit 2 times when solenoid valve S4 is not operated (1-trip detection logic)
Open in shift solenoid valve S4 circuit
Shift solenoid valve S4
ECM MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves ”ON/OFF”. When there is an open or short circuit in any shift solenoid valve circuit, the ECM detects the problem and illuminates the MIL and stores the DTC. And the ECM performs the fail-safe function and turns the other shift solenoid valves in good condition ”ON/OFF” (In case of an open or short circuit, the ECM stops sending current to the circuit.) (see page 05-916 ). MONITOR STRATEGY Related DTCs Required sensors/Components P0982: Shift solenoid valve S4/Range check (Low resistance) P0983: Shift solenoid valve S4/Range check (High resistance) Shift solenoid valve S4 Frequency of operation Continuous Duration 0.064 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS P0982: Range check (Low resistance) The monitor will run whenever this DTC is not present. See page 05-895 Shift solenoid valve S4 ON Battery voltage 8 V or more Ignition switch ON Starter OFF P0983: Range check (High resistance) The monitor will run whenever this DTC is not present. See page 05-895 Shift solenoid valve S4 OFF Battery voltage 8 V or more Ignition switch ON Starter OFF 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1161 05-972 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) TYPICAL MALFUNCTION THRESHOLDS P0982: Range check (Low resistance) 8 Ω or less Shift solenoid valve S4 resistance P0983: Range check (High resistance) Shift solenoid valve S4 resistance 100 kΩ or more COMPONENT OPERATING RANGE Resistance: 11 to 15 Ω at 20C (68F) Shift solenoid valve S4 WIRING DIAGRAM E10 Electronically Controlled Transmission Solenoid ECM +B 11 S4 E8 L R S4 8 CPU G31165 INSPECTION PROCEDURE 1 INSPECT TRANSMISSION WIRE(S4) (a) Transmission Wire Side: (Connector Front View): (b) E10 Disconnect the transmission wire connector from the transaxle. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20 C (68 F) 8 - Body ground 11 to 15 Ω S4 D25234 NG Go to step 3 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1162 DIAGNOSTICS 2 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-973 CHECK HARNESS AND CONNECTOR(TRANSMISSION WIRE - ECM) E7 E8 E9 E6 S4 C82158 (a) (b) (c) E5 ECM: C91565 Connect the transmission connector to the transaxle. Disconnect the connector from the ECM. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20 C (68 F) E8 - 11 (S4) - Body ground 11 to 15 Ω NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK REPLACE ECM (SEE PAGE 10-9 ) 3 INSPECT SHIFT SOLENOID VALVE(S4) Shift Solenoid Valve S4: (+) (-) G28386 (a) (b) Remove the shift solenoid valve S4. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20 C (68 F) Solenoid Connector (S4) - Solenoid Body (S4) 11 to 15 Ω (c) Connect positive (+) lead to the terminal of solenoid connector, negative (-) lead to the solenoid body. OK: The solenoid makes an operating noise. NG REPLACE SHIFT SOLENOID VALVE(S4) OK REPAIR OR REPLACE TRANSMISSION WIRE (SEE PAGE 40-34 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1163 05-974 DIAGNOSTICS DTC P2716 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05C19-26 PRESSURE CONTROL SOLENOID ”D” ELECTRICAL (SHIFT SOLENOID SLT) CIRCUIT DESCRIPTION Line Pressure Control Pressure Current Flow to Solenoid D02290 ON OFF The linear solenoid valve (SLT) controls the transmission line pressure for smooth transmission operation based on signals from the throttle position sensor and the vehicle speed sensor. The ECM adjusts the duty cycle of the SLT solenoid valve to control hydraulic line pressure coming from the primary regulator valve. Appropriate line pressure assures smooth shifting with varying engine outputs. (*): Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity in one cycle, and B is the period of non-continuity, then Duty Ratio=A/(A+B) x 100 (%) 1 cycle BE4056 DTC No. DTC Detection Condition Trouble Area Condition (a) or (b) below is detected 1 sec. or more: (1-trip detection logic) (a) SLT- terminal: 0V (b) SLT- terminal: 12V P2716
Open or short in shift solenoid valve SLT circuit
Shift solenoid valve SLT
ECM MONITOR DESCRIPTION When an open or short in the linear solenoid valve (SLT) circuit is detected, the ECM interprets this as a fault. The ECM will turn ON the MIL and store the DTC. MONITOR STRATEGY Related DTCs Required sensors/Components Frequency of operation Duration MIL operation Sequence of operation P2716: Shift solenoid valve SLT/Range check Shift solenoid valve SLT Continuous 1 sec. Immediate None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present. See page 05-895 Battery voltage 11 V or more Solenoid current cut status Not cut CPU commanded duty ratio to SLT 19% or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Solenoid status from IC Fail (Open or short) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1164 DIAGNOSTICS - 05-975 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) COMPONENT OPERATING RANGE Resistance: 5.0 to 5.6 Ω at 20C (68F) Shift solenoid valve SLT WIRING DIAGRAM E10 Electronically Controlled Transmission Solenoid O ECM 2 Y-R SLT+ +B 13 E8 SLT+ 7 G B-Y SLT- 12 SLT- E8 G31770 INSPECTION PROCEDURE 1 INSPECT TRANSMISSION WIRE(SLT) Transmission Wire Side: (Connector Front View): (a) SLT+ (b) E10 SLTD25234 (c) Disconnect the transmission wire connector from the transaxle. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20 C (68 F) 2 (SLT+) - 7 (SLT-) 5.0 to 5.6 Ω Measure the resistance according to the value(s) in the table below. Standard (Check for short): NG Tester Connection Specified Condition 2 (SLT+) - Body ground 10 kΩ or higher 7 (SLT-) - Body ground ↑ Go to step 3 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1165 05-976 2 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) CHECK HARNESS AND CONNECTOR(TRANSMISSION WIRE - ECM) E7 SLT+ C82158 E8 E9 SLT- E6 (a) (b) (c) E5 ECM: C91565 (d) Connect the transmission wire connector to the transaxle. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20 C (68 F) E8 - 13 (SLT+) - E8 - 12 (SLT-) 5.0 to 5.6 Ω Measure the resistance according to the value(s) in the table below. Standard (Check for short): Tester Connection Specified Condition E8 - 13 (SLT+) - Body ground 10 kΩ or higher E8 - 12 (SLT-) - Body ground ↑ NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK REPLACE ECM (SEE PAGE 10-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1166 DIAGNOSTICS 3 - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-977 INSPECT SHIFT SOLENOID VALVE(SLT) (a) (b) Shift Solenoid Valve SLT: 1 2 (c) 1 2 (-) Remove the shift solenoid valve (SLT). Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20 C (68 F) 1-2 5.0 to 5.6 Ω Connect the positive (+) lead with a 21 W bulb to terminal 2 and the negative (-) lead to terminal 1 of the solenoid valve connector, then check the movement of the valve. OK: The solenoid makes an operating noise. (+) D25466 NG REPLACE SHIFT SOLENOID VALVE(SLT) OK REPAIR OR REPLACE TRANSMISSION WIRE (SEE PAGE 40-34 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1167 05-978 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 0527R-37 DTC P2769 TORQUE CONVERTER CLUTCH SOLENOID CIRCUIT LOW (SHIFT SOLENOID VALVE DSL) DTC P2770 TORQUE CONVERTER CLUTCH SOLENOID CIRCUIT HIGH (SHIFT SOLENOID VALVE DSL) CIRCUIT DESCRIPTION The shift solenoid valve DSL is turned ”ON” and ”OFF” by signals from the ECM in order to control the hydraulic pressure operation, the lock-up relay valve, which then the controls operation of the lock-up clutch. DTC No. DTC Detection Condition Trouble Area P2769 ECM detects short in solenoid valve DSL circuit (0.1 sec.) when solenoid valve DSL is operated (2-trip detection logic)
Short in shift solenoid valve DSL circuit
Shift solenoid valve DSL
ECM P2770 ECM detects open in solenoid valve DSL circuit (0.1 sec.) when solenoid valve DSL is not operated (2-trip detection logic)
Open in shift solenoid valve DSL circuit
Shift solenoid valve DSL
ECM MONITOR DESCRIPTION Torque converter lock-up is controlled by the ECM based on engine rpm, engine load, engine temperature, vehicle speed, transmission temperature, and shift range selection. The ECM determines the lock-up status of the torque converter by comparing the engine rpm (NE) to the input turbine rpm (NT). The ECM calculates the actual transmission gear by comparing input turbine rpm (NT) to counter gear rpm (NC). When conditions are appropriate, the ECM requests ”lock-up” by applying control voltage to shift solenoid DSL. When the DSL is opened, solenoid DSL applies pressure to the lock-up relay valve and locks the torque converter clutch. If the ECM detects an open or short in the DSL solenoid circuit, the ECM interprets this as a fault in the DSL solenoid or circuit. The ECM will turn on the MIL and store the DTC. MONITOR STRATEGY Related DTCs Required sensors/Components P2769: Shift solenoid valve DSL/Range check (Low resistance) P2770: Shift solenoid valve DSL/Range check (High resistance) Shift solenoid valve DSL Frequency of operation Continuous Duration 0.064 sec. MIL operation Sequence of operation 2 driving cycles None TYPICAL ENABLING CONDITIONS P2769: Range check (Low resistance) The monitor will run whenever this DTC is not present. See page 05-895 Solenoid current cut status Not cut Shift solenoid valve DSL ON Battery voltage 8 V or more Ignition switch ON Starter OFF 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1168 DIAGNOSTICS - 05-979 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) P2770: Range check (High resistance) The monitor will run whenever this DTC is not present. See page 05-895 Shift solenoid valve DSL ON Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS P2769: Range check (Low resistance) 8 Ω or less Shift solenoid valve DSL resistance P2770: Range check (High resistance) Shift solenoid valve DSL resistance 100 kΩ or more COMPONENT OPERATING RANGE Resistance: 11 to 13 Ω at 20C (68F) Shift solenoid valve DSL WIRING DIAGRAM ECM E10 Electronically Controlled Transmission Solenoid +B G 3 Y-G 9 DSL E8 CPU DSL G31165 INSPECTION PROCEDURE 1 INSPECT TRANSMISSION WIRE(DSL) (a) Transmission Wire Side: (Connector Front View): (b) E10 Disconnect the transmission wire connector from the transaxle. Measure the resistance according to the value(s) in the table below. Standard: DSL D25234 NG Tester Connection Specified Condition 20 C (68 F) 3 - Body ground 11 to 13 Ω Go to step 3 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1169 05-980 2 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) CHECK HARNESS AND CONNECTOR(TRANSMISSION WIRE - ECM) E7 E8 E9 E6 (a) (b) (c) E5 Connect the transmission wire connector. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20 C (68 F) E8 - 9 (DSL) - Body ground 11 to 13 Ω ECM: DSL C82158 C91565 NG REPAIR OR REPLACE HARNESS CONNECTOR (SEE PAGE 01-36 ) OR OK REPLACE ECM (SEE PAGE 10-9 ) 3 INSPECT SHIFT SOLENOID VALVE(DSL) (a) (b) Shift Solenoid Valve DSL: (-) Remove the shift solenoid valve DSL. Measure the resistance according to the value(s) in the table below. Standard: Tester Connection Specified Condition 20 C (68 F) Solenoid Connector (DSL) - Solenoid Body (DSL) 11 to 13 Ω (+) (c) G28385 Connect positive (+) lead to the terminal of solenoid connector, negative (-) lead to the solenoid body. OK: The solenoid valve makes an operating noise. NG REPLACE SHIFT SOLENOID VALVE(DSL) OK REPAIR OR REPLACE TRANSMISSION WIRE (SEE PAGE 40-34 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1170 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-887 05F2V-05 ROAD TEST 1. (a) PROBLEM SYMPTOM CONFIRMATION Based on the result of the customer problem analysis, try to reproduce the symptoms. If the problem is that the transaxle does not shift up, shift down, or the shift point is too high or too low, conduct the following road test referring to the automatic shift schedule and simulate the problem symptoms. 2. ROAD TEST NOTICE: Perform the test at the ATF (Automatic Transmission Fluid) temperature 50 to 80°C (122 to 176°F) in the normal operation. (a) D position test: Shift into the D position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that 1 → 2, 2 → 3 and 3 → O/D up-shifts take place, and that the shift points conform to the automatic shift schedule (see page 03-51 ). HINT: O/D Gear Up-shift Prohibition Control
Engine coolant temperature is 60 °C (140 °F) or less and vehicle speed is at 70 km/h (43 mph) or less.
ATF temperature is 10 °C (50 °F) or less. O/D Gear Lock-up Prohibition Control
Brake pedal is depressed.
Accelerator pedal is released.
Engine coolant temperature is 60 °C (140 °F) or less. (2) (3) Check for shift shock and slip. Check for shock and slip at the 1 → 2, 2 → 3 and 3 → O/D up-shifts. Check for abnormal noise and vibration. Check for abnormal noise and vibration when up-shifting from 1 → 2, 2 → 3 and 3 → O/D while driving with the shift lever in the D position, and check while driving in the lock-up condition. HINT: The check for the cause of abnormal noise and vibration must be done thoroughly as it could also be due to loss of balance in the differential, torque converter clutch, etc. (4) Check kick-down operation. Check vehicle speeds when the 2nd to 1st, 3rd to 2nd and O/D to 3rd kick-downs take place while driving with the shift lever in the D position. Confirm that each speed is within the applicable vehicle speed range indicated in the automatic shift schedule (see page 03-51 ). (5) Check abnormal shock and slip at kick-down. (6) Check the lock-up mechanism.
Drive in D position (O/D gear), at a steady speed (lock-up ON).
Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. HINT:
There is no lock-up function in the 1st and 2nd gear.
If there is a big jump in engine speed, there is no lock-up. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1077 05-888 (b) DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 2 position test: Shift into the 2 position and fully depress the accelerator pedal and check the following points. (1) Check up-shift operation. Check that the 1 → 2 up-shift takes place and that the shift point conforms to the automatic shift schedule (see page 03-51 ). HINT: There is no 3rd up-shift and lock-up in the 2 position. (2) Check engine braking. While running in the 2 position and 2nd gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noise during acceleration and deceleration, and for shock at up-shift and down-shift. (c) L position test: Shift into the L position and fully depress the accelerator pedal and check the following points. (1) Check no up-shift. While running in the L position, check that there is no up-shift to 2nd gear. HINT: There is no lock-up in the L position. (2) Check engine braking. While running in the L position, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noise during acceleration and deceleration. (d) R position test: Shift into the R position, lightly depress the accelerator pedal, and check that the vehicle moves backward without any abnormal noise or vibration. CAUTION: Before conducting this test ensure that the test area is free from people and obstruction. (e) P position test: Stop the vehicle on the grade (more than 5°) and after shifting into the P position, release the parking brake. Then, check that the parking lock pawl holds the vehicle in place. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1078 05-882 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05F2U-05 SYSTEM DESCRIPTION 1. (a) SYSTEM DESCRIPTION The ECT (Electronic controlled automatic transmission/transaxle) is an automatic transmission/transaxle that electronically controls shift timing using the ECM. The ECM detects electrical signals that indicate engine and driving conditions, controls the shift point, and selects the appropriate shift pattern based on driver habits and road conditions. As a result, fuel efficiency and power transmission/transaxle performance are improved. Shift shock has been reduced by controlling the engine and transmission/transaxle simultaneously. In addition, the ECT has the following features:
Diagnostic function.
Fail-safe function when a malfunction occurs. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1072 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-881 05F2T-05 SYSTEM DIAGRAM The configuration of the electronic control system in the U241E/U140F automatic transaxles is as shown in the following chart. NE Crankshaft Position Sensor SL1 Engine Coolant Temperature Sensor Throttle Position Sensor THW VTA1, 2 VC Park/Neutral Position Switch Shift Solenoid Valve SL1 SL2 Shift Solenoid Valve SL2 NSW R, D, 2, L Transmission Control Switch (O/D Main Switch) ODMS SLT Speed Sensor Shift Solenoid Valve SLT ECM S4 Shift Solenoid Valve S4 Skid Control ECU Combination Meter SPD DSL Counter Gear Speed Sensor (Speed Sensor NC) NC Input Turbine Speed Sensor (Speed Sensor NT) NT Stop Lamp Switch Assy ATF (Automatic Transmission Fluid) Temperature Sensor Shift Solenoid Valve DSL W MIL (Malfunction Indicator Lamp) SIL DLC3 (Data Link Connector 3) STP THO TC 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1071 05-878 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05F38-05 PART AND SYSTEM NAME LIST This reference list indicates the part names used in this manual along with their definitions. Part and system name Definition Toyota HCAC system, Hydrocarbon adsorptive Catalyst (HCAC) system, HC adsorptive three-way catalyst HC adsorptive three-way catalytic converter Variable Valve Timing sensor, VVT sensor Camshaft position sensor Variable valve timing system, VVT system Camshaft timing control system Camshaft timing oil control valve, Oil control valve OCV, VVT, VSV Camshaft timing oil control valve Variable timing and lift, VVTL Camshaft timing and lift control Crankshaft position sensor ”A” Crankshaft position sensor Engine speed sensor Crankshaft position sensor THA Intake air temperature Knock control module Engine knock control module Knock sensor Engine knock sensor Mass or volume air flow circuit Mass air flow sensor circuit Vacuum sensor Manifold air pressure sensor Internal control module, Control module, Engine control ECU, PCM Power train control module FC idle Deceleration fuel cut Idle air control valve Idle speed control VSV for CCV, Canister close valve VSV for canister control Evaporative emissions canister vent valve VSV for EVAP, Vacuum switching valve assembly No. 1, EVAP VAV, Purge VSV Evaporative emissions canister purge valve VSV for pressure switching valve, Bypass VSV Evaporative emission pressure switching valve Vapor pressure sensor, EVAP pressure sensor, Evaporative emission control system pressure sensor Fuel tank pressure sensor Charcoal canister Evaporative emissions canister ORVR system On-boad refueling vapor recovery system Intake manifold runner control Intake manifold tuning system Intake manifold runner valve, IMRV, IACV (runner valve) Intake manifold tuning valve Intake control VSV Intake manifold tuning solenoid valve AFS Air fuel ratio sensor O2 sensor Heater oxygen sensor Oxygen sensor pumping current circuit Oxygen sensor output signal Oxygen sensor reference ground circuit Oxygen sensor signal ground Accel position sensor Accelerator pedal position sensor Throttle actuator control motor, Actuator control motor, Electronic throttle motor, Throttle control motor Electronic throttle actuator Electronic throttle control system, Throttle actuator control system Electronic throttle control system Throttle/pedal position sensor, Throttle/pedal position switch, Throttle position sensor/switch Throttle position sensor Turbo press sensor Turbocharger pressure sensor Turbo VSV Turbocharger pressure control solenoid valve P/S pressure switch Power-steering pressure switch VSV for ACM Active control engine mount Speed sensor, Vehicle speed sensor ”A”, Speed sensor for skid control ECU Vehicle speed sensor ATF temperature sensor, Trans. fluid temp. sensor, ATF temperature sensor ”A” Transmission fluid temperature sensor Electronic controlled automatic transmission, ECT Electronically controlled automatic Intermediate shaft speed sensor ”A” Counter gear speed sensor 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1068 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) Part and system name 05-879 Definition Output speed sensor Output shaft speed sensor Input speed sensor, Input turbine speed sensor ”A”, Speed sensor (NT), Turbine speed sensor Input turbine speed sensor PNP switch, NSW Park/neutral position switch Pressure control solenoid Transmission pressure control solenoid Shift solenoid Transmission shift solenoid valve Transmission control switch, Shift lock control unit Shift lock control module Engine immobilizer system, Immobilizer system Vehicle anti-theft system 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1069 05-886 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 0527I-43 CUSTOMER PROBLEM ANALYSIS CHECK Automatic Transaxle System Check Sheet Inspector’s Name : VIN Customer’s Name Production Date / / Licence Plate No. Date Vehicle Brought In / Date Problem Occurred How Often Does Problem Occur? / km mile Odometer Reading /
Continuous /
Intermittent (
Vehicle does not move (
Any position
No up-shift (
1st → 2nd
No down-shift (
O/D → 3rd times a day)
Particular position)
2nd → 3rd
3rd → O/D )
3rd → 2nd
2nd → 1st )
Lock-up malfunction Symptoms
Shift point too high or too low
Harsh engagement (
N → D
Lock-up
Any drive position)
Slip or shudder
No kick-down
Others Check Item MIL Normal Remains ON 1st Time Normal code Malfunction code (DTC ) 2nd Time Normal code Malfunction code (DTC ) DTC Check 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1076 05-920 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 0527K-48 DIAGNOSTIC TROUBLE CODE CHART If a DTC is displayed during the DTC check, check the parts listed in the table below and proceed to the page given. HINT:  *1 :
... MIL (Malfunction Indicator Lamp) light up  *2 :  ... Mark means ECM memorizes the malfunction code if the ECM detects the DTC detection condition.  This DTC may be output when the clutch, brake and gear components etc. inside the automatic transaxle are damaged. DTC No. (See Page) Detection Item Trouble Area MIL *1 Memory *2
 P0500 (05-216 ) Vehicle Speed Sensor ”A”  Combination meter  Open or short in vehicle speed sensor circuit  Vehicle speed sensor  ECM P0705 (05-922 ) Transmission Range Sensor Circuit Malfunction (PRNDL Input)  Open or short in park/neutral position switch circuit  Park/neutral position switch  ECM
 P0710 (05-928 ) Transmission Fluid Temperature Sensor ”A” Circuit  Open or short in ATF temperature sensor circuit  Transmission wire (ATF temperature sensor)  ECM
 P0711 (05-933 ) Transmission Fluid Temperature Sensor ”A” Performance  Open or short in ATF temperature sensor circuit  Transmission wire (ATF temperature sensor)  ECM
 P0712 (05-928 ) Transmission Fluid Temperature Sensor ”A” Circuit Low Input  Short in ATF temperature sensor circuit  Transmission wire (ATF temperature sensor)  ECM
 P0713 (05-928 ) Transmission Fluid Temperature Sensor ”A” Circuit High Input  Open in ATF temperature sensor circuit  Transmission wire (ATF temperature sensor)  ECM
 Turbine Speed Sensor Circuit No Signal  Open or short in transmission revolution sensor NT (speed sensor NT) circuit  Transmission revolution sensor NT (speed sensor NT)  ECM  Automatic transaxle assembly
 Brake Switch ”B” Circuit High  Short in stop light switch circuit  Stop light switch  ECM
 P0741 (05-944 ) Torque Converter Clutch Solenoid Performance (Shift Solenoid Valve DSL)  Shift solenoid valve DSL remains open or closed  Valve body is blocked  Shift solenoid valve DSL  Torque converter clutch  Automatic transaxle (clutch, brake or gear etc.)  Line pressure is too low  ECM
 P0746 (05-949 ) Pressure Control Solenoid ”A” Performance (Shift Solenoid Valve SL1)  Shift solenoid valve SL1 remains open or closed  Valve body is blocked  Shift solenoid valve SL1  Automatic transaxle (clutch, brake or gear etc.)  ECM
 P0748 (05-953 ) Pressure Control Solenoid ”A” Electrical (Shift Solenoid Valve SL1)  Open or short in shift solenoid valve SL1 circuit  Shift solenoid valve SL1  ECM
 P0717 (05-937 ) P0724 (05-940 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1110 DIAGNOSTICS - 05-921 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) P0766 (05-956 ) Shift Solenoid ”D” Performance (Shift Solenoid Valve S4)  Shift solenoid valve S4 remains open or closed  Valve body is blocked  Shift solenoid valve S4  Automatic transaxle (clutch, brake or gear etc.)  ECM P0776 (05-960 ) Pressure Control Solenoid ”B” Performance (Shift Solenoid Valve SL2)  Shift solenoid valve SL2 remains open or closed  Valve body is blocked  Shift solenoid valve SL2  Automatic transaxle (clutch, brake or gear etc.)  ECM
 P0778 (05-964 ) Pressure Control Solenoid ”B” Electrical (Shift Solenoid Valve SL2)  Open or short in shift solenoid valve SL2 circuit  Shift solenoid valve SL2  ECM
 P0793 (05-967 ) Intermediate Shaft Speed Sensor ”A”  Open or short in transmission revolution sensor NC (speed sensor NC) circuit  Transmission revolution sensor NC (speed sensor NC)  ECM
 P0982 (05-971 ) Shift Solenoid ”D” Control Circuit Low (Shift Solenoid Valve S4)  Short in shift solenoid valve S4 circuit  Shift solenoid valve S4  ECM
 P0983 (05-971 ) Shift Solenoid ”D” Control Circuit High (Shift Solenoid Valve S4)  Open in shift solenoid valve S4 circuit  Shift solenoid valve S4  ECM
 P2716 (05-974 ) Pressure Control Solenoid ”D” Electrical (Shift Solenoid Valve SLT)  Open or short in shift solenoid valve SLT circuit  Shift solenoid valve SLT  ECM
 P2769 (05-978 ) Torque Converter Clutch Solenoid Circuit Low (Shift Solenoid Valve DSL)  Short in shift solenoid valve DSL circuit  Shift solenoid valve DSL  ECM
 P2770 (05-978 ) Torque Converter Clutch Solenoid Circuit High (Shift Solenoid Valve DSL)  Open in shift solenoid valve DSL circuit  Shift solenoid valve DSL  ECM

 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1111 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-883 0527H-44 HOW TO PROCEED WITH TROUBLESHOOTING HINT:
The ECM of this system is connected to the multiplex communication system. Therefore, before starting troubleshooting, make sure to check that there is no trouble in the multiplex communication system. The hand-held tester can be used at steps 3, 4, 6, and 9.
1 Vehicle Brought to Workshop 2 Customer Problem Analysis (SEE PAGE 05-886 ) 3 Connect the OBD II scan tool or hand-held tester to DLC3 4 Check and Clear DTC and Freeze Frame Data (SEE PAGE 05-912 ) 5 Visual Inspection 6 Setting the Check Mode Diagnosis (SEE PAGE 05-914 ) 7 Problem Symptom Confirmation (SEE PAGE 05-887 ) Symptom does not occur: Go to step 8 Symptom occur: Go to step 9 8 Symptom Simulation (SEE PAGE 01-26 ) 9 DTC Check (SEE PAGE 05-912 ) DTC is not output: Go to step 10 DTC is output: Go to step 17 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1073 05-884 10 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) Basic Inspection (SEE PAGE 40-2 , 40-6 and 40-71 ) NG Go to step 19 OK 11 Mechanical System Test (SEE PAGE 05-889 ) NG Go to step 16 OK 12 Hydraulic Test (SEE PAGE 05-891 ) NG Go to step 16 OK 13 Manual Shifting Test (SEE PAGE 05-892 ) NG Go to step 15 OK 14 Problem Symptoms Table Chapter 1 (SEE PAGE 05-904 ) NG Go to step 18 OK 15 Problem Symptoms Table Chapter 2 (SEE PAGE 05-904 ) 16 Part Inspection Go to step 19 17 DTC Chart (SEE PAGE 05-920 ) 18 Circuit Inspection 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1074 DIAGNOSTICS 19 Repair or Replace 20 Confirmation Test - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-885 End 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1075 05-880 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 0527L-44 LOCATION Combination Meter
MIL (Malfunction Indicator Lamp) ECM Transmission Control Switch (O/D Main Switch) Pattern Select Switch (ECT SNOW Switch) Stop Lamp Switch Assy DLC3 (Data Link Connector 3) Speed Sensor (NT) Speed Sensor (NC) Shift Solenoid Valve SLT Shift Solenoid Valve SL1 Park/neutral Position Switch Assy Shift Solenoid Valve S4 Transmission Wire (ATF Temperature Sensor) Shift Solenoid Valve SL2 Shift Solenoid Valve DSL G32075 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1070 05-876 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05C0T-29 PRECAUTION NOTICE: Perform the RESET MEMORY (AT initialization) when replacing the automatic transaxle assy, engine assy or ECM (see page 05-893 ). HINT: Initialization can not be completed by only disconnecting the battery terminal. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1066 05-904 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 0527M-47 PROBLEM SYMPTOMS TABLE HINT: If a normal code is displayed during the diagnostic trouble code check although the trouble still occurs, check the electrical circuits for each symptom in the order given in the charts on the following pages and proceed to the page given for troubleshooting. The Matrix Chart is divided into 2 chapters. 1. Chapter 1: Electronic Circuit Matrix Chart  Refer to the table below when the trouble cause is considered to be electrical.  If the instruction ”Proceed to next circuit inspection shown on matrix chart” is given in the flow chart of each circuit, proceed to the circuit with the next highest number in the table to continue the check.  If the trouble still occurs even though there are no abnormalities in any of the other circuits, check and replace the ECM. HINT: *1: When the circuit on which mark *1 is attached is a malfunction, DTC could be output (see page 05-920 ). Symptom Suspect Area See page No up-shift (1st → 2nd) ECM 01-36 No up-shift (2nd → 3rd) ECM 01-36 No up-shift (3rd → O/D) 1. Transmission control switch (O/D OFF) circuit 2. ECM 05-981 01-36 No down-shift (O/D → 3rd) ECM 01-36 No down-shift (3rd → 2nd) ECM 01-36 No down-shift (2nd → 1st) ECM 01-36 No lock-up or No lock-up off ECM 01-36 Shift point too high or too low ECM 01-36 Up-shift to O/D from 3rd (While O/D main switch is OFF) 1. Transmission control switch (O/D OFF) circuit 2. ECM 05-981 01-36 Up-shift to O/D from 3rd while engine is cold 1. Engine coolant temp. sensor circuit *1 2. ECM 05-48 01-36 Harsh engagement (N → D) ECM 01-36 Harsh engagement (Lock-up) ECM 01-36 Harsh engagement (Any driving position) ECM 01-36 Poor acceleration ECM 01-36 Engine stalls when starting off or stopping ECM Malfunction in shifting 01-36 1. Park/neutral position switch 2. ECM circuit *1 05-922 01-36 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1094 DIAGNOSTICS 2. - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-905 Chapter 2: On-Vehicle Repair and Off-Vehicle Repair (
: U140F AUTOMATIC TRANSAXLE Repair Manual Pub. No. RM836U U241E AUTOMATIC TRANSAXLE Repair Manual Pub. No. RM840U) Symptom Suspect Area See page Vehicle does not move in any forward positions and reverse positions 1. 2. 3. 4. 5. 6. 7. Manual valve Primary regulator valve Front and rear planetary gear U/D planetary gear U/D one-way clutch (F2) Forward clutch (C1) U/D brake (B3)






Vehicle does not move in R position 1. 2. 3. 4. 5. Front and rear planetary gear unit U/D planetary gear unit Direct clutch (C2) U/D brake (C3) 1st and reverse brake (B2)




No up-shift (1st → 2nd) 1. Valve body assy 2. No. 1 one-way clutch (F1) 3. 2nd brake (B1) 40-40

No up-shift (2nd → 3rd) 1. Valve body assy 2. Direct clutch (C2) 40-40
No up-shift (3rd → O/D) 1. Valve body assy 2. U/D clutch (C3)

No down-shift (O/D → 3rd) Valve body assy
No down-shift (3rd → 2nd) Valve body assy 40-40 No down-shift (2nd → 1st) Valve body assy 40-40 No lock-up or No lock-up off 1. Lock-up relay valve 2. Torque converter clutch
40-29 Harsh engagement (N → D) 1. 2. 3. 4. 5. C1 accumulator Valve body assy Forward clutch (C1) U/D one-way clutch (F2) No. 1 one-way clutch (F1)
40-40


Harsh engagement (N → R) 1. Valve body assy 2. Direct clutch (C2) 3. 1st and reverse brake (B2) 40-40

Harsh engagement (Lock-up) 1. Lock-up relay valve 2. Torque converter clutch
40-29 Harsh engagement (2nd → 3rd) Valve body assy 40-40 Harsh engagement (3rd → O/D) Valve body assy 40-40 Harsh engagement (O/D → 3rd) Valve body assy 40-40 Slip or shudder (Forward position: After warm-up) 1. 2. 3. 4. 5. 6. 7. Oil strainer Torque converter clutch Forward clutch (C1) Direct clutch (C2) U/D brake (C3) No. 1 one-way clutch (F1) U/D one-way clutch (F2) 40-40 40-29




Slip or shudder (R position) 1. Oil strainer 2. Direct clutch (C2) 3. 1st and reverse brake (B2) 40-40

Slip or shudder (1st) No. 1 one-way clutch (F1)
2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1095 05-906 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) Slip or shudder (2nd) 1. U/D one-way clutch (F2) 2. 2nd brake (B1)

Slip or shudder (3rd) Direct clutch (C2)
Slip or shudder (O/D) U/D clutch (C3)
No engine braking (1st ∼ 3rd: D position) U/D brake (B3)
No engine braking (1st: L position) 1st and reverse brake (B2)
No engine braking (2nd: 2 position) 2nd brake (B1) Poor acceleration (All position) 1. Torque converter clutch 2. U/D planetary gear Poor acceleration (O/D) 1. U/D clutch (C3) 2. U/D planetary gear

Large shift shock or engine stalls when starting off or stopping Torque converter clutch 40-29 No kick-down Valve body assy 40-40
40-29
2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1096 DIAGNOSTICS - 05-907 ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05F36-05 TERMINALS OF ECM 1. ECM E7 E9 E8 E6 E5 C80654 C91969 HINT: Each ECM terminal’s standard voltage is shown in the table below. In the table, first follow the information under ”Condition”. Look under ”Symbols (Terminal No.)” for the terminals to be inspected. The standard voltage between the terminals is shown under ”Specific Condition”. Use the illustration above as a reference for the ECM terminals. Symbols (Terminals No.) Wiring Color Terminal Description Condition Specified Condition P (E5-6) - E1 (E9-1) V - BR P shift position switch signal IG switch ON and shift lever P position 10 to 14 V ↑ ↑ ↑ IG switch ON and shift lever except P position Below 1 V N (E5-7) - E1 (E9-1) GR - BR N shift position switch signal IG switch ON and shift lever N position 10 to 14 V ↑ ↑ ↑ IG switch ON and shift lever except N position Below 1 V NSW (E7-16) - E1 (E9-1) B-Y - BR Park neutral switch signal IG switch ON and shift lever P and N position Below 1 V ↑ ↑ ↑ IG switch ON and shift lever except P and N position 10 to 14 V DSL (E8-9) - E1 (E9-1) Y-G - BR S4 (E8-11) - E1 (E9-1) L - BR ↑ ↑ ↑ ↑ SL2+ (E8-15) - SL2- (E8-14) L-Y - L-R ↑ ↑ ↑ IG switch ON ↑ ↑ ↑ 1st or 2nd gear 10 to 14 V ↑ ↑ ↑ 3rd or O/D gear Below 1 SL1+ (E8-19) - SL1- (E8-18) R-B - B-W ↑ ↑ ↑ IG switch ON 10 to 14 V ↑ ↑ ↑ 1st gear 10 to 14 V ↑ ↑ ↑ Except 1st gear DSL solenoid signal Vehicle speed 65 km/h (40 mph), lock-up (ON to OFF) S4 solenoid signal IG switch ON Below 1 V ↑ O/D gear 10 to 14 V ↑ Except O/D gear Below 1 V Engine idle speed Pulse generation (See waveform 3) SL2 solenoid signal SL1 solenoid signal Pulse generation (See waveform 2) Below 1 Pulse generation (See waveform 4) Engine idle speed Below 1 NC+ (E8-26) - NC- (E8-34) Y - W-G Speed sensor (NC) signal Vehicle speed 30 km/h (19 mph): (3rd gear) Engine speed 1,400 rpm NT+ (E8-27) - NT- (E8-35) W - R-W Speed sensor (NT) signal Vehicle speed 20 km/h (12 mph) Pulse generation (See waveform 5) Pulse generation (See waveform 6) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1097 05-908 DIAGNOSTICS - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) SLT+ (E8-13) SLT- (E8-12) Y-R - B-Y SLT solenoid signal Engine idle speed Pulse generation (See waveform 1) THO (E8-32) - E2 (E7-28) G-Y - BR ATF temperature sensor signal ATF temperature: 115
C (239
F) or more Below 1.5 V L (E6-8) - E1 (E9-1) R - BR L shift position switch signal IG switch ON and shift lever L position 10 to 14 V ↑ ↑ ↑ IG switch ON and shift lever except L position Below 1 V 2 (E6-9) - E1 (E9-1) P - BR 2 shift position switch signal IG switch ON and shift lever 2 position 10 to 14 V ↑ ↑ ↑ IG switch ON and shift lever except 2 position Below 1 V D (E6-10) - E1 (E9-1) Y - BR D shift position switch signal IG switch ON and shift lever D position 10 to 14 V ↑ ↑ ↑ IG switch ON and shift lever except D position Below 1 V R (E6-11) - E1 (E9-1) L - BR R shift position switch signal IG switch ON and shift lever R position 10 to 14 V ↑ ↑ ↑ IG switch ON and shift lever except R position Below 1 V SPD (E6-17) - E1 (E9-1) Y - BR STP (E6-19) - E1 (E9-1) BR - BR ↑ ↑ ODMS (E5-16) - E1 (E9-1) GR - BR ↑ ↑ Pulse generation (See waveform 7) Speed signal Vehicle speed 20 km/h (12 mph) Stop lamp switch signal Brake pedal is depressed 7.5 to 14 V Brake pedal is released Below 1.5 V ↑ O/D main switch ↑ 5 V/DIV IG switch ON 10 to 14 V IG switch ON and press continuously O/D main switch Below 1 V Waveform 1 Reference: Terminal SLT+ - SLT- Tool setting 5V/DIV, 1ms/DIV Vehicle condition Engine idle speed GND 1 ms/DIV G23426 10 V/DIV GND Waveform 2 Reference: Terminal DSL - E1 Tool setting 10V/DIV, 100ms/DIV Vehicle condition Vehicle speed 65 km/h (40 mph), lock-up (ON to OFF) 100 ms/DIV C42677 C53420 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1098 DIAGNOSTICS 5 V/DIV - ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E/U140F) 05-909 Waveform 3 Reference: Terminal SL2+ - SL2- Tool setting 5V/DIV, 1ms/DIV Vehicle condition Engine idle speed GND 1 ms/DIV G23426 5 V/DIV Waveform 4 Reference: Terminal SL1+ - SL1- Tool setting 5V/DIV, 1ms/DIV Vehicle condition Engine idle speed GND 1 ms/DIV G23426 1 V/DIV GND Waveform 5 Reference: Terminal NC+ - NC- Tool setting 1V/DIV, 1ms/DIV Vehicle condition Vehicle speed 30 km/h (19 mph): (3rd gear) Engine speed 1,400 rpm 1 ms/DIV C93866 5 V/DIV GND Waveform 6 Reference: Terminal NT+ - NT- Tool setting 5V/DIV, 0.5ms/DIV Vehicle condition Vehicle speed 20 km/h (12 mph) 0.5 ms/DIV C53419 C42920 5 V/DIV Waveform 7 Reference: Terminal SPD - E1 Tool setting 5V/DIV, 20ms/DIV Vehicle condition Vehicle speed 20 km/h (12 mph) GND 20 ms/DIV A05135 C53421 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1099 05-1722 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM 05CF3-02 MUTE SIGNAL CIRCUIT (FROM TELEVISION DISPLAY ASSY) CIRCUIT DESCRIPTION The multi-display controller sub-assy controls the volume according to the MUTE signal from the television display assy. The MUTE signal is sent to reduce noise and a popping sound when modes, etc. are switched. WIRING DIAGRAM R28 Television Display Assy MUTE Multi-display Controller Sub-assy V 15 15 BK1 L 1 R31 MUTE I34951 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1912 05-1723 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(TELEVISION DISPLAY ASSY MULTI-DISPLA Y CONTROLLER SUB-ASSY) (a) Television Display Assy: (b) R28 MUTE Disconnect the connector from the television display assy and multi-display controller sub-assy. Measure the resistance according to the values in the table below. Standard: Tester connection Condition MUTE - MUTE Always Specified condition Below 1 Ω MUTE - Body ground Always 10 kΩ or higher I37212 NG Multi-display Controller Sub-assy: REPAIR OR CONNECTOR REPLACE HARNESS OR R31 MUTE I35962 I34943 OK 2 INSPECT TELEVISION DISPLAY ASSY (a) (b) Television Display Assy: MUTE R28 Connect the television display assy connector. Measure the voltage according to the values in the table below. Standard: Tester connection Condition Specified condition MUTE - Body ground DVD system sounding Approx. 3.5 V MUTE - Body ground DVD system changing Below 1.0 V NG I37213 REPLACE TELEVISION DISPLAY ASSY (SEE PAGE 67-26 ) OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1704 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1913 05-1724 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM 05CF4-03 SOUND SIGNAL CIRCUIT (FROM RADIO RECEIVER ASSY) CIRCUIT DESCRIPTION This is the sound signal circuit from the radio receiver assy to the multi-display controller sub-assy. WIRING DIAGRAM Multi-display Controller Sub-assy Radio Receiver Assy SLD1 14 R23 18 IP1 (Shielded) 27 R29 SG2 RSL- 18 R23 BR 17 IP1 G 23 R29 R-L- RSL+ 17 R23 SB 16 IP1 R 24 R29 R-L+ 16 R23 LG 15 IP1 W RSR- 15 RSR+ R23 P 14 IP1 B (Shielded) 25 R29 R-R26 R29 R-R+ I34952 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1914 05-1725 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(RADIO RECEIVER ASSY - MULTI-DISPLA Y CONTROLLER SUB-ASSY) (a) Radio Receiver Assy: R23 (b) RSR+ RSLRSL+ RSR- SLD1 I40203 Multi-display Controller Sub-assy: R29 R-L- SG2 R-R+ Disconnect the connector from the radio receiver assy and multi-display controller sub-assy. Measure the resistance according to the values in the table below. Standard: Tester connection Condition Specified condition SLD1 - SG2 Always Below 1 Ω RSL- - R-L- Always Below 1 Ω RSL+ - R-L+ Always Below 1 Ω RSR- - R-R- Always Below 1 Ω RSR+ - R-R+ Always Below 1 Ω RSL- - Body ground Always 10 kΩ or higher RSL+ - Body ground Always 10 kΩ or higher RSR- - Body ground Always 10 kΩ or higher RSR+ - Body ground Always 10 kΩ or higher NG R-L+ R-R- REPAIR OR CONNECTOR REPLACE HARNESS OR I34639 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1915 05-1726 DIAGNOSTICS 2 - REAR SEAT ENTERTAINMENT SYSTEM INSPECT RADIO RECEIVER ASSY Radio Receiver Assy: RSL- (a) (b) R23 Connect the connector. Using an oscilloscope, check the signal waveform between the terminals according to the conditions, as shown in the chart. RSR+ RSL+ RSRI40577 Standard: Tester connection Condition Specified condition RSL- - Body ground While voice sound is being produced A waveform synchronized with sound is output RSL+ - Body ground While voice sound is being produced A waveform synchronized with sound is output RSR- - Body ground While voice sound is being produced A waveform synchronized with sound is output RSR+ - Body ground While voice sound is being produced A waveform synchronized with sound is output NG REPLACE RADIO RECEIVER ASSY (SEE PAGE 67-6 ) OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page 05-1704 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1916 05-1727 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM 05CF5-02 SOUND SIGNAL CIRCUIT (FROM VIDEO (VIDEO ADAPTER) TERMINAL) CIRCUIT DESCRIPTION This is the sound signal circuit from the video (video adapter) terminal to the multi-display controller subassy. WIRING DIAGRAM V13 Video (Video Adapter) Terminal SGND AUXR AUXL Multi-display Controller Sub-assy 10 R30 SG7 (Shielded) 3 Y 12 R30 AUXR BR 11 R30 AUXL 1 2 I34948 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1917 05-1728 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(MULTI-DISPLA Y CONTROLLER SUB-ASSY - VIDEO(VIDEO ADAPTER)TERMINAL) (a) Video (Video Adapter) Terminal: (b) V13 AUXL SGND AUXR Multi-display Controller Sub-assy: Disconnect the connector from the video (video adapter) terminal and multi-display controller sub-assy. Measure the resistance according to the values in the table below. Standard: Tester connection Condition Specified condition SGND - SG7 Always Below 1 Ω AUXR - AUXR Always Below 1 Ω AUXL - AUXL Always Below 1 Ω AUXR - Body ground Always 10 kΩ or higher AUXL - Body ground Always 10 kΩ or higher R30 AUXR NG REPAIR OR CONNECTOR REPLACE HARNESS OR AUXL SG7 I40833 OK 2 INSPECT VIDEO(VIDEO ADAPTER) TERMINAL (a) (b) Video (Video Adapter) Terminal: Connect the connector. Using an oscilloscope, check the signal waveform between the terminals according to the conditions, as shown in the chart. HINT: External device system is playing (When the video (video adapter) terminal is used). AUXL AUXR V13 I37215 Standard: Tester connection Condition Specified condition AUXR - Body ground While voice sound is being produced A waveform synchronized with sound is output AUXL - Body ground While voice sound is being produced A waveform synchronized with sound is output NG REPLACE VIDEO(VIDEO ADAPTER) TERMINAL (See page 67-27 ) OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page 05-1704 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1918 05-1729 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM 05CF6-03 SOUND SIGNAL CIRCUIT (TO TELEVISION DISPLAY ASSY (HEADPHONE)) CIRCUIT DESCRIPTION This is the sound signal circuit from the multi-display controller sub-assy to the television display assy. WIRING DIAGRAM Multi-display Controller Sub-assy R28 Television Display Assy GND1 HP2L HP2R GND HP1R HP1L (Shielded) 25 BK1 L 24 BK1 BR 20 R30 HP2L P 23 BK1 Y 21 R30 HP2R (Shielded) 9 BK1 BR 7 BK1 R 9 R30 HP1R Y 8 BK1 G 8 R30 HP1L 25 24 23 9 7 8 19 R30 SG6 (Shielded) 7 R30 SG5 (Shielded) I34953 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1919 05-1730 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(TELEVISION DISPLAY ASSY MULTI-DISPLA Y CONTROLLER SUB-ASSY) (a) Television Display Assy: (b) R28 HP1L HP1R GND GND1 HP2R HP2L Multi-display Controller Sub-assy: R30 HP1L HP1R SG5 HP2R HP2L Disconnect the connector from television display assy and multi-display controller sub-assy. Measure the resistance according to the values in the table below. Standard: Tester connection Condition Specified condition GND1 - SG6 Always Below 1 Ω HP2L - HP2L Always Below 1 Ω HP2R - HP2R Always Below 1 Ω GND - SG5 Always Below 1 Ω HP1R - HP1R Always Below 1 Ω HP1L - HP1L Always Below 1 Ω HP2L - Body ground Always 10 kΩ or higher HP2R - Body ground Always 10 kΩ or higher HP1R - Body ground Always 10 kΩ or higher HP1L - Body ground Always 10 kΩ or higher NG SG6 REPAIR OR CONNECTOR REPLACE HARNESS OR I37216 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1920 05-1731 DIAGNOSTICS 2 - REAR SEAT ENTERTAINMENT SYSTEM INSPECT MULTI-DISPLA Y CONTROLLER SUB-ASSY (a) (b) Multi-display Controller Sub-assy: HP1L SG5 R30 HP1R Connect the connector. Using an oscilloscope, check the signal waveform between the terminals according to the conditions, as shown in the chart. HP2R HP2L SG6 I35265 Standard: Tester connection Condition Specified condition HP2L - Body ground While voice sound is being produced A waveform synchronized with sound is output HP2R - Body ground While voice sound is being produced A waveform synchronized with sound is output HP1R - Body ground While voice sound is being produced A waveform synchronized with sound is output HP1L - Body ground While voice sound is being produced A waveform synchronized with sound is output NG REPLACE MULTI-DISPLA Y SUB-ASSY (See page 67-23 ) CONTROLLER OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page 05-1704 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1921 05-1732 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM 05CF7-03 SOUND SIGNAL CIRCUIT (TO TELEVISION DISPLAY ASSY (WIRELESS HEADPHONE)) CIRCUIT DESCRIPTION This is the sound signal circuit from the television display assy to the multi-display controller sub-assy. WIRING DIAGRAM Multi-display Controller Sub-assy R28 Television Display Assy (Shielded) SLD HPL- HPL+ HPR- HPR+ 30 30 BK1 (Shielded) 20 R31 SLD1 P 29 BK1 G 16 R31 HPL- LG 28 BK1 W 17 R31 HPL+ SB 27 BK1 R 18 R31 HPR- BR 26 BK1 B 19 R31 HPR+ 29 28 27 26 I34954 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1922 05-1733 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(MULTI-DISPLA Y CONTROLLER SUB-ASSY - TELEVISION DISPLAY ASSY) (a) Multi-display Controller Sub-assy: R31 (b) HPL+ HPL- SLD1 HPRHRL+ Television Display Assy: R28 Disconnect the connector from the multi-display controller sub-assy and television display assy. Measure the resistance according to the values in the table below. Standard: Tester connection Condition Specified condition SLD - SLD1 Always Below 1 Ω HPL- - HPL- Always Below 1 Ω HPL+ - HPL+ Always Below 1 Ω HPR- - HPR- Always Below 1 Ω HPR+ - HPR+ Always Below 1 Ω HPL- - Body ground Always 10 kΩ or higher HPL+ - Body ground Always 10 kΩ or higher HPR- - Body ground Always 10 kΩ or higher HPR+ - Body ground Always 10 kΩ or higher NG SLD HPL- REPAIR OR CONNECTOR REPLACE HARNESS OR HPL+ HRL+ HPR- I37217 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1923 05-1734 DIAGNOSTICS 2 - REAR SEAT ENTERTAINMENT SYSTEM INSPECT MULTI-DISPLA Y CONTROLLER SUB-ASSY (a) (b) Multi-display Controller Sub-assy: R31 SLD1 Connect the connector. Using an oscilloscope, check the signal waveform between the terminals according to the conditions, as shown in the chart. HPL- HPR- HPR+ HPL+ I35265 Standard: Tester connection Condition Specified condition HPL- - Body ground While voice sound is being produced A waveform synchronized with sound is output HPL+ - Body ground While voice sound is being produced A waveform synchronized with sound is output HPR- - Body ground While voice sound is being produced A waveform synchronized with sound is output HPR+ - Body ground While voice sound is being produced A waveform synchronized with sound is output NG REPLACE MULTI-DISPLA Y SUB-ASSY (See page 67-23 ) CONTROLLER OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page 05-1704 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1924 05-1735 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM 05CF8-02 SOUND SIGNAL CIRCUIT (FROM TELEVISION DISPLAY ASSY) CIRCUIT DESCRIPTION This is the sound signal circuit from the television display assy to the multi-display controller sub-assy. WIRING DIAGRAM Multi-display Controller Sub-assy R28 Television Display Assy SGND AL- AR- AL+ AR+ (Shielded) 10 10 BK1 (Shielded) 6 R31 SG4 G 14 BK1 G 2 R31 AL- W 12 BK1 W 4 R31 AR- R 13 BK1 R 3 R31 AL+ B 11 BK1 B 14 12 13 11 5 R31 AR+ I34955 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1925 05-1736 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(TELEVISION DISPLAY ASSY MULTI-DISPLA Y CONTROLLER SUB-ASSY) (a) Multi-display Controller Sub-assy: (b) R31 AL- Disconnect the connector from the television display assy and multi-display controller sub-assy. Measure the resistance according to the values in the table below. Standard: Tester connection Condition Specified condition SGND - SG4 Always Below 1 Ω AL- - AL- Always Below 1 Ω AR- - AR- Always Below 1 Ω AL+ - AL+ Always Below 1 Ω SG4 AL+ AR+ ARTelevision Display Assy: R28 AR+ - AR+ Always Below 1 Ω AL- - Body ground Always 10 kΩ or higher AR- - Body ground Always 10 kΩ or higher AL+ - Body ground Always 10 kΩ or higher AR+ - Body ground Always 10 kΩ or higher ALAL+ AR- AR+ SGND I37217 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1926 05-1737 DIAGNOSTICS 2 - REAR SEAT ENTERTAINMENT SYSTEM INSPECT TELEVISION DISPLAY ASSY (a) (b) Television Display Assy: AL- AL+ R28 AR- AR+ Connect the connector. Using an oscilloscope, check the signal waveform between the terminals according to the conditions, as shown in the chart. I37213 Standard: Tester connection Condition Specified condition AL- - Body ground While voice sound is being produced A waveform synchronized with sound is output AR- - Body ground While voice sound is being produced A waveform synchronized with sound is output AL+ - Body ground While voice sound is being produced A waveform synchronized with sound is output AR+ - Body ground While voice sound is being produced A waveform synchronized with sound is output NG REPLACE TELEVISION DISPLAY ASSY (See page 67-26 ) OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page 05-1704 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1927 05-1738 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM 05CF9-02 DISPLAY SIGNAL CIRCUIT (TO TELEVISION DISPLAY ASSY) CIRCUIT DESCRIPTION This is the display signal circuit from the multi-display controller sub-assy to the television display assy. WIRING DIAGRAM Multi-display Controller Sub-assy R28 Television Display Assy R G B VR SYNC VG 22 G 22 BK1 G 21 W 21 BK1 W 20 R 20 BK1 R 18 Y 18 BK1 Y 19 B 19 BK1 B 17 (Shielded) 17 BK1 13 R30 R2 14 R30 G2 15 R30 B2 17 (Shielded) R30 VR2 16 R30 SYN2 18 R30 VG2 I34946 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1928 05-1739 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(TELEVISION DISPLAY ASSY MULTI-DISPLA Y CONTROLLER SUB-ASSY) (a) Television Display Assy: (b) R28 Disconnect the connector from the television display assy and multi-display controller sub-assy. Measure the resistance according to the values in the table below. Standard: Tester connection Condition Specified condition R - R2 Always Below 1 Ω G - G2 Always Below 1 Ω VG R G B VR SYNC B - B2 Always Below 1 Ω SYNC - SYN2 Always Below 1 Ω Below 1 Ω VR - VR2 Always VG - VG2 Always Below 1 Ω R - Body ground Always 10 kΩ or higher G - Body ground Always 10 kΩ or higher B - Body ground Always 10 kΩ or higher SYNC - Body ground Always 10 kΩ or higher VR - Body ground Always 10 kΩ or higher Multi-display Controller Sub-assy: R30 R2 VG2 VR2 G2 SYN2 B2 I37216 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page 05-1704 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1929 05-1740 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM 05CFA-02 DISPLAY SIGNAL CIRCUIT (FROM TELEVISION DISPLAY ASSY) CIRCUIT DESCRIPTION This is the display signal circuit from the television display assy to the multi-display controller sub-assy. WIRING DIAGRAM R28 Television Display Assy S. GND NTSC SG Multi-display Controller Sub-assy 31 BR 31 BK1 R 9 R31 SGN2 32 Y 32 BK1 G 8 R31 NTS2 16 (Shielded) 16 BK1 (Shielded) 10 R31 SG9 I34949 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1930 05-1741 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(TELEVISION DISPLAY ASSY MULTI-DISPLA Y CONTROLLER SUB-ASSY) (a) Multi-display Controller Sub-assy: (b) R31 SG9 SGN2 Disconnect the connector from the television display assy and multi-display controller sub-assy. Measure the resistance according to the values in the table below. Standard: Tester connection Condition Specified condition S. GND - SGN2 Always Below 1 Ω NTSC - NTS2 Always Below 1 Ω SG - SG9 Always Below 1 Ω NTSC - Body ground Always 10 kΩ or higher NTS2 Television Display Assy: R28 NG SG NTSC S. GND REPAIR OR CONNECTOR REPLACE HARNESS OR I37217 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page 05-1704 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1931 05-1742 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM 05CFB-03 DISPLAY SIGNAL CIRCUIT (FROM VIDEO (VIDEO ADAPTER) TERMINAL) CIRCUIT DESCRIPTION This is the display signal circuit from the video (video adapter) terminal to the multi-display controller subassy. WIRING DIAGRAM Multi-display Controller Sub-assy V13 Video (Video Adapter) Terminal 22 R30 SG6 (Shielded) SLD 7 NTSC G 24 R30 NTS4 R 23 R30 SGN5 5 SGND 6 I34947 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1932 05-1743 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(MULTI-DISPLA Y CONTROLLER SUB-ASSY - VIDEO(VIDEO ADAPTER)TERM) (a) Video (Video Adapter) Terminal: (b) V13 NTSC SLD SGND Disconnect the connector from the video (video adapter) terminal and multi-display controller sub-assy. Measure the resistance according to the values in the table below. Standard: Tester connection Condition Specified condition SLD - SG6 Always Below 1 Ω NTSC - NTS4 Always Below 1 Ω SGND - SGN5 Always Below 1 Ω NTSC - Body ground Always 10 kΩ or higher Multi-display Controller Sub-assy: R30 NG NTS4 REPAIR OR CONNECTOR REPLACE HARNESS OR SGN5 SG6 I40833 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page 05-1704 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1933 05-1746 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM 05CFC-02 AVC-LAN CIRCUIT (MULTI-DISPLA Y CONTROLLER SUB-ASSY TELEVISION DISPLAY ASSY) CIRCUIT DESCRIPTION Each unit of the rear seat entertainment system connected with AVC-LAN (communication bus) transfers the signal of each switch by communication. When +B short and GND short occur in this AVC-LAN, the rear seat entertainment system will not function normally as the communication is discontinued. WIRING DIAGRAM R28 Television Display Assy TX+ TX- Multi-display Controller Sub-assy 5 O 5 BK1 P 5 R30 TX2+ 4 V 4 BK1 LG 4 R30 TX2- I34971 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1936 05-1747 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM INSPECTION PROCEDURE 1 (a) SERVICE CHECK MODE(TELEVISION DISPLAY ASSY) Perform service check. (1) Start the diagnosis system and read check result for television display assy. Standard: A ”NCON” is displayed or no display (Rr-TV) B ”OK” is displayed B REPLACE MULTI-DISPLA Y SUB-ASSY (See page 67-23 ) CONTROLLER A 2 CHECK HARNESS AND CONNECTOR(TELEVISION DISPLAY ASSY MULTI-DISPLA Y CONTROLLER SUB-ASSY) (a) Television Display Assy: (b) R28 TX+ TX- Disconnect the connector from the television display assy and multi-display controller sub-assy. Measure the resistance according to the values in the table below. Standard: Tester connection Condition Specified condition TX+ - TX2+ Always Below 1 Ω TX- - TX2- Always Below 1 Ω TX+ - Body ground Always 10 kΩ or higher TX- - Body ground Always 10 kΩ or higher Multi display Controller Sub-assy: R30 NG TX2+ REPAIR OR CONNECTOR REPLACE HARNESS OR TX2I37216 OK REPLACE TELEVISION DISPLAY ASSY (See page 67-26 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1937 05-1720 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM 05CF2-03 MUTE SIGNAL CIRCUIT (FROM RADIO RECEIVER ASSY) CIRCUIT DESCRIPTION The Multi-display controller sub-assy controls the volume according to the RMUT signal from the radio receiver assy. The RMUT signal is sent to reduce noise and a popping sound when modes, etc. are switched. WIRING DIAGRAM Multi-display Controller Sub-assy Radio Receiver Assy 19 RMU R23 O 3 IP1 L 28 R29 RMUT I34950 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1910 05-1721 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(RADIO RECEIVER ASSY - MULTI-DISPLA Y CONTROLLER SUB-ASSY) (a) Radio Receiver Assy: R23 Disconnect the connector from the radio receiver assy and multi-display controller sub-assy. Measure the resistance according to the values in the table below. Standard: (b) RMU Tester connection Condition RMU - RMUT Always Specified condition Below 1 Ω RMU - Body ground Always 10 kΩ or higher I40203 NG Multi-display Controller Sub-assy: REPAIR OR CONNECTOR REPLACE HARNESS OR R29 RMUT I34639 OK 2 INSPECT RADIO RECEIVER ASSY Radio Receiver Assy: (a) (b) R23 RMU Connect the radio receiver assy connector. Measure the voltage according to the values in the table below. Standard: Tester connection Condition Specified condition RMU - Body ground Audio system sounding Approx. 3.5 V RMU - Body ground Audio system changing Below 1.0 V NG I40577 REPLACE RADIO RECEIVER ASSY (SEE PAGE 67-6 ) OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE 05-1704 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1911 05-1744 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM 05IVA-01 VIDEO (VIDEO ADAPTOR) TERMINAL SET SIGNAL CIRCUIT WIRING DIAGRAM V13 Video (Video Adapter) Terminal CE 8 Multi-display Controller Sub-assy 3 R30 GAUX SB I41227 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1934 05-1745 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM INSPECTION PROCEDURE 1 CHECK HARNESS AND CONNECTOR(VIDEO (VIDEO ADAPTOR) TERMINAL MULTI-DISPLA Y CONTROLLER SUB-ASSY) (a) Video (Video Adapter) Terminal: (b) CE V13 Disconnect the video (video adapter) terminal and multidisplay controller sub-assy connectors. Measure the resistance according to the values in the table below. Standard: Tester connection Condition CE - GAUX Always Specified condition Below 1 Ω CE - Body ground Always 10 kΩ or higher Multi-display Controller Sub-assy: GAUX R30 I40833 NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page 05-1704 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1935 05-1748 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM 05AU5-04 A REMOTE CONTROL SYSTEM DOES NOT OPERATE INSPECTION PROCEDURE 1 (a) CHECK BATTERY(SWITCH & VOLUME ASSY) Check battery. (1) Check that the dry-cell battery used for the switch & volume assy is not dead. Standard: It is not dead NG BATTERY IS DEAD OK 2 CLEAN THE INFRARED RAY EMITTED PORTION (a) Infrared Ray Emitted Portion Clean the infrared ray emitted portion. (1) Clean the infrared ray emitted portion on the television display assy. (2) Check whether the same malfunction occurs. Standard: The function returns to normal. NG I40585 PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page 05-1704 ) OK NORMAL 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1938 05-1715 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM 05ATT-04 POWER SOURCE CIRCUIT(MULTI-DISPLA Y CONTROLLER SUB-ASSY) CIRCUIT DESCRIPTION This circuit is the power source circuit to operate the multi-display controller sub-assy. WIRING DIAGRAM Engine Room R/B W CRT 2 1 J17 J/C 16 IK2 V 2 V Passenger Side J/B 8 4D A A B 1 1H RAD No.2 1 1A AM1 1 F7 FL Block 2 ALT 3 W 1 16 R29 +B1 32 R29 ACC G G A I15 Ignition SW Instrument Panel J/B Y Y J18 J/C 14 IO1 W 21 IO2 V A 2 2 4E Multi-display Controller Sub-assy 2 1C L 6 1C W 3 ACC AM1 2 2 W-B 7 R31 SELD W-B 29 R29 GND C J18 J/C FL MAIN C C W-B Battery BF I37210 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1905 05-1716 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM INSPECTION PROCEDURE 1 INSPECT MULTI-DISPLA Y CONTROLLER SUB-ASSY(+B1, ACC, GND, SELD) (a) Multi-display Controller Sub-assy: ACC R29 R31 +B1 SELD GND (b) I37211 (c) Disconnect the connector from the multi-display controller sub-assy. Measure the resistance according to the values in the table below. Standard: Tester connection Condition Specified condition GND - Body ground Always Below 1 Ω SELD - Body ground Always Below 1 Ω Measure the voltage according to the values in the table below. Standard: Tester connection Condition Specified condition +B1 - GND Always 10 to 14 V ACC - GND Ignition SW ACC 10 to 14 V NG REPAIR OR CONNECTOR REPLACE HARNESS OR OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page 05-1704 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1906 05-1717 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM 05CF1-03 POWER SOURCE CIRCUIT(TELEVISION DISPLAY ASSY) CIRCUIT DESCRIPTION This circuit is the power source circuit to operate the television display assy. The power source is sent from the battery to the television display assy through the multi-display controller sub-assy. WIRING DIAGRAM R28 Television Display Assy +B ACC GND Multi-display Controller Sub-assy 1 G 1 BK1 V 1 R30 +B2 2 GR 2 BK1 GR 2 R30 ACC2 6 W-B 6 BK1 W-B 6 R30 GND1 I34945 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1907 05-1718 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM INSPECTION PROCEDURE 1 INSPECT TELEVISION DISPLAY ASSY(+B, ACC, GND) (a) Television Display Assy: (b) R28 +B GND (c) ACC I37212 Disconnect the connector from the television display assy. Measure the resistance according to the value in the table below. Standard: Tester connection Condition Specified condition GND - Body ground Always Below 1 Ω Measure the voltage according to the values in the table below. Standard: Tester connection Condition Specified condition +B - GND Always 10 to 14 V ACC - GND Ignition SW ACC 10 to 14 V NG Go to step 2 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page 05-1704 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 1908 05-1719 DIAGNOSTICS 2 - REAR SEAT ENTERTAINMENT SYSTEM CHECK HARNESS AND CONNECTOR(TELEVISION DISPLAY ASSY MULTI-DISPLA Y CONTROLLER SUB-ASSY) (a) Television Display Assy: (b) R28 +B GND ACC I37212 Multi-display Controller Sub-assy: Disconnect the connector from the multi-display controller sub-assy. Measure the resistance according to the values in the table below. Standard: Tester connection Condition Specified condition +B - +B2 Always Below 1 Ω Below 1 Ω ACC - ACC2 Always GND - GND1 Always Below 1 Ω +B - Body ground Always 10 kΩ or higher ACC - Body ground Always 10 kΩ or higher NG R30 GND1 REPAIR OR CONNECTOR REPLACE HARNESS OR +B2 ACC2 I35960 I36913 OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (See page 05-1704 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1909 05-1695 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM 05ATN-04 CUSTOMER PROBLEM ANALYSIS CHECK RSE SYSTEM Check Sheet Inspector’s name: VIN Production Date Customer’s Name Licence Plate No. Brought-in Date / / / Date of First Occurrence Frequency of Problem Occurrence km mile Odometer Reading
Constant /
Intermittent ( Times a day) Problem Symptom
Switch & Volume Assy
Headphone
Multi-display Controller Sub-assy
Disc Player Controller (Built in ”Television Display Assy”)
Television Display Assy DTC Check Parts name DTC (1st time) DTC (2nd time) Multi-display Controller Sub-assy Disc Player Controller Television Display Assy 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1885 05-1691 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM 05CEY-02 DESCRIPTION 1. (a) OUTLINE OF AVC-LAN What is AVC-LAN? AVC-LAN is the abbreviation for Audio Visual Communication-Local Area Network. This is a unified standard co-developed by 6 audio manufacturers associated with Toyota Motor Corporation. The unified standard includes signals, such as audio, visual and signals for switch indication and communication. Stereo Component Amplifier Assy Example: Network Gateway ECU Multi-display Controller Sub-assy Multi-display Assy Radio Receiver Assy Navigation ECU : AVC-LAN I34376 (b) Objectives Recently developments in car audio systems have been rapid and functions have been changed drastically. The conventional system has been switched to the multi-media type such as a navigation system. At the same time, customers want to upgrade their audio systems. This is the factor that lies behind this standardization. The concrete objectives are explained below. (1) When products by different manufacturers were combined together, malfunctions such as sound failure occurred. This problem can be solved by standardization of signals. (2) Various types of after market products are available. (3) Because of the above (2), each manufacturer has been able to concentrate on developing products in their strongest field. This has enabled the development of inexpensive products. (4) In general, a new product developed by one particular manufacturer could not be used due to a lack of compatibility with other manufacturers’ products. By developing this new standard, users can enjoy a range of compatible products from different manufacturers anytime they want. HINT:




When +B short or GND short is detected in AVC-LAN circuit, communication stops, and the audio system does not function normally. When audio system is not equipped with a navigation system, the audio head unit is the master unit. When the audio system is equipped with a navigation system, the radio receiver is the master unit. The master unit is equipped with a resistor (60 to 80 Ω) for communication. The car audio system using AVC-LAN circuit has a diagnosis function. Each product has its own specified number called a physical address (three-digit number). Numbers are also allotted to each function within a product, which are called logical addresses (two-digit number). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1881 05-1692 DIAGNOSTICS 2. (a) - REAR SEAT ENTERTAINMENT SYSTEM COMMUNICATION SYSTEM This system performs communication between components through the Main AVC-LAN and Sub AVC-LAN. Main AVC-LAN Radio Receiver Assy Television Display Assy Sub AVC-LAN Multi-display Controller Sub-assy I35063 (b) The multi-display controller sub-assy functions as a master unit, which performs communication between the multi-display controller sub-assy and television display assy, in the Sub AVC-LAN circuit. HINT: Refer to ”LEXUS NAVIGATION SYSTEM” (See page 05-1757 ) and ”AUDIO SYSTEM” (See page 05-1615 ) for the Main AVC-LAN circuit. (c) 3. (a) The multi-display controller sub-assy is equipped with a resistor (60 to 80 Ω) for communication. DIAGNOSIS FUNCTION The multi-display controller sub-assy functions as a master unit in the Sub AVC-LAN circuit on this circuit. It identifies trouble in this circuit, and the identified information is displayed on the television display assy. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1882 05-1712 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM 05ATP-05 DIAGNOSTIC TROUBLE CODE CHART Terms Meaning Physical address Three-digit code (shown in hexadecimal) which is given to each component comprising the AVC-LAN. Corresponding to the function, individual symbols are specified. Logical address Two-digit code (shown in hexadecimal) which is given to each function in the inner system of the AVC-LAN. HINT: The DTC of the Main AVC-LAN circuit is displayed on the radio receiver assy or multi-display, and the DTC of the Sub AVC-LAN circuit is displayed on the television display assy. Titles for each unit are stated in the following order: physical address, (parts name) and [name indicated on the DTC display]. 1. MULTI-DISPLA Y CONTROLLER SUB-ASSY (Physical address: 16C, 16D) [RSE-ECU] HINT:
*1: Even if no failure is detected, this code may be stored depending on the battery condition or voltage for starting the engine.
*2: This code is stored 180 seconds after the power supply connector is disconnected after engine start.
*3: This code may be stored when the engine key is turned back to the ON position and then turned again to the START position after engine start.
*4: This code may be stored when the engine key is turned back to the ON position and then turned again to the START position in 1 minute after engine start. (a) Logical address: 01 (Communication control) DTC D8 *2 D9 *1 DA DB *1 DC *4 Diagnosis item Condition Countermeasure and inspected parts No Response To Connection Check Component shown by sub-code is or had been disconnected from system after engine start. 1. Check harness for power supply system of component shown by sub-code. 2. Check harness for communication system of component shown by sub-code. Last Mode Error Component operated (sound and/or image was provided) before engine stop is or was disconnected with ignition switch in the ACC or ON position. 1. Check harness for power supply of component shown by sub-code. 2. Check harness for communication system of component shown by sub-code. No Response to ON/OFF Instruction No response is identified when changing mode (audio and visual mode change). Detected when sound and picture do not change by button operation. 1. Check harness for power supply system of component shown by sub-code. 2. Check harness for communication system of component shown by sub-code. 3. If error occurs again, replace component shown by auxiliary code. Mode Status Error Dual alarm is detected. 1. Check harness for power supply system of component shown by sub-code. 2. Check harness for communication system of component shown by sub-code. Transmission Error Transmission to component shown by subcode failed. (This code does not necessarily mean actual failure.) If same sub-code is recorded in other component(s), check harness for power supply and communication system of all components shown by code. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1902 05-1713 DIAGNOSTICS DTC DE *3 E4 *1 Diagnosis item - REAR SEAT ENTERTAINMENT SYSTEM Condition Countermeasure and inspected parts Slave Reset (Momentary Interruption) After engine start, slave component has been disconnected. 1. Check harness for power supply system of component shown by sub-code. 2. Check harness for communication system of component shown by sub-code. Multiple Frame Abort Multiple frame transmission is aborted. Since this DTC is provided for engineering purpose, it may be detected when no actual failure exists. 2. TELEVISION DISPLAY ASSY (Physical address: 1B0) [Rr-TV] HINT:
*1: Even if no failure is detected, this code may be stored depending on the battery condition or voltage for starting the engine.
*2: This code may be stored when the engine key is turned again in 1 minute after the engine start.
*3: This code may be stored when the engine key is turned again after the engine start.
*4: The code is stored 210 seconds after the power supply connector of the master component is disconnected with the ignition switch in the ACC or ON position. (a) Logical address: 01 (Communication control) DTC 22 D6 *1 D7 *4 DC *2 Diagnosis item RAM Error Condition Countermeasure and inspected parts Abnormal condition of RAM is detected. Replace television display assy Component in which this code is recorded was disconnected from system with the ignition switch in the ACC or ON position. Or, when this code was recorded, multi-display controller sub-assy was disconnected. 1. Check harness for power supply of multi-display controller sub-assy (see page 05-1715 ). 2. Check harness for communication system of multi-display controller sub-assy (see page 05-1864 ). 3. Check harness for power supply of television display assy (see page 05-1717 ). 4. Check harness for communication system of television display assy (see page 05-1746 ). Communication Check Error Component in which this code is recorded is or was disconnected from system after engine start. Or, when recording this code, multi-display controller sub-assy was disconnected. 1. Check harness for power supply of multi-display controller sub-assy (see page 05-1715 ). 2. Check harness for communication system of multi-display controller sub-assy (see page 05-1864 ). 3. Check harness for power supply of television display assy (see page 05-1717 ). 4. Check harness for communication system of television display assy (see page 05-1746 ). Transmission Error Transmission to component shown by subcode failed. (Detecting this DTC does not necessarily mean actual failure.) If the same sub-code is recorded in other components, check harness for power supply and communication system of all components shown by code. Absence of Master 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1903 05-1714 DIAGNOSTICS DTC Diagnosis item - REAR SEAT ENTERTAINMENT SYSTEM Condition Countermeasure and inspected parts Master Reset (Momentary Interruption) After engine start, multi-display controller sub-assy was disconnected from system. 1. Check harness for power supply of multi-display controller sub-assy (see page 05-1715 ). 2. Check harness for communication system of multi-display controller sub-assy (see page 05-1864 ). 3. If this error occurs frequently, replace multi-display controller sub-assy. DF *4 Master Error Due to defective condition of component with a display, master function is switched to audio equipment. Error occurs in communication between sub-master (audio) and master component. 1. Check harness for power supply of multi-display controller sub-assy (see page 05-1715 ). 2. Check harness for communication system of multi-display controller sub-assy (see page 05-1864 ). E0 *1 Registration Completion Instruction Error ”Registration Completion Instruction” command from master cannot be received. Since this DTC is provided for engineering purposes, it may be detected when no actual failure exists. E2 ON/OFF Instruction Parameter Error Error occurs in ON/OFF controlling command from multi-display controller subassy. Replace multi-display controller sub-assy. E3 *1 Registration Request Transmission
Registration Request command is output from slave component.
Registration Connection Check Instruction, Registration Request command is output from sub-master component. Since this DTC is provided for engineering purposes, it may be detected when no actual failure exists. E4 *1 Multiple Frame Abort Multiple frame transmission is aborted. Since this DTC is provided for engineering purposes, it may be detected when no actual failure exists. DD *3 (b) Logical address: 44 (DVD) DTC Diagnosis item Condition Countermeasure and inspected parts 42 No Disc Readout Disc cannot be read. Inspect disc 44 DVD Error Error is detected in disc player controller. Inspect disc, Television display assy 45 EJECT Error Disc cannot be ejected. Inspect disc, Television display assy 46 Disc Crack A crack or dirt is in a disc. Inspect disc, Television display assy 52 Player Error Clamp malfunction occurs. Inspect disc, Television display assy 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1904 05-1693 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM 05ATM-04 HOW TO PROCEED WITH TROUBLESHOOTING 1 Vehicle Brought to Workshop 2 Customer Problem Analysis (See page 05-1695 ) (a) Interview and confirm the trouble. (1) Confirm the condition of the trouble. 3 (a) Basic Inspection Basic inspection. (1) Measure the battery voltage. Standard: 11 to 14 V w/ Navigation system: Check the power supply to the multi-display assy. (1) Turn the ignition switch to the ACC position. (2) Check whether or not the display appears on the multi-display assy. (b) Display does not appear (Proceed to problem symptom table ”Black Screen (Multi Display Assy)”) (See page 05-1778 ). Display appears (Go to step 4). (c) w/o Navigation system: Check the power supply to the radio receiver assy. (1) Turn the ignition switch to the ACC position. (2) Check whether or not the display appears on the radio receiver assy. Display does not appear (Proceed to problem symptom table) (See page 05-1632 ) Display appears (Go to step 4). 4 (a) Check Body Multiplex Communication System (See page 05-2040 ) Check that the DTC is output. DTC is not output (Go to step 5). DTC is output (Proceed to ”Body Multiplex Communication System”). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1883 05-1694 DIAGNOSTICS 5 (a) - REAR SEAT ENTERTAINMENT SYSTEM DTC Check (See page 05-1696 ) Check that the DTC is output. DTC is output (Go to step 6). DTC is not output (Go to step 7). 6 DTC Chart (See page 05-1712 ) Go to step 8 7 Problem Symptom Table (See page 05-1704 ) 8 Circuit Inspection and Part Inspection (See page 05-1715 - 05-1748 ) 9 Identification of Problem 10 Repair or Replace 11 Confirmation Test End 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1884 05-1690 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM REAR SEAT ENTERTAINMENT SYSTEM 05ATQ-04 LOCATION Television Display Assy (Disc Player Controller) Engine Room J/B
CRT Fuse FL Block
ALT Fuse w/o 3rd seat: Multi-display Controller Sub-assy Video (Video Adapter) Terminal Instrument Panel J/B
RAD No.2 Fuse
AM1 Fuse w/ 3rd seat: Multi-display Controller Sub-assy Multi-display Radio Receiver Assy I40586 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1880 05-1696 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM 05CEZ-02 PRE-CHECK 1. DIAGNOSIS CHECK HINT: Diagnosis system mode is operated as follows. RSE system normal operation Diagnosis start-up w/ Navigation system (See page 05-1784 ) w/o Navigation system (See page 05-1618 ) Start-up of the diagnostics function for the ”audio system and navigation system” is linked with the start-up of the diagnostic function of the ”rear display”. Select ”MENU” and enter ”Diagnosis MENU” using a remote controller. Enter ”Service Check Mode.” (See step 2) Enter ”Display Check.” (See step 3) I35064 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1886 05-1697 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM HINT: RSE system inspects the devices consisting of Sub AVC-LAN multi-display controller sub-assy. (a) Starting Main AVC-LAN diagnosis mode (See page 05-1784 , 05-1618 ). HINT:
Starting Main AVC-LAN operates the diagnosis mode, and sub AVC-LAN also automatically enters the diagnosis mode and performs the diagnosis mode operation on the multi-display controller sub-assy.
Use a switch & volume assy to operate diagnosis mode. (b) Finishing the diagnosis mode. Turn the ignition switch off to finish the diagnosis mode. Switch & Volume Assy: I35000 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1887 05-1698 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM 2. SERVICE CHECK MODE HINT: ”Service Check Mode” is operated as follows. Enter ”Diagnosis MENU.” (See step 1) Recheck Master Component Registration clearance DTC memory clearance DTC clear I36928 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1888 05-1699 DIAGNOSTICS (a) - REAR SEAT ENTERTAINMENT SYSTEM Service Check Mode (1) Start the Diagnosis System. Display Item *6 Component Names/*1 Component names including optional components (15 components max.) are displayed. When the names are not identified, their physical addresses are displayed. Check Result/*2 Check results are displayed. Memory Clear switch/*3 Pressing this switch for 3 sec. deletes all the information about master component registration. DTC Clear switch/*4 Pressing this switch for 3 sec. deletes diagnosis memory of all the components. It deletes the check results. Recheck/*5 Pressing this switch performs Service Check again. MENU/*6 Pressing this switch activates the Diagnosis Menu screen. LAN Monitor screen switch/*7 Pressing this switch activates the LAN Monitor screen, which displays the logical address 01 with DTC D0 - FE. *2 *1 *1 *7 *4 *3 Function *5 I35066 Components:/*1 Display RSE-ECU Name Multi-display Controller Sub-assy Rr-TV Television Display Assy HINT: Service Check displays the check results based on the information obtained from each component’s response to ”System Check Execution” and ”Diagnosis Memory Request”, and the information of ”Current DTC Notification” (the ”Unit Check” that will be displayed on the next screens). (2) Read Check Result Check Result Meaning OK No DTC is identified. EXCH One or more DTCs requesting an exchange are detected. CHEK One or more DTCs requesting a check are detected. NCON No connection response to Diagnosis System start-up, however it has connection response to the AVC LAN system when the power switch is turned on (when IG is turned to the ACC position). Old One or more DTCs are detected because of old version. NRES No response to the information about the Diagnosis System, whereas it responds to the Diagnosis System start-up. HINT:

After repairing and checking, press ”Code CLR” for more than 3 seconds to delete diagnosis memory. After deleting diagnosis memory, press ”Recheck” and make sure ”OK” is displayed on the screen. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1889 05-1700 DIAGNOSTICS - (3) *1 *3 REAR SEAT ENTERTAINMENT SYSTEM ”EXCH”, ”CHEK” and ”Old” can be used as switches to activate ”Unit Check Mode” for detailed information. When inspecting the malfunctioning area, refer to the DTC code list. Display Item *2 *5 *6 Component name/*1 Name of component to be checked is displayed. DTC clear switch/*2 Pressing this switch for 3 sec. deletes DTC memory of the selected diagnosis component. Service check mode screen switch/*3 Pressing this returns to the Service Check Mode screen. Date/Time/*4 The date and time stamped at the time of DTC occurrence are displayed in the order of year-month-day-hour-minutesecond. (If the date and time data is invalid, it is displayed as a blank.) Current/ *5 Up to 6 DTC codes detected during the System Check are displayed. Memory/ *6 DTC memories stored and current DTC notification are displayed. *4 I35067 Description HINT:

Detecting unit DTC activates the ”Unit Check Mode” on the screen. In the ”Unit Check Mode”, DTCs which are identified as ”EXCH” in the ”Service Check” are classified into ”Current” DTC and ”Past” DTC. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1890 05-1701 DIAGNOSTICS - (4) REAR SEAT ENTERTAINMENT SYSTEM ”CHECK” can be used as a switch to activate ”LAN Monitor” for detailed information. When inspecting the malfunctioning area, refer to the DTC code list. Display Item I35068 *1 *4 *2 *5 Description Component name/*1 Names of component to be checked are displayed. Segment/*2 Logical address codes corresponding to DTC are displayed. DTC/*3 DTC is displayed. Sub-Code (address numbers of related components)/*4 Physical address codes memorized together with DTC are displayed. Sub-code (Connection confirmation number) /*5 Connection confirmation numbers memorized together with DTC are displayed. Sub-code (Number of occurrence) /*6 The number of occurrence of the same DTC is displayed. HINT: *6
*3 I35069 Detecting no LAN DTC activates the LAN Monitor on the screen. The LAN Monitor chooses and displays the LAN DTC out of DTC of components identified as ”CHEK” in the LAN Monitor. (5) Read Check Result
Check Result Meaning OK No DTC is identified. CHEK One or more DTCs requesting a check are detected. NCON No connection response to Diagnosis System start-up, however it has connection response to the AVC-LAN system when the power switch is turned on (when IG is turned to the ACC position). NRES No response to the information about the Diagnosis System, whereas it responds to the Diagnosis System start-up. Old One or more DTCs are detected because of old version. HINT:

After repairing and checking, press ”Code CLR” for more than 3 seconds to delete diagnosis memory. After deleting diagnosis memory, press ”Recheck” and make sure ”OK” is displayed on the screen. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1891 05-1702 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM 3. DISPLAY CHECK MODE HINT: Display check mode is operated as follows. Enter ”Diagnosis MENU.” (See step 1) Select color by remote control operation Press ENTER on remote control The entire screen is changed to the color which is selected in the color bar check mode. I35070 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1892 05-1703 DIAGNOSTICS (a) - REAR SEAT ENTERTAINMENT SYSTEM Display Check Mode Display *1 Contents Color Bar Check/*1 Color display is checked. Remote Commander/*2 Operating condition of remote commander display is checked. *2 HINT: In Display Check Mode, above checks can be performed. I35071 (b) Select color by remote control operation Press ENTER on remote control The entire screen is changed to the color which is selected in the color bar check mode. Display Color Bar Check (1) Start the Diagnosis System. (2) Select ”MENU”. (3) Select ”Display Check”. (4) Select ”Color Bar Check”. (5) Make sure that each color name is corresponding to each color on the bar. HINT: Select Black, Red, Green, Blue, White and Stripe to display selected colors and stripe on the entire screen. (6) Compare the color with the ”Color Bar Check”, and make sure that the color is the same. I35072 (c) Display Remote Commander Check (1) Start the Diagnosis system. (2) Select ”MENU”. (3) Select ”Display Check”. (4) Select ”Remote Commander”. (5) Press each switch and make sure that it corresponds to the display on the screen. I35073 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1893 05-1704 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM 05ATS-04 PROBLEM SYMPTOMS TABLE HINT: Inspect the ”Fuse” and ”Relay” before confirming the suspected area as shown in the charts below. TELEVISION DISPLAY ASSY: Symptom Suspected Area See page 1. Power source circuit (multi-display controller sub-assy) 2. Power source circuit (television display assy) 3. AVC-LAN circuit (multi-display controller sub-assy television display assy) 4. Multi-display controller sub-assy 05-1715 05-1717 05-1746 Display screen is not stabilized (Synchronous error). 1. 2. 3. 4. 5. Power source circuit (multi-display controller sub-assy) Power source circuit (television display assy) Display signal circuit (To television display) Television display assy Multi-display controller sub-assy 05-1715 05-1717 05-1738 67-26 67-23 Color on display screen is unusual (RGB signal error). 1. 2. 3. 4. Rear display color bar check of display check mode Display signal circuit (To television display) Television display assy Multi-display controller sub-assy 05-1696 05-1738 67-26 67-23 Black screen. 67-23 DISC PLAYER CONTROLLER (Built in ”TELEVISION DISPLAY ASSY”): Symptom Suspected Area See page Only DVD screen is not displayed or not stabilized. 1. 2. 3. 4. 5. Power source circuit (multi-display controller sub-assy) Power source circuit (television display assy) Display signal circuit (From television display) Television display assy Multi-display controller sub-assy 05-1715 05-1717 05-1740 67-26 67-23 Only DVD is not heard or the sound quality is poor. 1. 2. 3. 4. 5. 6. 7. 8. Power source circuit (multi-display controller sub-assy) Power source circuit (television display assy) Sound signal circuit (From television display assy) RSE sound signal circuit (RSE-Radio receiver assy) Mute signal circuit (From television display assy) AMP mute signal circuit (From RSE ECU) Multi-display controller sub-assy Television display assy 05-1715 05-1717 05-1735 05-1671 05-1722 67-23 67-26 VIDEO (VIDEO ADAPTER) TERMINAL: Symptom Only display screen input from the external device is not displayed or not stabilized. Only sound quality input from the external device is poor or no sound can be heard. The operation to the external device cannot be performed. Suspected Area See page 1. Power source circuit (multi-display controller sub-assy) 2. Power source circuit (television display assy) 3. Display signal circuit (From video (video adapter) terminal) 4. VIDEO (Video adapter) terminal 5. Multi-display controller sub-assy 05-1715 05-1717 05-1742 1. Power source circuit (multi-display controller sub-assy) 2. Power source circuit (television display assy) 3. Sound signal circuit (From video (video adapter) terminal) 4. VIDEO (Video adapter) terminal 5. Multi-display controller sub-assy 05-1715 05-1717 05-1727 1. 2. 3. 4. 5. 05-1715 05-1717 05-1744 67-27 67-23 Power source circuit (multi-display controller sub-assy) Power source circuit (television display assy) VIDEO (Video adapter) terminal set signal circuit VIDEO (Video adapter) terminal Multi-display controller sub-assy 67-27 67-23 67-27 67-23 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1894 05-1705 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM RSE SYSTEM: Symptom Suspected Area See page Quality of sound from wireless headphone is poor or no sound can be heard. 1. 2. 3. 4. 5. Power source circuit (multi-display controller sub-assy) Power source circuit (television display assy) Sound signal circuit (Wireless headphone) Multi-display controller sub-assy Television display assy 05-1715 05-1717 05-1732 67-23 67-26 Quality of sound from headphone connected to headphone terminal is poor or no sound can be heard. 1. 2. 3. 4. 5. Power source circuit (multi-display controller sub-assy) Power source circuit (television display assy) Sound signal circuit (Headphone) Multi-display controller sub-assy Television display assy 05-1715 05-1717 05-1729 67-23 67-26 1. 2. 3. 4. A remote control system does not operate Power source circuit (multi-display controller sub-assy) Power source circuit (television display assy) AVC-LAN circuit (multi-display controller sub-assy television display assy) REMOTE CONTROL: Symptom A remote control system does not operate. Suspected Area See page 05-1748 05-1715 05-1717 05-1746 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1895 05-1706 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM 05CF0-03 TERMINALS OF ECU 1. MULTI-DISPLA Y CONTROLLER SUB-ASSY R29 R31 R30 I34999 Symbols (Terminals No.) L- - GND (R29-7 - R29-29) L+ - GND (R29-8 - R29-29) R- - GND (R29-9 - R29-29) Wiring Color G - W-B R - W-B W - W-B Terminal Description Condition Specification DVD system is playing A waveform synchronized with sound is output DVD system is playing A waveform synchronized with sound is output DVD system is playing A waveform synchronized with sound is output Sound signal (Output) DVD system is playing A waveform synchronized with sound is output Ground Always Below 1 V Sound signal (Output) Sound signal (Output) Sound signal (Output) R+ - GND (R29-10 - R29-29) B - W-B SG1 - Body ground (R29-11 - Body ground) Shielded - Body ground LMUT - GND (R29-12 - R29-29) V - W-B Mute signal Disc player changer or disc player controller is changing Below 1 V +B1 - GND (R29-16 - R29-29) Y - W-B Battery Always 10 to 14 V TX3+ (R29-17) BR AVC-LAN communication signal See ”Service Check Mode” - TX3- (R29-18) Y AVC-LAN communication signal See ”Service Check Mode” - TX- (R29-30) GR AVC-LAN communication signal See ”Service Check Mode” - TX+ (R29-31) LG AVC-LAN communication signal See ”Service Check Mode” - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1896 05-1707 DIAGNOSTICS - REAR SEAT ENTERTAINMENT SYSTEM SG33 - Body ground (R29-19 - Body ground) Shielded - Body ground Ground Always Below 1 V SGN1 - Body ground (R29-20 - Body ground) R - Body ground Ground Always Below 1 V NTS1 - GND (R29-21 - R29-29) G - W-B Display signal DVD system is displayed Pulse generation RSE system is playing A waveform synchronized with sound is output RSE system is playing A waveform synchronized with sound is output RSE system is playing A waveform synchronized with sound is output Sound signal (Input) RSE system is playing A waveform synchronized with sound is output Ground Always Below 1 V Mute signal Audio source is changing Below 1 V Ground Always Below 1 V R-L- - GND (R29-23 - R29-29) R-L+ - GND (R29-24 - R29-29) R-R- - GND (R29-25 - R29-29) G - W-B R - W-B W - W-B Sound signal (Input) Sound signal (Input) Sound signal (Input) R-R+ - GND (R29-26 - R29-29) B - W-B SG2 - Body ground (R29-27 - Body ground) Shielded - Body ground RMUT - GND (R29-28 - R29-29) L - W-B GND - Body ground (R29-29 - Body ground) W-B - Body ground ACC - GND (R29-32 - R29-29) G - W-B Ignition (ACC) Ignition switch in the ACC position 10 to 14 V +B2 - GND (R30-1 - R29-29) V - W-B Battery Always 10 to 14 V ACC2 - GND (R30-2 - R29-29) GR - W-B Ignition (ACC) Ignition switch in the ACC position 10 to 14 V Ground External device system is playing (At that time of VTR jack use) A waveform synchronized with sound is output GAUX - GND (R30-3 - R29-29) SB - W-B TX2- (R30-4) LG AVC-LAN communication signal See ”Service Check Mode” - TX2+ (R30-5) P AVC-LAN communication signal See ”Service Check Mode” - GND1 - Body ground (R30-6 - Body ground) W-B - Body ground Ground Always Below 1 V SG5 - Body ground (R30-7 - Body ground) Shielded - Body ground Ground Always Below 1 V Sound signal (Input) External device system is playing (At that time of VTR jack use) A waveform synchronized with sound is output Sound signal (Input) External device system is playing (At that time of VTR jack use) A waveform synchronized with sound is output Ground Always HP1L - GND (R30-8 - R29-29) G - W-B HP1R - GND (R30-9 - R29-29) R - W-B SG7 - Body ground (R30-10 - Body ground) Shielded - Body ground Below 1 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1897 05-1708 DIAGNOSTICS AUXL - GND (R30-11 - R29-29) BR - W-B - REAR SEAT ENTERTAINMENT SYSTEM Sound signal External device system is playing (At that time of VTR jack use) A waveform synchronized with sound is output A waveform synchronized with sound is output AUXR - GND (R30-12 - R29-29) Y - W-B Sound signal External device system is playing (At that time of VTR jack use) R2 - GND (R30-13 - R29-29) G - W-B Display signal (Red) Display is on (Television display assy) Pulse generation G2 - GND (R30-14 - R29-29) W - W-B Display signal (Green) Display is on (Television display assy) Pulse generation B2 - GND (R30-15 - R29-29) R - W-B Display signal (Blue) Display is on (Television display assy) Pulse generation SYN2 - GND (R30-16 - R29-29) B - W-B Display signal (Synchronize) Display is on (Television display assy) Pulse generation VR2 - Body ground (R30-17 - Body ground) Y - Body ground Ground Always Below 1 V VG2 - Body ground (R30-18 - Body ground) Shielded - Body ground Ground Always Below 1 V SG6 - Body ground (R30-19 - Body ground) Shielded - Body ground Ground Always Below 1 V Sound signal (Output) Audio system is playing (Headphone) A waveform synchronized with sound is output Sound signal (Output) Audio system is playing (Headphone) A waveform synchronized with sound is output HP2L - GND (R30-20 - R29-29) BR - W-B HP2R - GND (R30-21 - R29-29) Y - W-B SG6 - Body ground (R30-22 - Body ground) Shielded - Body ground Ground Always Below 1 V SGN5 - Body ground (R30-23 - Body ground) R - Body ground Ground Always Below 1 V NTS4 - GND (R30-24 - R29-29) G - W-B Display signal External device system displayed (At that time of VTR jack use) Pulse generation MUTE - GND (R31-1 - R29-29) L - W-B Mute signal Disc player controller is changing Below 1 V AL- - GND (R31-2 - R29-29) AL+ - GND (R31-3 - R29-29) AR- - GND (R31-4 - R29-29) G - W-B R - W-B W - W-B AR+ - GND (R31-5 - R29-29) B - W-B SG4 - Body ground (R31-6 - Body ground) Shielded - Body ground DVD system is playing A waveform synchronized with sound is output DVD system is playing A waveform synchronized with sound is output DVD system is playing A waveform synchronized with sound is output Sound signal (Input) DVD system is playing A waveform synchronized with sound is output Ground Always Sound signal (Input) Sound signal (Input) Sound signal (Input) Below 1 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1898 05-1709 DIAGNOSTICS SELD - Body ground (R31-7 - Body ground) W-B - Body ground NTS2 - GND (R31-8 - R29-29) G - W-B SGN2 - Body ground (R31-9 - Body ground) SG9 - Body ground (R31-10 - Body ground) HPL- - GND (R31-16 - R29-29) HPL+ - GND (R31-17 - R29-29) HPR- - GND (R31-18 - R29-29) 2. - REAR SEAT ENTERTAINMENT SYSTEM Ground Always Display signal DVD system is displayed R - Body ground Ground Always Below 1 V Shielded - Body ground Ground Always Below 1 V G - W-B W - W-B R - W-B HPR+ - GND (R31-19 - R29-29) B - W-B SLD1 - Body ground (R31-20 - Body ground) Shielded - Body ground Below 1 V Pulse generation RSE system is playing A waveform synchronized with sound is output RSE system is playing A waveform synchronized with sound is output RSE system is playing A waveform synchronized with sound is output Sound signal (Output) RSE system is playing A waveform synchronized with sound is output Ground Always Sound signal (Output) Sound signal (Output) Sound signal (Output) Below 1 V TELEVISION DISPLAY ASSY R28 I35015 Terminals No. (Symbols) Wiring Color +B - GND (R28-1 - R28-6) G - W-B ACC - GND (R28-2 - R28-6) GR - W-B TX- (R28-4) Condition Condition Specification Battery Always 10 to 14 V Ignition (ACC) Ignition switch in the ACC position 10 to 14 V V AVC-LAN communication signal See ”Service Check Mode” - TX+ (R28-5) O AVC-LAN communication signal See ”Service Check Mode” - GND - Body ground (R28-6 - Body ground) W-B - Body ground Ground Always Sound signal (Input) While voice sound is being produced HP1R - GND (R28-7 - R28-6) BR - W-B Below 1 V A waveform synchronized with sound is output 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1899 05-1710 DIAGNOSTICS HP1L - GND (R28-8 - R28-6) Y - W-B GND - Body ground (R28-9 - Body ground) SGND - Body ground (R28-10 - Body ground) AR+ - GND (R28-11 - R28-6) AR- - GND (R28-12 - R28-6) AL+ - GND (R28-13 - R28-6) - REAR SEAT ENTERTAINMENT SYSTEM A waveform synchronized with sound is output Sound signal (Input) While voice sound is being produced Shielded - Body ground Ground Always Below 1 V Shielded - Body ground Ground Always Below 1 V B - W-B W - W-B R - W-B Sound signal (Output) Sound signal (Output) Sound signal (Output) DVD system is sounding A waveform synchronized with sound is output DVD system is sounding A waveform synchronized with sound is output DVD system is sounding A waveform synchronized with sound is output A waveform synchronized with sound is output AL- - GND (R28-14 - R28-6) G - W-B Sound signal (Output) DVD system is sounding MUTE - GND (R28-15 - R28-6) V - W-B Mute signal DVD system is sounding → DVD system is changing 3.5 V → Below 1 V SG - Body ground (R28-16 - Body ground) Shielded - Body ground Ground Always Below 1 V VG - Body ground (R28-17 - Body ground) Shielded - Body ground Ground Always Below 1 V VR - Body ground (R28-18 - Body ground) Y - Body ground Ground Always Below 1 V SYNC - VR (R28-19 - R28-18) B-Y Display signal (Synchronize) Television display is ON Pulse generation B - VR (R28-20 - R28-18) R-Y Display signal (Blue) Television display is ON Pulse generation G - VR (R28-21 - R28-18) W-Y Display signal (Green) Television display is ON Pulse generation R - VR (R28-22 - R28-18) G-Y Display signal (Red) Television display is ON Pulse generation Sound signal (Input) While voice sound is being produced A waveform synchronized with sound is output Sound signal (Input) While voice sound is being produced A waveform synchronized with sound is output Ground Always Sound signal (Input) While voice sound is being produced HP2R - GND (R28-23 - R28-6) P - W-B HP2L - GND (R28-24 - R28-6) L - W-B GND1 - Body ground (R28-25 - Body ground) Shielded - Body ground HPR+ - GND (R28-26 - R28-6) BR - W-B Below 1 V A waveform synchronized with sound is output 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1900 05-171 1 DIAGNOSTICS HPR- - GND (R28-27 - R28-6) HPL+ - GND (R28-28 - R28-6) SB - W-B LG - W-B - REAR SEAT ENTERTAINMENT SYSTEM Sound signal (Input) While voice sound is being produced A waveform synchronized with sound is output Sound signal (Input) While voice sound is being produced A waveform synchronized with sound is output Sound signal (Input) While voice sound is being produced A waveform synchronized with sound is output HPL- - GND (R28-29 - R28-6) P - W-B SLD - Body ground (R28-30 - Body ground) Shielded - Body ground Ground Always Below 1 V S. GND - Body ground (R28-31 - Body ground) BR - Body ground Ground Always Below 1 V NTSC - GND (R28-32 - R28-6) Y - W-B Display signal Rear display is on Pulse generation 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 1901 05-10 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05ESL-05 BASIC INSPECTION When the malfunction is not confirmed in the DTC check, troubleshooting should be carried out in all the possible circuits considered as possible causes of the problem. In many cases, by carrying out the basic engine check shown in the following flowchart, the problem can be found quickly and efficiently. Therefore, using this check is essential in the engine troubleshooting. 1 CHECK BATTERY VOLTAGE NOTICE: Carry out the battery voltage check with the engine stopped and ignition switch OFF. Voltage NG OK NG 11 V or more Less than 11 V CHARGE OR REPLACE BATTERY OK 2 CHECK IF ENGINE WILL CRANK NG PROCEED TO PROBLEM SYMPTOMS TABLE ON PAGE 05-31 NG Go to step 7 OK 3 CHECK IF ENGINE STARTS OK 4 CHECK AIR FILTER Visually check if the air filter is contaminated with dirty or oily. NG CLEAN OR REPLACE OK 5 CHECK IDLE SPEED (See page 14-1 ) NG PROCEED TO PROBLEM SYMPTOMS TABLE ON PAGE 05-31 OK 6 CHECK FUEL PRESSURE (See page 11-4 ) NG PROCEED TO PAGE 11-4 AND CONTINUE TO TROUBLESHOOT OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 200 05-1 1 DIAGNOSTICS 7 - SFI SYSTEM (2AZ-FE) CHECK FOR SPARK (See page 18-3 ) NG PROCEED TO PAGE 18-1 AND CONTINUE TO TROUBLESHOOT OK PROCEED TO PROBLEM SYMPTOMS TABLE ON PAGE 05-31 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 201 05-24 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05MOJ-01 CHECKING MONITOR STATUS NOTICE: The monitor status (mode 6) is not applicable to the heated oxygen sensor (HO2S). However, HO2S test values can be checked by O2S TEST RESULT (mode 5). Refer to page 05-22 1. Outline The monitor results and the test values can be checked with the OBDII scan tool. The engine control module (ECM) monitors the emissions-related components as the thermostat, catalyst converter and evaporative emissions (EVAP), and determines whether they are functioning normally or not. When finished monitoring, the ECM stores the monitor results and the test values. The monitor result indicates whether the component is functioning normally or not. The test value is the value that was used to determine the monitor result. If the test value is outside the test limit (malfunction criterion), the ECM determines the component is malfunctioning. Some emissions-related components have multiple test values to determine monitor result. If one of these test values is outside test limit, the ECM determines the component is malfunctioning. 2. Description The test value and test limit information are described as shown in the following table. This information is included under ”MONITOR RESULT” in the emissions-related DTC sections: TID $08: Thermostat TLT CID Unit Conversion 1 $01 Multiply by 0.625 and subtract 40 [C]



Description of Test Value Description of Test Limit ECT sensor output when estimated ECT Malfunction criterion for thermostat has reached to malfunction criterion TID (Test Identification Data) is assigned to each emissions-related component. TLT (Test Limit Type): If TLT is 0, the component is malfunctioning when the test value is higher than the test limit. If TLT is 1, the component is malfunctioning when the test value is lower than the test limit. CID (Component Identification Data) is assigned to each test value. Unit Conversion is used to calculate the test value indicated on generic OBDII scan tools. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 214 05-25 DIAGNOSTICS 3. (a) (b) (c) (d) - SFI SYSTEM (2AZ-FE) Procedure (using hand-held tester) Connect the hand-held tester to the DLC3. Turn the ignition switch and hand-held tester ON. Clear DTCs. Allow the vehicle to drive, in accordance with the applicable drive pattern described in the READINESS MONITOR DRIVE PATTERN section (see page 05-26 ). (e) MONITOR RESULT CATALYST#1 B1 . INCMP CATALYST#1 B2 . INCMP O2S HEAT B1S1 . INCMP
O2S HEAT B1S2 . INCMP O2S HEAT B2S1 . INCMP O2S HEAT B2S2 . INCMP THERMOSTAT . . . . . PASS

Press [ENTER] to Select the Label . Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBDII, MONITOR INFO and MONITOR RESULT. The monitor result appears after the component name. INCMP indicates the component has not been monitored yet. PASS indicates the component is functioning normally. FAIL indicates the component is malfunctioning. A82674 (f) Thermostat malfunction VAL. . . . . . . . . . . . . . 119.375C LMT. . . . . . . . . . . . . . . 75.000C


TLT. . . . . . . . . . . . . . . . . . . . . . 1 (g)
[HELP] to notice [EXIT] to return A82675

Select the component and press ENTER. If the monitor result has been PASS or FAIL, the accuracy test value appears. VAL indicates the test value. LMT indicates the test limit (malfunction criterion). TLT indicates the test limit type. Compare the test value with the test limit. If TLT is 0, the component is malfunctioning when the test value is higher than the test limit. If TLT is 1, the component is malfunctioning when the test value is lower than the test limit. If the test value is on the borderline of the test limit, a malfunction is concealed in the component. HINT: The monitor result might on rare occasions be PASS even if the malfunction indicator lamp (MIL) is illuminated. This indicates the system malfunctioned on a previous driving cycle. This might be caused by an intermittent problem. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 215 05-9 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05ESK-05 CHECK FOR INTERMITTENT PROBLEMS Hand-held tester only: Inspect the vehicle’s ECM using check mode. Intermittent problems are easier to detect when the ECM is in check mode with the hand-held tester. In check mode, the ECM uses 1 trip detection logic, which has a higher sensitivity to malfunctions than normal mode (default), which uses 2 trip detection logic. (a) Clear the DTCs (see page 05-38 ). (b) Set the check mode (see page 05-40 ). (c) Perform a simulation test (see page 01-26 ). (d) Check the connector and terminal (see page 01-36 ). (e) Wiggle the harness and the connector (see page 01-36 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 199 05-40 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05ITD-02 CHECK MODE PROCEDURE Hand-held Tester DLC3 HINT: Hand-held tester only: Check mode has a higher sensitivity to malfunctions and can detect malfunctions that normal mode cannot detect. Check mode can also detect all the malfunctions that normal mode can detect. 1. CHECK MODE PROCEDURE (Using the hand-held tester) (a) Make sure that the items below are true: (1) Battery positive voltage 11 V or more (2) Throttle valve fully closed (3) Transmission in the P or N position (4) A/C switched OFF (b) Turn the ignition switch OFF. (c) Connect the hand-held tester to the DLC3. (d) Turn the ignition switch ON. A80020 (e) 0.13 seconds ON OFF 0.13 seconds A76900 Change the ECM to check mode with the hand-held tester. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / CHECK MODE. Make sure the MIL flashes as shown in the illustration. NOTICE: All DTCs and freeze frame data recorded will be erased if: 1) the hand-held tester is used to change the ECM from normal mode to check mode or vice-versa; or 2) during check mode, the ignition switch is turned from ON to ACC or OFF. (f) Start the engine. The MIL should turn off after the engine starts. (g) Simulate the conditions of the malfunction described by the customer. (h) After simulating the malfunction conditions, use the hand-held tester diagnosis selector to check the DTC, freeze frame data and other data. (1) After checking the DTC, inspect the applicable circuit. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 230 05-41 DIAGNOSTICS 2. (a) (b) (c) 3. Engine Room J/B (a) EFI NO. 1 - SFI SYSTEM (2AZ-FE) CLEAR DTC (Using the OBD II scan tool or hand-held tester) Connect the OBD II scan tool or the hand-held tester to the DLC3. Turn the ignition switch ON. Erase DTCs and freeze frame data with the OBD II scan tool (complying with SAE J1978) or the hand-held tester. For the hand-held tester: 1) enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CLEAR CODES; and 2) press YES. For the OBD II scan tool, see its instruction manual. CLEAR DTC (Not using the OBD II scan tool or handheld tester) Remove the EFI NO. 1 fuse from the engine room J/B and ETCS fuse from the engine room R/B No. 2 for more than 60 seconds. Or, disconnect the battery cable for more than 60 seconds. After disconnecting the battery terminal, perform the ”INITIALIZE” procedure (see page 05-893 ). Engine Room R/B No. 2 ETCS P A90343 A80017 A91474 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 231 05-1 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) SFI SYSTEM (2AZ-FE) 05ESI-05 DEFINITION OF TERMS Term Definition Monitor description Description of what the ECM monitors and how it detects malfunctions (monitoring purpose and its details). Related DTCs A group of diagnostic trouble codes that are output by the ECM based on the same malfunction detection logic. Typical enabling condition Preconditions that allow the ECM to detect malfunctions. With all preconditions satisfied, the ECM sets the DTC when the monitored value(s) exceeds the malfunction threshold(s). Sequence of operation The priority order that is applied to monitoring, if multiple sensors and components are used to detect the malfunction. When a sensor is being monitored, the next sensor or component will not be monitored until the current sensor monitoring is finished. Required sensor/components The sensors and components that are used by the ECM to detect malfunctions. Frequency of operation The number of times that the ECM checks for malfunctions per driving cycle. ”Once per driving cycle” means that the ECM detects the malfunction only one time during a single driving cycle. ”Continuous” means that the ECM detects the malfunction every time an enabling condition is met. Duration The minimum time that the ECM must sense a continuous deviation in the monitored value(s) before setting a DTC. This timing begins after the ”typical enabling conditions” are met. Malfunction thresholds Beyond this value, the ECM will conclude that there is a malfunction and set a DTC. MIL operation MIL illumination timing after a defect is detected. ”Immediate” means that the ECM illuminates the MIL the instant the ECM determines that there is a malfunction. ”2 driving cycles” means that the ECM illuminates the MIL if the same malfunction is detected again in the 2nd driving cycle. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 191 05-35 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05ESO-05 DIAGNOSIS SYSTEM 1. DESCRIPTION When troubleshooting On-Board Diagnostic (OBD II) vehicles, the vehicle must be connected to the OBD II scan tool (in compliance with SAE J1978) or the hand-held tester. Various data output from the vehicle’s ECM can then be read.
OBD II regulations require that the vehicle’s on-board computer illuminates the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in: 1) the emission control system/components, or 2) the powertrain control components (which affect vehicle emissions), or 3) the computer. In addition, the applicable Diagnostic Trouble Codes (DTCs) prescribed by SAE J2012 are recorded in the ECM memory (see page 05-48 ). If the malfunction does not reoccur in 3 consecutive trips, the MIL turns off automatically but the DTCs remain recorded in the ECM memory.
FI0534
Hand-held Tester DLC3 A80020
To check DTCs, connect the hand-held tester or OBD II scan tool to the Data Link Connector 3 (DLC3) of the vehicle. The hand-held tester or OBD II scan tool also enables you to erase the DTC and check the freeze frame data and various forms of engine data (see the instruction manual for the OBD II scan tool or the hand-held tester). The DTC includes SAE controlled codes and manufacturer controlled codes. SAE controlled codes must be set according to the SAE, while manufacturer controlled codes can be set by a manufacturer with certain restrictions (see the DTC chart on page 05-48 ). The diagnosis system operates in ”normal mode” during normal vehicle use. In ”normal mode”, 2 trip detection logic* is used to ensure accurate detection of malfunctions. A ”check mode” is also available to technicians as an option. In ”check mode”, 1 trip detection logic is used for simulating malfunction symptoms and increasing the system’s ability to detect malfunctions, including intermittent malfunctions (hand-held tester only) (see page 05-40 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 225 05-36 DIAGNOSTICS - SFI SYSTEM (2AZ-FE)
*2 trip detection logic: When a malfunction is first detected, the malfunction is temporarily stored in the ECM memory (1st trip). If the ignition switch is turned OFF and then ON again, and the same malfunction is detected again, the MIL will illuminate (2nd trip).
Freeze frame data: The freeze frame data records the engine conditions (fuel system, calculated load, engine coolant temperature, fuel trim, engine speed, vehicle speed, etc.) when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. Priorities for troubleshooting: When multiple DTCs occur, find out the order in which the DTCs should be inspected by checking the component’s DTC chart. If no instructions are written in the DTC chart, check DTCs in the following order of priority: (a) DTCs other than fuel trim malfunction DTCs (P0171 and P0172) and misfire DTCs (P0300 to P0304). (b) Fuel trim malfunction DTCs (P0171 and P0172). (c) Misfire DTCs (P0300 to P0304). 2. CG SG SIL 1 2 3 4 5 6 7 8 9 10111213141516 DLC3 CHECK DLC3 The vehicle’s ECM uses the ISO 9141-2 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 9141-2 format. BAT A04550 Symbol Terminal No. Name Reference terminal Result Condition SIL 7 Bus ”+” line 5 - Signal ground Pulse generation During transmission CG 4 Chassis ground Body ground Below 1 Ω Always SG 5 Signal ground Body ground Below 1 Ω Always BAT 16 Battery positive Body ground 9 to 14 V Always 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 226 05-37 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) HINT: Connect the cable of the OBD II scan tool or the hand-held tester to the DLC3, turn the ignition switch ON and attempt to use the OBD II scan tool or the hand-held tester. If the screen displays UNABLE TO CONNECT TO VEHICLE, a problem exists in the vehicle side or the tester side.
If the communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle.
If the communication is still impossible when the tool is connected to another vehicle, the problem is probably in the tool itself. Consult the Service Department listed in the tool’s instruction manual. 3. CHECK BATTERY VOLTAGE Standard: 11 to 14 V If the voltage is below 11 V, recharge the battery before proceeding. 4. CHECK MIL (a) The MIL turns on when the ignition switch is turned ON and the engine is not running. HINT: If the MIL does not turn on, troubleshoot the MIL circuit (see page 05-359 ). (b) When the engine is started, the MIL should turn off. If the lamp remains on, the diagnosis system has detected a malfunction or abnormality in the system. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 227 05-43 DIAGNOSTICS - SFI SYSTEM (2AZ-FE)(From August, 2004) 05ESS-05 DATA LIST/ACTIIVE TEST/SYSTEM CHECK/SYSTEM CHECK 1. DATA LIST HINT: Using the hand-held tester DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to shorten labor time. NOTICE: In the table below, the values listed under ”Normal Condition” are reference values. Do not depend solely on the these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the hand-held tester or the OBD II scan tool to the DLC3. (d) Turn the ignition switch ON. (e) Turn ON the hand-held tester or the OBD II scan tool. (f) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST. (g) According to the display on tester, read the ”DATA LIST”. Hand-held Tester Display Measurement Item/Range (Display) Normal Condition* Diagnostic Note Injection period/ Minimum: 0 ms, Maximum: 32.64 ms Idling: 1.92 to 3.37 ms - Ignition timing advance/ Minimum: -64 deg., Maximum: 63.5 deg. Idling: BTDC 5 to 15 deg. - Calculated load by ECM/ Minimum: 0 %, Maximum: 100 %
Idling: 3.3 to 26.7 %
Racing without load (2500 rpm): 12.0 to 14.7 % - MAF Air flow rate from MAF meter/ Minimum: 0 gm/s, Maximum: 655 gm/s
Idling: 0.58 to 4.67 gm/second
Racing without load (2,500 rpm): 3.33 to 9.17 gm/second If value is approximately 0.0 gm/s:
Mass air flow meter power source circuit open
VG circuit open or short If value is 160.0 gm/s or more:
EVG circuit open ENGINE SPD Engine Speed/ Minimum: 0 rpm, Maximum: 16,383 rpm Idling: 550 to 750 rpm INJECTOR IGN ADVANCE CALC LOAD - After warming up: 80 to 95°C (176 to 203°F)
If value is -40C (-40F): sensor circuit is open
If value is 140C (284F) or more: sensor circuit is shorted Intake air temperature/ Minimum: -40C, Maximum: 140C Equivalent to ambient temperature (after cold soak)
If value is -40C (-40F): sensor circuit is open
If value is 140C (284F) or more: sensor circuit is shorted Absolute throttle position sensor/ Minimum: 0 %, Maximum: 100 %
Throttle fully closed: 6 to 16 %
Throttle fully open: 64 to 98 % Read value with ignition switch ON (do not start engine) Closed throttle position switch/ ON or OFF
Throttle fully closed: ON
Throttle open: OFF VEHICLE SPD Vehicle speed/ Minimum: 0 km/h, Maximum: 255 km/h Vehicle stopped: 0 km/h (0 mph) Speed indicated on speedometer ACCEL POS #1 Accelerator pedal position sensor No.1 output voltage/ Minimum: 0 V, Maximum: 5 V
Accelerator released: 0.5 to 1.1 V
Accelerator depressed: 2.6 to 4.5 V Read value with ignition switch ON (do not start engine) ACCEL POS #2 Accelerator pedal position sensor No. 2 output voltage/ Minimum: 0 V, Maximum: 5 V
Accelerator released: 1.2 to 2.0 V
Accelerator depressed: 3.4 to 5.3 V Read value with ignition switch ON (do not start engine) COOLANT TEMP INTAKE AIR THROTTLE POS CTP SW Coolant temperature/ Minimum: -40C, Maximum: 140C Author
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: 233 05-44 DIAGNOSTICS - SFI SYSTEM (2AZ-FE)(From August, 2004) Hand-held Tester Display Measurement Item/Range (Display) THROTTLE POS #2 Throttle position sensor No. 2 output voltage/ Minimum: 0 V, Maximum: 5 V
Throttle fully closed: 2.1 to 3.1 V
Throttle fully open: 4.5 to 5.5 V Read value with ignition switch ON (do not start engine) THROTTLE TARGT Target position of throttle valve/ Minimum: 0 V, Maximum: 5 V Idling: 0.4 to 1.1 V Read value with ignition switch ON (do not start engine) Throttle fully closed: 0 %
When accelerator pedal is depressed, duty ratio is increased
Read value with ignition switch ON (do not start engine) Normal Condition* Diagnostic Note THROTTLE OPN DUTY Throttle actuator opening duty ratio/ Minimum: 0 %, Maximum: 100 % THROTTLE CLS DUTY Throttle actuator closed duty ratio/ Minimum: 0 %, Maximum: 100 % Throttle fully open: 0 %
When accelerator pedal is quick released, duty ratio is increased
Read value with ignition switch ON (do not start engine) Whether or not throttle actuator control is permitted/ ON or OFF Idling: ON Read value with ignition switch ON (do not start engine) Whether or not electric throttle control system power is input/ ON or OFF Idling: ON - Vapor Pressure/ Minimum: 97.175 kPa, Maximum: 103.425 kPa Usable range: 60 to 110 kPa Pressure inside of fuel tank as read by vapor pressure sensor Idling: 0.1 to 0.9 V Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check voltage output of each sensor Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables technician to check voltage output of each sensor THROTTLE MOT +BM VAPOR PRESS O2S B1 S2 Oxygen sensor output voltage of the bank 1 sensor 2/ Minimum: 0 V, Maximum: 1.275 V AFS B1 S1 A/F sensor output voltage of the bank 1 sensor 1/ Minimum: 0 V, Maximum: 7.999 V Idling: 2.8 to 3.8 V ACCEL IDL POS Whether or not accelerator pedal position sensor is detecting idle/ ON or OFF Idling: ON  THROTTLE IDL POS Whether or not throttle position sensor is detecting idle/ ON or OFF Idling: ON  FAIL #1 Whether or not fail safe function is executed/ ON or OFF ETCS has failed: ON  FAIL #2 Whether or not fail safe function is executed/ ON or OFF ETCS has failed: ON  THROTTLE INITIAL Throttle fully closed (learned value) Minimum: 0 V, Maximum: 5 V 0.5 to 0.9 V  ACCEL LEARN VAL Accelerator fully closed (learned value) Minimum: 0 V, Maximum: 5 V 0.4 to 0.8 V  Throttle motor current Minimum: 0 A, Maximum: 20 A Idling: 0 to 3.0 A  Short term fuel trim of bank 1/ Minimum: -100 %, Maximum: 100 % 0 ± 20 % This item is short-term fuel compensation used to maintain air-fuel ratio at stoichiometric air-fuel ratio This item is overall, long-term fuel compensation that helps to maintain air-fuel ratio at stoichiometric air fuel ratio (steadies long term deviations of short-term fuel trim from central value). THROTTLE MOT SHORT FT #1 LONG FT #1 Long term fuel trim of bank 1/ Minimum: -100 %, Maximum: 100 % 0 ± 20 % TOTAL FT #1 Total fuel trim of bank 1/ Minimum: 0.5, Maximum: 1.496 Idling: 0.5 to 1.4 Author
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: 234 05-45 DIAGNOSTICS Hand-held Tester Display Measurement Item/Range (Display) AF FT B1 S1 Short term fuel trim associated with bank 1, sensor 1/ Minimum: 0, Maximum: 1.999 - SFI SYSTEM (2AZ-FE)(From August, 2004) Normal Condition* Diagnostic Note
Value less than 1 (0.000 to 0.999) = LEAN
Stoichiometric Air-Fuel Ratio=1
Value greater than 1 (1.001 to 1.999) = RICH - Fuel system status (Bank 1) / OL or CL or OL DRIVE or OL FAULT or CL FAULT Idling after warming up: CL
OL (Open Loop) : Has not yet satisfied conditions to go closed loop
CL (Closed Loop) : Using heated oxygen sensor(s) as feed back for fuel control
OL DRIVE: Open loop due to driving conditions (fuel enrichment)
OL FAULT: Open loop due to detected system fault
CL FAULT: Closed loop but one of heated oxygen sensors, which is used for fuel control, is malfunctioning FC IDL Idle fuel cut/ ON or OFF Fuel cut operation: ON FC IDL = ON when throttle valve is fully closed and engine speed is over 1,500 rpm MIL MIL status/ ON or OFF MIL ON: ON - Starter signal/ ON or OFF Cranking: ON - A/C signal/ ON or OFF A/C ON: ON - PNP switch signal/ ON or OFF P or N position: ON - Electrical load signal/ ON or OFF Defogger switch ON: ON - Stop lamp switch/ ON or OFF
Brake pedal depressed: ON
Brake pedal released: OFF - Power steering signal/ ON or OFF
While turning steering wheel: ON
While not turning steering wheel: OFF Idle-up control is performed when PS is ON Power steering signal/ ON or OFF When steering wheel is turned This signal is usually ON until Ignition switch is turned OFF FUEL PUMP / SPD Fuel pump / speed status / ON/H or OFF/M,L Idling: ON - A/C MAG CLUTCH A/C magnet clutch status / ON or OFF A/C magnet clutch ON: ON - EVAP VSV EVAP VSV status control / ON or OFF VSV operating: ON VVT CTRL B1 VVT control status (Bank 1) / ON or OFF VVT system operation: ON - IGNITION Ignition counter/ Minimum: 0, Maximum: 400 0 to 400 - Misfire ratio of cylinder 1 to 4/ Minimum: 0 %, Maximum: 50 % 0% MISFIRE LOAD Engine load for first misfire range/ Minimum: 0 g/rev, Maximum: 3.98 g/rev. Misfire 0: 0 g/rev.  MISFIRE RPM Engine RPM for first misfire range/ Minimum: 0 rpm, Maximum: 6,375 rpm Misfire 0: 0 rpm  FC TAU Fuel Cut TAU: Fuel cut during very light load/ ON or OFF Fuel cut operating: ON Fuel cut is being performed under very light load to prevent engine combustion from becoming incomplete Check mode/ ON or OFF Check mode ON: ON See page 05-40 FUEL SYS #1 STARTER SIG A/C SIG PNP SW [NSW] ELECT LOAD SIG STOP LIGHT SW PS OIL PRESS SW PS SIGNAL CYL #1, #2, #3, #4 CHECK MODE EVAP VSV is controlled by ECM (ground side duty control) This item is displayed in only idling Author
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: 235 05-46 DIAGNOSTICS - SFI SYSTEM (2AZ-FE)(From August, 2004) HINT: *: If no conditions are specifically stated for ”ldling”, the shift lever is in the N or P position, the A/C switch is OFF and all accessory switches are OFF. 2. ACTIVE TEST HINT: Performing the hand-held tester ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to shorten labor time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the hand-held tester or the OBD II scan tool to the DLC3. (d) Turn the ignition switch ON. (e) Turn ON the hand-held tester or the OBD II scan tool. (f) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST. (g) According to the display on tester, perform the ”ACTIVE TEST. Hand-held Tester Display INJ VOL A/F CONTROL Test Details Diagnostic Note [Test Details] Control injection volume Minimum: -12.5 %, Maximum: 25 % [Vehicle Condition] Engine speed: 3000 rpm or less
All injectors are tested at once
Injection volume is gradually changed between -12.5 and 25 % [Test Details] Control injection volume -12.5 or 25 % (change the injection volume -12.5 % or 25 %) [Vehicle Condition] Engine speed: 3000 rpm or less Following A/F CONTROL procedure enables technician to check and graph voltage outputs of both A/F sensor and heated oxygen sensor For displaying the graph, enter ”ACTIVE TEST / A/F CONTROL / USER DATA”, select ”AFS B1S1 and O2S B1S2” by pressing ”YES” and push ”ENTER”, Then press ”F4” EVAP VSV (ALONE) [Test Details] Activate EVAP VSV control ON or OFF - A/C MAG CLUTCH [Test Details] Control A/C magnet clutch ON or OFF - FUEL PUMP / SPD [Test Details] Control fuel pump ON or OFF - [Test Details] Vacuum pump ON or OFF - [Test Details] Vent valve ON or OFF - VCUUM PUMP (ALONE) VENT VALVE (ALONE) VVT CTRL B1 TC/TE1 FC IDL PROHBT [Test Details] Activate VVT system (Bank 1) ON or OFF
ON: Rough idle or engine stall
OFF: Normal engine speed [Test Details] Connect TC and TE1 ON or OFF - [Test Details] Control idle fuel cut prohibit ON or OFF - Author
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: 236 05-47 DIAGNOSTICS Hand-held Tester Display TC/TE1 FC IDL PROHBT - SFI SYSTEM (2AZ-FE)(From August, 2004) Test Details Diagnostic Note [Test Details] Connect TC and TE1 ON or OFF - [Test Details] Control idle fuel cut prohibit ON or OFF - 3. SYSTEM CHECK HINT: Performing the hand-held tester SYSTEM CHECK allows the system which is composed of multiple actuators to be operated without removing any parts. Operate the system by performing SYSTEM CHECK and check for DTCs. And, potential malfunctions in the system can be detected on the tester. (a) Connect the hand-held tester to the DLC3. (b) Turn ON the ignition switch and the hand-held tester. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK. (d) According to the display on the tester, perform the ”SYSTEM CHECK. Hand-held Tester Display EVAP SYS CHECK (AUTO OPERATION) EVAP SYS CHECK (MANUAL OPERATION) Test Details Diagnostic Note EVAP key-off monitor is operated automatically by performing 7 steps in order. Fuel temperature: 35C (95F) or less is recommended
If there is no DTC displayed on PENDING DTC after SYSTEM CHECK, system is functioning normally Refer to EVAP INSPECTION PROCEDURE (on page 05-317 ) EVAP key-off monitor is operated manually by performing 7 steps in order. Fuel temperature: 35C (95F) or less is recommended
Used to detect a malfunctioning part Refer to EVAP INSPECTION PROCEDURE (on page 05-317 ) Author
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: 237 05-38 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05ESP-05 DTC CHECK/CLEAR Hand-held Tester DLC3 A80020 NOTICE:
If no DTC appears in normal mode: On the OBD II scan tool or the hand-held tester check the pending fault code using the Continuous Test Results function (Mode 7 for SAE J1979).
When the diagnosis system is changed from normal mode to check mode or vice-versa, all DTCs and freeze frame data recorded in normal mode will be erased. Before changing modes, always check and make a note of DTCs and freeze frame data. 1. CHECK DTC (Using the OBD II scan tool or hand-held tester) (a) Connect the OBD II scan tool or hand-held tester to the DLC3. (b) Turn the ignition switch ON. (c) Use the OBD II scan tool or the hand-held tester to check the DTCs and freeze frame data and then write them down. For the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. For the OBD II scan tool, see its instruction manual. (d) See page 05-48 to confirm the details of the DTCs. NOTICE: When simulating a symptom with the OBD II scan tool (excluding hand-held tester) to check for DTCs, use the normal mode. For DTCs subject to ”2 trip detection logic”, perform either of the following actions.
Turn the ignition switch OFF after the symptom is simulated once. Then repeat the simulation process again. When the problem has been simulated twice, the MIL illuminates and the DTCs are recorded in the ECM.
Check the pending fault code using the Continuous Test Results function (Mode 7 for SAE J1979) on the OBD II scan tool. 2. CLEAR DTC (Using the OBD II scan tool or hand-held tester) (a) Connect the OBD II scan tool or the hand-held tester to the DLC3. (b) Turn the ignition switch ON. (c) Erase DTCs and freeze frame data with the OBD II scan tool (complying with SAE J1978) or the hand-held tester. For the hand-held tester: 1) enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CLEAR CODES; and 2) press YES. For the OBD II scan tool, see its instruction manual. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 228 05-39 DIAGNOSTICS 3. Engine Room J/B (a) EFI NO. 1 - SFI SYSTEM (2AZ-FE) CLEAR DTC (Not using the OBD II scan tool or handheld tester) Remove the EFI NO. 1 fuse from the engine room J/B and ETCS fuse from the engine room R/B No. 2 for more than 60 seconds. Or, disconnect the battery terminal for more than 60 seconds. After disconnecting the battery cable, perform the ”INITIALIZE” procedure (see page 05-893 ). Engine Room R/B No. 2 ETCS P A90343 A80017 A91474 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 229 05-312 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05EVZ-05 ECM POWER SOURCE CIRCUIT CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery voltage is applied to terminal IGSW of the ECM. The ECM ”MREL” output signal causes current to flow to the coil, closing the contacts of the EFI relay (Marking: EFI) and supplying power to terminal +B of the ECM. If the ignition switch is turned OFF, the ECM holds the EFI relay ON for a maximum of 2 seconds to allow for the initial setting of the throttle valve. WIRING DIAGRAM Instrument Panel J/B Assy 1 GR IGN 6 4 1G 1C Passenger Side J/B W 1 4M ECM J6 J/C P 4E P E E 9 E5 IGSW 6 IG2 I15 Ignition Switch AM2 7 Y 1 IC1 L-Y F7 10 FL Block Assy AM2 Engine Room J/B 1 3 W 2I EFI Relay EFI NO. 1 5 3 4 10 W 2B W IK2 1 E5 +B 1 W FL Main W-B 4 5 2F 2B 2 1 13 IK3 P-L B 8 E5 BR 1 E9 J7 J/C A BR A A J2 J/C MREL E1 Battery EH EE A90306 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 502 05-313 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) INSPECTION PROCEDURE 1 INSPECT ECM (+B VOLTAGE) E1 (-) E9 ECM (a) (b) +B (+) E5 ECM Turn the ignition switch ON. Measure the voltage between of the ECM connectors. Standard: OK A67446 Tester Connection Specified Condition E5-1 (+B) - E9-1 (E1) 9 to 14 V PROCEED TO NEXT CIRCUIT INSPECTION SHOWN ON PROBLEM SYMPTOMS TABLE (See page 05-31 ) NG 2 CHECK WIRE HARNESS (ECM - BODY GROUND) (a) (b) Wire Harness Side Disconnect the E9 ECM connector. Measure the resistance of the wire harness side connectors. Standard: E1 E9 ECM A81698 NG Tester Connection Specified Condition E9-1 (E1) - Body ground Below 1 Ω REPAIR OR CONNECTOR REPLACE HARNESS AND OK 3 INSPECT ECM (IGSW VOLTAGE) E1 (-) E9 ECM IGSW (+) E5 ECM A67446 (a) (b) Turn the ignition switch ON. Measure the voltage of the ECM connectors. Standard: OK Tester Connection Specified Condition E5-9 (IGSW) - E9-1 (E1) 9 to 14 V Go to step 6 NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 503 05-314 DIAGNOSTICS 4 - SFI SYSTEM (2AZ-FE) CHECK FUSE (IGN) (a) (b) Instrument Panel J/B Assy Remove the IGN fuse from the instrument panel J/B Assy. Measure the resistance of the IGN fuse. Standard: Below 1 Ω IGN Fuse A90344 NG REPLACE FUSE OK 5 INSPECT IGNITION OR STARTER SWITCH ASSY (a) I15 Ignition Switch 4 3 2 1 8 7 6 5 Measure the resistance of the ignition switch terminals. Standard: Switch Condition Tester Condition Specified Condition LOCK 6 (IG2) - 7 (AM2) 10 kΩ or higher ON 6 (IG2) - 7 (AM2) Below 1 Ω NG AM2 IG2 A56879 REPLACE IGNITION OR STARTER SWITCH ASSY OK CHECK AND REPAIR HARNESS AND CONNECTOR (BATTERY - IGNITION SWITCH, IGNITION SWITCH - ECM) 6 INSPECT ECM (MREL VOLTAGE) E1 (-) E9 ECM MREL (+) E5 ECM A67446 (a) (b) Turn the ignition switch ON. Measure the voltage of the ECM connectors. Standard: NG Tester Connection Specified Condition E5-8 (MREL) - E9-1 (E1) 9 to 14 V REPLACE ECM (See page 10-9 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 504 05-315 DIAGNOSTICS 7 - SFI SYSTEM (2AZ-FE) CHECK FUSE (EFI NO. 1) (a) (b) Engine Room J/B EFI NO. 1 fuse A90343 Remove the EFI NO. 1 fuse from the engine room J/B. Measure the resistance of the EFI NO. 1 fuse. Standard: Below 1 Ω NG REPLACE FUSE OK 8 INSPECT RELAY (EFI) 1 3 1 5 2 2 5 (a) (b) Remove the EFI relay from the engine room J/B. Measure the resistance of the EFI relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 3 B60778 NG REPLACE RELAY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 505 05-316 DIAGNOSTICS 9 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS (EFI RELAY - ECM, EFI RELAY - BODY GROUND) Wire Harness Side Engine Room J/B (a) Check the wire harness between the EFI relay and ECM. (1) Remove the EFI relay from the engine room J/B. (2) Disconnect the E5 ECM connector. (3) Measure the resistance of the wire harness side connectors. Standard: Tester Connection EFI Relay (b) E5 ECM A90291 A67445 MREL A92643 Specified Condition J/B EFI relay terminal 1 - E5-8 (MREL) Below 1 Ω J/B EFI relay terminal 1 or E5-8 (MREL) - Body ground 10 kΩ or higher Check the wire harness between the EFI relay and body ground. (1) Remove the EFI relay from the engine room J/B. (2) Measure the resistance of the wire harness side connector and the body ground. Standard: OK Tester Connection Specified Condition J/B EFI relay terminal 2 - Body ground Below 1 Ω REPAIR OR CONNECTOR REPLACE HARNESS AND NG CHECK AND REPAIR HARNESS AND CONNECTOR (TERMINAL +B OF ECM - BATTERY POSITIVE TERMINAL) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 506 05-317 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05IRG-02 EVAP INSPECTION PROCEDURE DTCS RELATING TO EVAP SYSTEM DTCs Monitoring Items See Page P043E 0.02 inch orifice clogged (built into pump module) 05-190 P043F 0.02 inch orifice high-flow (built into pump module) 05-190 P0441
Purge VSV (Vacuum Switching Valve) stuck closed
Purge VSV stuck open
Purge flow 05-196 P0450 Pressure sensor (built into pump module) voltage abnormal fluctuation 05-202 P0451
Pressure sensor (built into pump module) noising
Pressure sensor stuck (built into pump module) 05-202 P0452 Pressure sensor (built into pump module) voltage low 05-202 P0453 Pressure sensor (built into pump module) voltage high 05-202 P0455 EVAP gross leak 05-211 P0456 EVAP small leak 05-211 P2401 Vacuum pump stuck OFF (built into pump module) 05-288 P2402 Vacuum pump stuck ON (built into pump module) 05-288 P2419 Vent valve stuck closed (built into pump module) 05-294 P2420 Vent valve stuck open (vent) (built into pump module) 05-294 P2610 Soak timer (built into ECM) 05-300 If any EVAP system DTCs are set, the malfunctioning area can be determined using the table below. DTCs Malfunctioning Areas P043E P043F P0441 P0450 P0451 P0452 P0453 P0455 P0456 P2401 P2402 P2419 P2420 0.02 inch orifice clogged 0.02 inch orifice high-flow Purge VSV stuck open Purge VSV stuck closed Pressure sensor stuck Pressure sensor noise Pressure sensor low output Pressure sensor high output Gross leak Small leak Vacuum pump stuck OFF Vacuum pump stuck ON Vent valve stuck closed Vent valve stuck open (vent) NOTICE: If the 0.02 inch reference pressure difference between the first and second checks is greater than the specification, the DTCs corresponding to the reference pressure (P043E, P043F, P0441, P0455, P0456, P2401, P2420) will be all stored. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 507 05-318 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) CIRCUIT DESCRIPTION Location of EVAP (Evaporative Emission) system: Pump Module Pressure Sensor Vacuum Pump Canister EVAP Hose (To Throttle Body) Vent Valve Air Filter Purge Line Refueling Valve EVAP Hose (From Canister) Purge VSV Fuel Tank Fuel Cap A93865 EVAP System Circuit Air Cleaner Throttle Valve ECM Soak Timer Intake Manifold Purge VSV Pump Module (refer to fig. 1) Fuel Cap Air Filter Canister Refueling Valve Service Port Restrictor (0.08 inch) Roll-over Valve Cut-of f Valve Fuel Tank A93866 While the engine is running, if a predetermined condition (closed-loop, etc.) is met, the purge VSV is opened by the ECM and stored fuel vapors in the canister are purged to the intake manifold. The ECM changes the duty cycle ratio of the purge VSV to control purge flow volume. The purge flow volume is also determined by the intake manifold pressure. Atmospheric pressure is allowed into the canister through the vent valve to ensure that the purge flow is maintained when the negative pressure (vacuum) is applied to the canister. The following two monitors run to confirm appropriate EVAP system operation. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 508 05-319 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) Key-off monitor This monitor checks for EVAP (Evaporative Emission) system leaks and pump module malfunctions. The monitor starts 5 hours* after the ignition switch is turned OFF. More than 5 hours are required to allow enough time for the fuel to cool down to stabilize the Fuel Tank Pressure (FTP), thus making the EVAP system monitor more accurate. The electric vacuum pump creates negative pressure (vacuum) in the EVAP system and the pressure is measured. Finally, the ECM monitors for leaks from the EVAP system, and malfunctions in both the pump module and purge VSV, based on the EVAP pressure. HINT: *:If the engine coolant temperature is not below 35C 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later. If it is still not below 35C 7 hours after the ignition switch is turned off, the monitor check starts 2.5 hours later. Purge flow monitor The purge flow monitor consists of the two monitors. The 1st monitor is always conducted every time and the 2nd monitor is activated if necessary.
The 1st monitor While the engine is running and the purge VSV (Vacuum Switching Valve) is ON (open), the ECM monitors the purge flow by measuring the EVAP pressure change. If negative pressure is not created, the ECM begins the 2nd monitor.
The 2nd monitor The vent valve is turned ON (closed) and the EVAP pressure is then measured. If the variation in the pressure is less than 0.5 kpa (3.75 mmHg), the ECM interprets this as the purge VSV being stuck closed, and illuminates the MIL and sets DTC P0441 (2 trip detection logic). Atmospheric pressure check: In order to ensure reliable malfunction detection, the variation between the atmospheric pressures, before and after conduction of the purge flow monitor, is measured by the ECM. EVAP Purge Flow: fuel tank cap Refueling Valve To Atmosphere Purge VSV (ON) Fuel Tank 0.02 Inch Orifice Canister Pressure Sensor To Intake Manifold Air Filter ECM Vent Valve (OFF) Vacuum Pump (OFF) Pump Module Soak Timer A97610 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 509 05-320 DIAGNOSTICS Components - SFI SYSTEM (2AZ-FE) Operations Canister Contains activated charcoal to absorb EVAP (Evaporative Emissions) generated in fuel tank. Cut-of f valve Located in fuel tank. Valve floats and closes when fuel tank is 100 % full. Purge VSV (Vacuum Switching Valve) Opens or closes line between canister and intake manifold. ECM uses purge VSV to control EVAP purge flow. In order to discharge EVAP absorbed by canister to intake manifold, ECM opens purge VSV. EVAP discharge volume to intake manifold controlled by purge VSV duty cycle ratio (current-carrying time). (Open: ON, Close: OFF) Refueling valve Controls EVAP pressure from fuel tank to canister. Valve consists of diaphragm, spring and restrictor (diameter: 0.08 inch). When fuel vapor and pressure inside fuel tank increase, valve opens. While EVAP purged, valve closes and restrictor prevents large amount of vacuum from affecting pressure in fuel tank. Valve opened while refueling. When valve open, adding fuel into fuel tank possible. Roll-over valve Located in fuel tank. Valve closes by its own weight when vehicle overturns to prevent fuel from spilling out. Service port Used for connecting vacuum gauge for inspecting EVAP system. Soak timer Built into ECM. To ensure accurate EVAP monitor, measures 5 hours* after ignition switch turned to OFF. This allows fuel to cool down, stabilizing Fuel Tank Pressure (FTP). When apprx. 5 hours* elapsed, ECM activates. Pump module Consists of (a) to (d) below. Pump module cannot be disassembled. (a) Vent valve Vents and closes EVAP system. When ECM turns valve ON, EVAP system closed. When, ECM turns valve OFF, EVAP system vented. Negative pressure (vacuum) created in EVAP system to check for EVAP leaks by closing purge VSV, turning on vent valve (closed) and operating vacuum pump (refer to fig. 1). (b) Pressure sensor Indicates pressure as voltages. ECM supplies regulated 5 V to pressure sensor, and uses feedback from sensor to monitor EVAP system pressure (refer to fig 2). (c) Vacuum pump Creates negative pressure (vacuum) in EVAP system for leak check. (d) 0.02 inch orifice Has opening with 0.02 inch diameter. Vacuum produced through orifice by closing purge VSV, turning off vent valve and operating vacuum pump, to monitor 0.02 inch leak pressure. 0.02 inch leak pressure indicates small leak of EVAP. HINT: *:If the engine coolant temperature is not below 35C after 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later. If it is still not below 35C 7 hours after the ignition switch is turned off, the monitor check starts 2.5 hours later. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 510 05-321 DIAGNOSTICS Pump Module (fig. 1) - SFI SYSTEM (2AZ-FE) : Airflow Condition: Leak Check Condition: Purge Flow Vent Valve: OFF (vent) Vent Valve: ON (closed) To Air Filter (Atmosphere) Canister 0.02 Inch Orifice Pressure Sensor From Refueling Valve Vacuum Pump: ON Vacuum Pump: OFF A97611 Pressure Sensor Specification (fig. 2) Malfunction Area Soak Timer Circuit (fig. 3) Ignition Switch Output Voltage ECM IGSW 4.900 V EFI MAIN +B Power Source IC MREL Main Relay Control IC 15 A 4.150 V Usable Range Battery 1.425 V Malfunction Area Soak Timer IC 0.450 V 60 kPa 110 kPa Pressure HINT: Standard atmospheric pressure is 101.3 kPa A71562 A85251 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 511 05-322 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) WIRING DIAGRAM C17 Pump Module Pressure Sensor ECM 16 BJ1 4 L 12 BJ1 3 Y BR Vacuum Pump 1 W 8 B W-B Y 17 BJ1 BR 13 BJ1 W 14 BJ1 R 18 BJ1 V 2 6 L Vent Valve 9 R 7 IO1 P 15 IO1 BR BJ1 15 12 IM1 16 IO1 SB GR 5 IM1 1 2I W FL MAIN A Battery BR B-R 28 E2 E7 4 MPMP E5 27 VPMP E5 Y-G 1 G 34 PRG E7 B 8 MREL E5 2 V4 Purge VSV B-R 2 BF 5 S29 LG 14 IM1 5V Engine Room J/B EFI No. 2 W-B J19 J/C 5 S28 BR VC 21 PPMP E5 L 4 IO1 5 IO1 18 E7 Y 3 IO1 1 EB1 B-R 13 IM1 2 EFI No. 1 4 2F W-B A EFI Relay 5 3 3 2D 2 1 5 2B Y P-L 13 IK3 J2 J/C EH A85256 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 512 05-323 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) INSPECTION PROCEDURE NOTICE: A hand-held tester is required to conduct the following diagnostic troubleshooting procedure. HINT:
Using hand-held tester monitor results enables the EVAP (Evaporative Emission) system to be confirmed.
Read freeze frame data using a hand-held tester Freeze frame data record the engine condition when malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data, from the time the malfunction occurred. 1 CONFIRM DTC (a) Turn the ignition switch OFF and wait 10 seconds. (b) Turn the ignition switch ON. (c) Turn the ignition switch OFF and wait 10 seconds. (d) Connect the hand-held tester to the DLC3. (e) Turn the ignition switch ON and press the hand-held tester switch ON. (f) Enter the following menus: DIAGNOSIS/ ENHANCED OBD II/ DTC INFO/ CURRENT CODES. (g) Confirm the DTCs and freeze frame data. If any EVAP system DTCs are set, the malfunctioning area can be determined using the table below. DTCs Malfunctioning Areas P043E P043F P0441 P0450 P0451 P0452 P0453 P0455 P0456 P2401 P2402 P2419 P2420 0.02 inch orifice clogged 0.02 inch orifice high-flow Purge VSV stuck open Purge VSV stuck closed Pressure sensor stuck Pressure sensor noise Pressure sensor low output Pressure sensor high output Gross leak Small leak Vacuum pump stuck OFF Vacuum pump stuck ON Vent valve stuck closed Vent valve stuck open (vent) NOTICE: If the 0.02 inch reference pressure difference between the first and second checks is greater than the specification, the DTCs corresponding to the reference pressure (P043E, P043F, P0441, P0455, P0456, P2401, P2420) will be all stored. NEXT 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 513 05-324 DIAGNOSTICS 2 - SFI SYSTEM (2AZ-FE) PERFORM EVAP SYSTEM CHECK(AUTO OPERATION) NOTICE:
In the EVAP SYSTEM CHECK (AUTO OPERATION), the series of 5 EVAP SYSTEM CHECK steps is performed automatically. It takes a maximum of approximately 18 minutes.
Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90% full because the cut-off valve may be closed and making the leak check of the fuel tank unavailable.
Do not run the engine in this step.
When the temperature of the fuel is 35C (95F) or more, a large amount of vapor forms and any check results become inaccurate. When performing the EVAP SYSTEM CHECK, keep the temperature below 35C (95F). (a) Clear DTCs (see page 05-38 ). (b) On the hand-held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (c) After the EVAP SYSTEM CHECK is completed, check for pending DTCs by selecting the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. HINT: If no pending DTC is displayed, perform the Monitor Confirmation after this repair is completed. After this confirmation, check for pending DTCs. If no DTC is displayed, the EVAP system is normal. NEXT 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 514 05-325 DIAGNOSTICS 3 - SFI SYSTEM (2AZ-FE) PERFORM EVAP SYSTEM CHECK(MANUAL OPERATION) EVAP SYSTEM CHECK ON: Open OFF: Closed ON Purge VSV Vent Valve ON Vacuum Pump ON ON: Closed OFF: Vent EVAP Pressure Positive Gross Leak Negative Second 0.02 inch Leak Pressure Standard x 0.2 Small Leak First 0.02 inch Leak Pressure Standard Steps Time (Reference) No Leak 1/5 10 sec Normal Pressure 5/5 4/5 2/5 3/5 60 sec Within 15 minutes 10 sec 60 sec G36782 NOTICE:
In the EVAP SYSTEM CHECK (MANUAL OPERATION), the series of 5 EVAP SYSTEM CHECK steps is performed manually.
Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90% full because the cut-off valve may be closed and making the leak check of the fuel tank unavailable.
Do not run the engine in this step.
When the temperature of the fuel is 35C (95F) or more, a large amount of vapor forms and any check results become inaccurate. When performing the EVAP SYSTEM CHECK, keep the temperature below 35C (95F). (a) Clear DTCs (see page 05-38 ). (b) On the hand-held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / MANUAL OPERATION. NEXT 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 515 05-326 DIAGNOSTICS 4 - SFI SYSTEM (2AZ-FE) PERFORM EVAP SYSTEM CHECK(STEP 1/5) ON: Open OFF: Closed ON Purge VSV Vent Valve ON Vacuum Pump ON ON: Closed OFF: Vent Pressure Sensor Noising EVAP Pressure Positive Negative OK First 0.02 inch Leak Pressure Standard Steps Time (Reference) 1/5 10 sec G36783 (a) Check the EVAP pressure in step 1/5. Result: DTCs* Test Results Suspected Trouble Areas Proceed To  Virtually no variation in EVAP pressure Not yet determined A P0451 EVAP pressure fluctuates by
0.3 kPa (2.25 mmHg) or more Pressure sensor noising B *: The DTCs relating to the EVAP system displayed on a hand-held tester when checking. B Go to step 30 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 516 05-327 DIAGNOSTICS 5 - SFI SYSTEM (2AZ-FE) PERFORM EVAP SYSTEM CHECK(STEP 1/5 TO 2/5) ON: Open OFF: Closed ON Purge VSV Vent Valve ON Vacuum Pump ON ON: Closed OFF: Vent EVAP Pressure Positive Negative Vacuum Pump Stuck ON First 0.02 inch Leak Pressure Standard Steps Time (Reference) 1/5 2/5 10 sec 60 sec G36784 (a) Check the EVAP pressure in step 1/5 and 2/5. Result: DTCs* Test Results Suspected Trouble Areas Proceed To  Virtually no variation in EVAP pressure during step 1/5. Then decreases to 0.02 inch leak pressure standard* Not yet determined A P2402 Small difference between EVAP pressures during steps 1/5 and 2/5 Vacuum pump stuck ON B *: The DTCs relating to the EVAP system displayed on a hand-held tester when checking. HINT: The first 0.02 inch leak pressure standard is the value determined in step 2/5. B Go to step 23 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 517 05-328 DIAGNOSTICS 6 - SFI SYSTEM (2AZ-FE) PERFORM EVAP SYSTEM CHECK(STEP 2/5) ON Vent Valve ON: Closed OFF: Vent ON Vacuum Pump EVAP Pressure ON: Open OFF: Closed ON Purge VSV Vacuum Pump Stuck OFF 0.02 inch Orifice High-flow 4 sec Positive Vent Valve Stuck closed Negative OK First 0.02 inch Leak Pressure Standard 0.02 inch Orifice Clogged Steps Time (Reference) 2/5 3/5 60 sec Within 15 minutes G36785 HINT: Make a note of the pressures checked in steps (a) and (b) below. (a) Check the EVAP pressure 4 seconds after the vacuum pump is activated*. (b) Check the EVAP pressure again when it has stabilized. This pressure is the 0.02 inch leak pressure standard. *: The vacuum pump begins to operate as step 1/5 is proceeded to step 2/5. Result: DTCs* Test Results  EVAP pressure in step (b) between -4.85 kPa and -1.06 kPa (-36.38 mmHg and -7.95 mmHg) Suspected Trouble Areas Proceed To Not yet determined A P043F and P2401 EVAP pressure in step (b) -1.06 kPa (-7.95 mmHg) or more
0.02 inch orifice high-flow
Vacuum pump stuck OFF B P043E EVAP pressure in step (b) below -4.85 kPa (-36.38 mmHg) 0.02 inch orifice clogged C P2419 EVAP pressure in step (a) more than -1.06 kPa (-7.95 mmHg) Vent valve stuck closed D *: The DTCs relating to the EVAP system displayed on a hand-held tester when checking. B Go to step 11 C Go to step 30 D Go to step 19 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 518 05-329 DIAGNOSTICS 7 - SFI SYSTEM (2AZ-FE) PERFORM EVAP SYSTEM CHECK(STEP 2/5 TO 3/5) ON: Open OFF: Closed ON Purge VSV ON Vent Valve ON: Closed OFF: Vent ON Vacuum Pump EVAP Pressure Positive Negative Vent Valve Stuck open (vent) First 0.02 inch Leak Pressure Standard Steps 2/5 Time (Reference) 3/5 Within 15 minutes G36786 (a) Check the EVAP pressure increase in step 3/5. Result: DTCs* Test Results  EVAP pressure increases by 0.3 kPa (2.25 mmHg) or more within 10 seconds of proceeding from step 2/5 to step 3/5 Suspected Trouble Areas Proceed To Not yet determined A P2420 No variation in EVAP pressure despite proceeding from step 2/5 to step 3/5 Vent valve stuck open (vent) B P0451 No variation in EVAP pressure during steps 1/5 through 3/5 Pressure sensor malfunction stuck C *: The DTCs relating to the EVAP system displayed on a hand-held tester when checking. B Go to step 20 C Go to step 30 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 519 05-330 DIAGNOSTICS 8 - SFI SYSTEM (2AZ-FE) PERFORM EVAP SYSTEM CHECK(STEP 3/5) ON: Open OFF: Closed ON Purge VSV Vent Valve ON Vacuum Pump ON ON: Closed OFF: Vent EVAP Pressure Positive Negative First 0.02 inch Leak Pressure Standard Steps Time (Reference) 3/5 Within 15 minutes G38126 (a) Wait until the EVAP pressure change is less than 0.1 kPa (0.75 mmHg) for 30 seconds. (b) Measure the EVAP pressure and record it. HINT: A few minutes are required for the EVAP pressure to become saturated. When there is little fuel in the fuel tank, it takes up to 15 minutes. NEXT 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 520 05-331 DIAGNOSTICS 9 - SFI SYSTEM (2AZ-FE) PERFORM EVAP SYSTEM CHECK(STEP 4/5) ON: Open OFF: Closed ON Purge VSV ON Vent Valve ON: Closed OFF: Vent ON Vacuum Pump EVAP Pressure OK Positive Negative Puge VSV Stuck Closed First 0.02 inch Leak Pressure Standard Steps 4/5 Time (Reference) 10 sec G36776 (a) Check the EVAP pressure in step 4/5. DTCs* Test Results Suspected Trouble Areas Proceed To  EVAP pressure increases by 0.3 kPa (2.25 mmHg) or more within 10 seconds of proceeding from step 3/5 to step 4/5 Not yet determined A P0441 EVAP pressure increases by 0.3 kPa (2.25 mmHg) or more within 10 seconds of proceeding from step 3/5 to step 4/5 Problems in EVAP hose between pure VSV and throttle body B P0441 Variation in EVAP pressure is less than 0.3 kPa (2.25 mmHg) for 10 seconds, after proceeding from step 3/5 to step 4/5 Purge VSV stuck closed C *: The DTCs relating to the EVAP system displayed on a hand-held tester when checking. B Go to step 15 C Go to step 12 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 521 05-332 DIAGNOSTICS 10 - SFI SYSTEM (2AZ-FE) PERFORM EVAP SYSTEM CHECK(STEP 5/5) ON: Open OFF: Closed ON Purge VSV Vent Valve ON Vacuum Pump ON ON: Closed OFF: Vent EVAP Pressure Gross Leak Positive Negative Second 0.02 inch Leak Pressure Standard x 0.2 Small Leak First 0.02 inch Leak Pressure Standard No Leak Steps 5/5 60 sec Time (Reference) G36782 (a) (b) Check the EVAP pressure in step 5/5. Compare the EVAP pressure in step 3/5 and the second 0.02 inch leak pressure standard (step 5/5). Result: DTCs* Suspected Trouble Areas Proceed To EVAP pressure (step 3/5) lower than the second 0.02 inch leak pressure standard (step 5/5) Not yet determined (no leakage from EVAP system) A P0441 and P0455 EVAP pressure (step 3/5) higher than [second 0.02 inch leak pressure standard (step 5/5) x 0.2]
Purge VSV stuck open
EVAP gross leak B P0456 EVAP pressure (step 3/5) higher than second 0.02 inch leak pressure standard (step 5/5) EVAP small leak B  Test Results *: The DTCs relating to the EVAP system displayed on a hand-held tester when checking. A Go to step 36 B Go to step 12 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 522 05-333 DIAGNOSTICS 11 - SFI SYSTEM (2AZ-FE) PERFORM EVAP SYSTEM CHECK(STEP 3/5) ON Vent Valve ON: Closed OFF: Vent ON Vacuum Pump EVAP Pressure ON: Open OFF: Closed ON Purge VSV Vacuum Pump Stuck OFF Positive Negative 0.02 inch Oriffice High-flow First 0.02 inch Leak Pressure Standard Steps 2/5 3/5 Time (Reference) Within 15 minutes G36788 (a) Check the EVAP pressure in step 3/5. Result: DTCs* Test Results Suspected Trouble Areas Proceed To P043F and P2401 EVAP pressure less than [0.02 inch leak pressure standard x 0.2] 0.02 inch orifice high-flow A P043F and P2401 EVAP pressure more than [0.02 inch leak pressure standard x 0.2] Vacuum pump stuck OFF B *: The DTCs relating to the EVAP system displayed on a hand-held tester when checking. HINT: The 0.02 inch leak pressure standard is the value determined in step 2/5. A Go to step 30 B Go to step 23 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 523 05-334 DIAGNOSTICS 12 - SFI SYSTEM (2AZ-FE) PERFORM ACTIVE TEST(PURGE VSV) (a) On the hand-held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II/ ACTIVE TEST / EVAP VSV. Disconnect the hose (connected to the canister) from the purge VSV. Start the engine. On the tester, turn off the purge VSV (EVAP VSV: OFF). Use your finger to confirm that the purge VSV has no suction. Using the tester, turn on the purge VSV (EVAP VSV: ON). Use your finger to confirm that the purge VSV has suction. (b) Purge VSV Hose (to canister) (c) (d) (e) A85254 (f) (g) Result: Test Results Suspected Trouble Areas Proceed To No suction when purge VSV turned OFF, and suction applied when tuned ON Purge VSV normal A Suction applied when purge VSV turned OFF Purge VSV stuck open B No suction when purge VSV turned ON
Purge VSV stuck closed
Problems with EVAP hose between purge VSV and throttle body C (h) Reconnect the hose. B Go to step 14 C Go to step 15 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 524 05-335 DIAGNOSTICS 13 - SFI SYSTEM (2AZ-FE) CHECK FUEL TANK CAP ASSY (a) Check that the fuel tank cap is correctly installed. (b) Confirm that the fuel tank cap is tightened until a few click sounds are heard. HINT: If an EVAP tester is available, check the fuel tank cap using the tester. (1) Remove the fuel tank cap and install it onto a fuel tank cap adaptor. (2) Connect an EVAP tester pump hose to the adaptor, and pressurize to 3.2 to 3.7 kPa (24 to 28 mmHg) using an EVAP tester pump. (3) Seal the adaptor and wait for 2 minutes. (4) Check the pressure. If the pressure is 2 kPa (15 mmHg) or more, the fuel tank cap is normal. (5) Reinstall the fuel tank cap. Result: Test Results Suspected trouble Areas Proceed To  A Fuel tank cap correctly installed
Fuel tank cap improperly installed
Defective fuel tank cap
Fuel tank cap does not meet OEM specifications Fuel tank cap loose  No fuel tank cap 14 B A Go to step 29 B Go to step 27 C Go to step 28 C INSPECT VACUUM SWITCHING VALVE ASSY NO.1 (a) (b) (c) Turn the ignition switch to OFF. Disconnect the purge VSV connector. Disconnect the hose (connected to the canister) from the purge VSV. Start the engine. Use your finger to confirm that the purge VSV has no suction. (d) (e) Purge VSV Hose (to canister) A85254 Result: Test Results Suspected Trouble Areas Proceed To No suction ECM A Suction applied Purge VSV B (f) (g) Reconnect the purge VSV connector. Reconnect the hose. A Go to step 35 B Go to step 31 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 525 05-336 DIAGNOSTICS 15 - SFI SYSTEM (2AZ-FE) CHECK EVAP HOSE(PURGE VSV - THROTTLE BODY) (a) Hose (to throtlle body) Disconnect the hose (connected to the throttle body) from the purge VSV. Start the engine. Use your finger to confirm that the hose has suction. (b) (c) Purge VSV A85261 Result: Test Results Suspected Trouble Areas Proceed To Suction applied EVAP hose between purge VSV and throttle body normal A No suction
Throttle body
EVAP hose between purge VSV and throttle body B (d) Reconnect the hose. B Go to step 26 A 16 NSPECT VACUUM SWITCHING VALVE ASSY NO.1(PURGE VSV) (a) (b) (c) Purge VSV Remove the purge VSV. Apply battery voltage to the terminals of the purge VSV. Using an air gun, confirm that air flows from port A to port B. A B A68357 Result: Test Results Suspected Trouble Areas Proceed To Air flowed Purge VSV normal A No air flow Purge VSV B (d) Install the purge VSV. B Go to step 31 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 526 05-337 DIAGNOSTICS 17 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS AND CONNECTOR(POWER SOURCE OF PURGE VSV) (a) (b) (c) Wire Harness Side V4 Purge VSV Disconnect the V4 Purge VSV connector. Turn the ignition switch ON. Measure the voltage between terminal 1 of the V4 connector and the body ground. A56870 Result: Test Results Suspected Trouble Areas Proceed To Between 11 V and 14 V Normal A Other than result above Wire harness or connectors between purge VSV and ECM B (d) Reconnect the purge VSV connector. B Go to step 32 A 18 CHECK WIRE HARNESS AND CONNECTOR(PURGE VSV - ECM) (a) Disconnect the E7 connector and the V4 purge VSV connector. (b) Check the resistance. Standard: ECM E7 Tester Connections 34 (PRG) A81699 Specified Conditions E7-34 (PRG) - V1-1 Below 1 Ω E7-34 (PRG) - Body ground 10 kΩ or higher V4-2 - Body ground 10 kΩ or higher (c) (d) Reconnect the purge VSV connector. Reconnect the ECM connector. Wire Harness Side V4 Purge VSV A56870 OK Go to step 35 NG Go to step 32 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 527 05-338 DIAGNOSTICS 19 - SFI SYSTEM (2AZ-FE) PERFORM ACTIVE TEST USING HAND-HELD TESTER(FOR VENT VALVE) (a) (b) ECM Turn the ignition switch to ON. On the hand-held tester, select the following menu items: DIAGNOSIS/ ENHANCED OBD II/ ACTIVE TEST/ VENT VALVE (ALONE). Measure the voltage between terminal VPMP of the ECM connector and the body ground when the vent valve is turned ON (close) and OFF (vent) using the tester. E5 (c) 27 (VPMP) A85259 Result: Test Results Suspected Trouble Areas Proceed To Between 9 V and 14 V when OFF Below 3 V when ON Vent valve A Below 3 V when OFF and ON ECM B 20 A Go to step 22 B Go to step 35 PERFORM ACTIVE TEST USING HAND-HELD TESTER(FOR VENT VALVE) (a) (b) ECM Turn the ignition switch to ON. On the hand-held tester, select the following menu items: DIAGNOSIS/ ENHANCED OBD II/ ACTIVE TEST/ VENT VALVE (ALONE). Measure the voltage between terminal VPMP of the ECM connector and the body ground when the vent valve is turned ON (close) and OFF (vent) using the tester. E5 (c) 27 (VPMP) A85259 Result: Test Results Suspected Trouble Areas Proceed To Below 3 V when OFF and ON Power source of vent valve A Between 9 V and 14 V when OFF Below 3 V when ON Vent valve B Between 9 V and 14 V when OFF and ON ECM C B Go to step 22 C Go to step 35 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 528 05-339 DIAGNOSTICS 21 - SFI SYSTEM (2AZ-FE) INSPECT PUMP MODULE(POWER SOURCE FOR VENT VALVE) (a) (b) (c) (d) Turn the ignition switch OFF. Disconnect the C17 canister connector. Turn the ignition switch to ON. Measure the voltage between terminal 9 of the canister connector and the body ground. C17 A85252 Wire Harness Side C17 Canister A85258 Result: Test Results Suspected Trouble Areas Proceed To Between 9 V and 14 V Normal A Between 0 V and 3 V Power source wire harness of vent valve B (e) Reconnect the canister connector. B Go to step 32 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 529 05-340 DIAGNOSTICS 22 - SFI SYSTEM (2AZ-FE) INSPECT PUMP MODULE(VENT VALVE OPERATION) (a) (b) (c) 9 (+) 8 (-) Turn the ignition switch to OFF. Disconnect the canister connector. Apply the battery voltage to terminals 9 and 8 of the pump module. Touch the pump module to confirm the vent valve operation. (d) A85253 Result: Test Results Suspected Trouble Areas Proceed To Operating Wire harness between vent valve and ECM A Not operating Vent valve B (e) 23 Reconnect the canister connector. A Go to step 32 B Go to step 30 PERFORM ACTIVE TEST USING HAND-HELD TESTER(FOR PUMP MODULE(VACUUM PUMP) (a) ECM On the hand-held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VACUUM PUMP (ALONE). Measure the voltage between terminal MPMP of the ECM connector and the body ground when the vacuum pump is turned ON and OFF using the tester. E5 (b) 4 (MPMP) A85259 Result: Tests Results Suspected Trouble Areas Proceed To Between 0 V and 3 V when OFF Between 9 V and 14 V when ON ECM normal A Between 9 V and 14 V when OFF Between 0 V and 3 V when ON ECM B B Go to step 35 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 530 05-341 DIAGNOSTICS 24 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS AND CONNECTOR(PUMP MODULE - ECM) (a) (b) (c) (d) Turn the ignition switch OFF. Disconnect the C17 canister connector. Turn the ignition switch to ON. On the hand- held tester, select the following menu items:DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VACUUM PUMP (ALONE). Turn the vacuum pump ON. Measure the voltage between terminal 1 of the canister connector and the body ground. (e) (f) C17 A85252 Wire Harness Side C17 Canister A85258 Result: Test Results Suspected Trouble Areas Proceed To Between 9 V and 14 V Normal A Between 0 V and 3 V Wire harness between ECM and vacuum pump B (g) Reconnect the canister connector. B Go to step 32 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 531 05-342 DIAGNOSTICS 25 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS AND CONNECTOR(PUMP MODULE - GROUND) (a) (b) (c) Wire Harness Side Disconnect the C17 canister connector. Turn the ignition switch to OFF. Check the resistance between terminal 6 of the canister connector and the body ground. C17 Canister A85258 Result: Test Results Suspected Trouble Areas Proceed To Below 1 Ω Vacuum pump A 10 kΩ or more Wire harness between vacuum pump and body ground B (d) 26 (a) (b) (c) (d) Reconnect the canister connector. A Go to step 30 B Go to step 32 INSPECT THROTTLE BODY ASSY Stop the engine. Disconnect the EVAP hose from the throttle body. Start the engine. Use your finger to confirm that the port of the throttle body has suction. Result: Suspected Trouble Areas Proceed To Suction applied Test Results EVAP hose between throttle body and purge VSV A No suction Throttle body B (e) 27 Reconnect the EVAP hose. A Go to step 33 B Go to step 34 CORRECTLY REINSTALL OR REPLACE FUEL TANK CAP HINT:

When reinstalling the fuel tank cap, tighten it until a few click sounds are heard. When replacing the fuel tank cap, use a fuel tank cap that meets OEM specifications, and tighten it until a few click sounds are heard. NEXT Go to step 37 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 532 05-343 DIAGNOSTICS 28 - SFI SYSTEM (2AZ-FE) REPLACE FUEL TANK CAP ASSY HINT: When installing the fuel tank cap, tighten it until a few click sounds are heard. NEXT 29 Go to step 37 REPAIR EVAP LEAK PART (a) (b) (c) (d) Reinstall the fuel cap. Remove the exhaust tail pipe. Remove the heat insulator under the canister. Pinch the atmospheric side hose of the pump module with the clip to close the canister’s passage to air. A85255 (e) Pressure Gauge Pressure B06546 Connect the pressure gauge (SST) to the service port (green cap near the air cleaner box). (f) Pressurize the EVAP system to 3.2 to 3.7 kPa (24 to 28 mmHg). NOTICE: More than 35 mmHg of pressure will damage the EVAP system. Pay attention to the pressure. (g) Apply soapy water to the piping and connecting parts of the EVAP system. Look for the area where bubbles appear. This area cause leaks. HINT:
If the system has leaks, a whistling sound will be heard.
Disconnect the hose between canister and fuel tank from the canister. Close the canister on the area where the hose was connected and perform an inspection. The fuel tank can be eliminated from the suspected areas for leak checks. (h) Repair or replace the leak point. NEXT 30 Go to step 37 REPLACE CHARCOAL CANISTER ASSY NEXT Go to step 37 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 533 05-344 DIAGNOSTICS 31 - SFI SYSTEM (2AZ-FE) REPLACE VACUUM SWITCHING VALVE ASSY NO.1(PURGE VSV) (a) (b) (c) (d) Disconnect the connector and the hoses from the purge VSV. Remove the purge VSV. Install a new purge VSV. Reconnect the connector and hoses. Purge VSV A85254 32 NEXT Go to step 37 REPAIR OR REPLACE WIRE HARNESS AND CONNECTOR In case that the exhaust tail pipe is removed, go to the next step before installing it. NEXT 33 REPLACE EVAP HOSE(THROTTLE BODY - PURGE VSV) NEXT 34 (a) (b) Remove the throttle body (see page 10-6 ). Check that there is no clog in the EVAP purge port of the throttle body. If necessary, replace the throttle body. (a) Go to step 37 REPLACE ECM (see page 10-9 ) NEXT 36 Go to step 37 INSPECT THROTTLE BODY ASSY NEXT 35 Go to step 37 Go to step 37 REPAIR OR REPLACE PARTS AND COMPONENTS INDICATED BY OUTPUT DTCS Repair the malfunctioning areas indicated by the DTCs that had been confirmed when the vehicle was brought in. NEXT Go to step 37 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 534 05-345 DIAGNOSTICS 37 - SFI SYSTEM (2AZ-FE) PERFORM EVAP SYSTEM CHECK(AUTO OPERATION) NOTICE:
In the EVAP SYSTEM CHECK (AUTO OPERATION), the series of 5 EVAP SYSTEM CHECK steps is performed automatically. It takes a maximum of approximately 18 minutes.
Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90% full because the cut-off valve may be closed, making the leak check of the fuel tank unavailable.
Do not run the engine in this step.
When the temperature of the fuel is 35C (95F) or more, a large amount of vapor forms and any check results become inaccurate. When performing an EVAP SYSTEM CHECK, keep the temperature below 35C (95F). (a) Clear DTCs (see page 05-38 ). (b) On the hand-held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / SYSTEM CHECK / EVAP SYS CHECK / AUTO OPERATION. (c) After the SYSTEM CHECK is completed, check for pending DTCs by selecting the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. HINT: If no pending DTC is found, the repair has been successfully completed. NEXT COMPLETED 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 535 05-346 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) Monitor Confirmation HINT: After a repair, check Monitor Status by performing the Key-Off Monitor Confirmation and Purge Flow Monitor Confirmation described below. 1. KEY-OFF MONITOR CONFIRMATION (a) Preconditions The monitor will not run unless:
The vehicle has been driven for 10 minutes or more (in a city area or on a free way)
The fuel tank is less than 90% full
The altitude is less than 8,000 ft (2,400 m)
The Engine Coolant Temperature (ECT) is between 4.4C and 35C (40F and 95F)
The Intake Air Temperature (IAT) is between 4.4C and 35C (40F and 95F)
The vehicle remains stationary (the vehicle speed is 0 mph [0 km/h]) (b) Monitor Conditions (1) Allow the engine to idle for at least 5 minutes. (2) Turn the ignition switch OFF and wait for 6 hours (8 or 10.5 hours). HINT: Do not start the engine until checking MONITOR STATUS. If the engine is started, the steps described above must be repeated. (c) Monitor Status (1) Connect a hand-held tester to the DLC3. (2) Turn the ignition switch ON and turn the tester ON. (3) On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR STATUS. (4) Check the Monitor Status displayed on the tester. HINT: If INCMP is displayed, the monitor is not completed. Make sure that the preconditions have been met, and perform the Monitor Conditions again. 2. PURGE FLOW MONITOR CONFIRMATION (P0441) HINT: Perform this monitor confirmation after the Key-Off Monitor Confirmation shows COMPL (complete). (a) Preconditions The monitor will not run unless:
The vehicle has been driven for 10 minutes or more (in a city area or on a free way)
The ECT is between 4.4C and 35C (40F and 95F)
The IAT is between 4.4C and 35C (40F and 95F) (b) Monitor Conditions (1) Release the pressure from the fuel tank by removing and reinstalling the fuel tank cap. (2) Warm the engine up until the ECT reaches more than 75C (167F). (3) Increase the engine speed to 3,000 rpm once. (4) Allow the engine to idle and turn A/C ON for 1 minute. (c) Monitor Status (1) Turn the ignition switch OFF (where ON or the engine is running). (2) Connect a hand-held tester to the DLC3. (3) Turn the ignition switch to ON and turn the tester ON. (4) On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR STATUS. (5) Check the Monitor Status displayed on the tester. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 536 05-347 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) HINT: If INCMP is displayed, the monitor is not completed. Make sure that the preconditions have been met, and perform the Monitor Conditions again. MONITOR RESULT Refer to page 05-26 for detailed information. The test value and test limit information are described as shown in the following table. Check the monitor result and test values after performing the monitor drive pattern (Refer to ”Confirmation Monitor”).
TID (Test Identification Data) is assigned to each emissions-related component.
TLT (Test Limit Type): If TLT is 0, the component is malfunctioning when the test value is higher than the test limit. If TLT is 1, the component is malfunctioning when the test value is lower than the test limit.
CID (Component Identification Data) is assigned to each test value.
Unit Conversion is used to calculate the test value indicated on generic OBD ll scan tools. (d) Key - off TID $02: EVAP system (Key-off monitor) TLT CID Unit Conversion Description of Test Data Description of Test Limit 1 $01 Multiplied by 0.0156 subtract 2 (kPa) Test value for small leak (P0456): Refer to pressure D* Malfunction criteria (0 kPa) 1 $02 Multiplied by 0.0156 subtract 2 (kPa) Test value for gross leak (P0455): Refer to pressure E* Malfunction criteria (0 kPa) 1 $03 Multiplied by 0.0156 subtract 2 (kPa) Test value for vacuum pump stuck OFF (P2401): Refer to pressure A* Malfunction criteria (0 kPa) 1 $04 Multiplied by 0.0156 subtract 2 (kPa) Test value for vacuum pump stuck ON (P2402): Refer to pressure A* Malfunction criteria (0 kPa) 1 $05 Multiplied by 0.0156 subtract 2 (kPa) Test value for vent valve stuck OFF (vent) (P2420): Refer to pressure C* Malfunction criteria (0 kPa) 1 $06 Multiplied by 0.0156 subtract 2 (kPa) Test value for vent valve stuck ON (closed) (P2419): Refer to pressure A* Malfunction criteria (0 kPa) 1 $07 Multiplied by 0.0156 subtract 2 (kPa) Test value for 0.02 inch orifice low flow (P043E): Refer to pressure B* Malfunction criteria (0 kPa) 1 $08 Multiplied by 0.0156 subtract 2 (kPa) Test value for 0.02 inch orifice high flow (P043F): Refer to pressure A* Malfunction criteria (0 kPa) 1 $11 Multiplied by 0.0156 subtract 2 (kPa) Test value for purge VSV stuck close (P0441): Refer to pressure F* Malfunction criteria (0 kPa) 1 $12 Multiplied by 0.0156 subtract 2 (kPa) Test value for purge VSV stuck open (P0441): Refer to pressure E* Malfunction criteria (0 kPa) 1 $13 Multiplied by 0.0156 subtract 2 (kPa) Test value for purge flow (P0441): Refer to pressure G* Malfunction criteria (0 kPa) * Pressures A to G are indicated as shown in the diagram below. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 537 05-348 DIAGNOSTICS Key-off Monitor - SFI SYSTEM (2AZ-FE) Monitor Start ON (Open) Purge VSV ON (Close) Vent Valve ON Pump EVAP Pressure (Reference) Atomosphere (0 kPa) Criterion 2 (Criterion 4 x 0.2) Criterion 1 (-1.2 kPa) A C Criterion 3 (0.3 kPa) F E B Criterion 5 (-4.3 kPa) Elapsed Time (Seconds) Criterion 4 D Criterion 6 (0.3 kPa) 4 60 10 Within 720 10 60 Purge Flow Monitor Sequence 2 1 ON (Open) Purge VSV ON (Close) If pressure change in sequence 1 is greater than criterion 7, purge flow monitor is completed (functioning normally). Vent Valve EVAP Pressure (Reference) If pressure change in sequence 1 is smaller than criterion 7, sequence 2 is run. Criterion 7 (0.1 kPa) Criterion 8 (1kPa) G If pressure change in sequence 2 is smaller than criterion 8, purge flow is insufficient. G38136 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 538 05-42 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05ESR-05 FAIL-SAFE CHART If any of the following codes are recorded, the ECM enters fail-safe mode. DTC No. Fail-Safe Operation Fail-Safe Deactivation Conditions P0031 P0032 P0037 P0038 Turn off heater Ignition switch OFF P0100 P0102 P0103 Ignition timing is calculated from engine speed and throttle angle ”Pass” condition detected P0110 P0112 P0113 Intake air temperature is fixed at 20°C (68°F) ”Pass” condition detected P0115 P0116 P0117 P0118 Engine coolant temperature is fixed at 80°C (176°F) ”Pass” condition detected P0120 P0121 P0122 P0123 P0220 P0222 P0223 P0604 P0606 P0607 P0657 P2102 P2103 P2111 P2112 P2118 P2119 P2135 If Electronic Throttle Control System (ETCS) has malfunction, ECM cuts off current to throttle control motor. Throttle control valve returns to predetermined opening angle (approximately 16
) by force of return spring. ECM then adjusts engine output by controlling fuel injection (intermittent fuel-cut) and ignition timing in accordance with accelerator pedal opening angle to enable vehicle to continue at minimal speed. If accelerator pedal is depressed firmly and slowly, vehicle can be driven slowly. If accelerator pedal is depressed quickly, vehicle may speed up and slow down erratically. ”Pass” condition is detected and then ignition switch is turned OFF, fail-safe operation will stop and system will return to normal condition P0325 P0327 P0328 Maximum timing retardation Ignition switch OFF P0351 P0352 P0353 P0354 Fuel is cut ”Pass” condition detected P2120 P2121 P2122 P2123 P2125 P2127 P2128 P2138 Accelerator pedal position sensor has two (main and sub) sensor circuits. If malfunction occurs in either of sensor circuits, ECM detects abnormal signal voltage difference between two sensor circuits and switches to limp mode. In limp mode, remaining circuit is used to calculate accelerator pedal opening to allow vehicle to continue driving. If both circuits malfunction, ECM regards opening angle of accelerator pedal to be fully closed. In this case, throttle valve will remain closed as if engine is idling. ”Pass” condition is detected and then ignition switch is turned OFF, fail-safe operation will stop and system will return to normal condition 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 232 05-349 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05EW0-05 FUEL PUMP CONTROL CIRCUIT CIRCUIT DESCRIPTION When the engine is cranked, current flows from the ignition switch terminal ST1 to the starter relay coil (Marking: STARTER), and current flows to terminal STA of the ECM (STA signal). When the STA signal and NE signal are input to the ECM, Tr is turned ON, current flows to coil of the circuit opening relay, (Marking) the relay switches on, power is supplied to the fuel pump and the fuel pump operates. While the NE signal is generated and the engine is running, the ECM keeps Tr ON (Circuit Opening relay ON) and the fuel pump also keeps operating. Circuit Opening Relay EFI Relay ECM Fuel Pump EFI NO. 1 FC Tr MREL Ignition Switch STARTER AM2 AM1 AM1 ST1 AM2 IG2 ST2 IGN IGSW PNP Switch ALT (STA Signal) STA (NE Signal) NE STARTER Relay Main Battery Starter A90307 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 539 05-350 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) WIRING DIAGRAM Passenger Side J/B Instrument Panel J/B Assy 1 GR 6 IGN 1C W 1G 4 1 4M 4F ECM W 13 P-L I15 Ignition Switch 6 IG2 AM2 8 Y 2B 1 5 2B EFI Relay 1 1 1 5 Circuit Opening Relay IC1 5 2 F7 10 FL Block Assy 2 3 EFI NO. 1 L-Y 1 2I 4 2F 1 W 1 BR AM2 3 MREL R/B No.1 3 1 E5 B IC2 Engine Room J/B 7 1 IK3 2 W 8 B W-B 8 IA2 10 Y A W J2 J/C FL Main EH FC 4 F12 Fuel Pump 5 Battery E5 L W-B BC A90308 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 540 05-351 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) INSPECTION PROCEDURE Hand-held tester: 1 (a) (b) (c) (d) PERFORM ACTIVE TEST USING HAND-HELD TESTER (OPERATE CIRCUIT OPENING RELAY) Connect the hand-held tester to the DLC3. Turn ON the ignition switch. Push the hand-held tester main switch. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD. Check the relay operation while operating it with the hand-held tester. OK: Operating noise can be heard from the relay. OK Go to step 5 NG 2 INSPECT CIRCUIT OPENING RELAY 2 1 3 1 5 (a) (b) 5 2 Remove the circuit opening relay from the R/B sub-assy. Measure the resistance of the circuit opening relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 3 B60778 NG REPLACE CIRCUIT OPENING RELAY OK 3 INSPECT ECM (FC VOLTAGE) E1 (-) E9 ECM (a) (b) FC (+) E5 ECM A67446 Turn the ignition switch ON. Measure the voltage of the ECM connectors. Standard: OK Tester Connection Specified Condition E5-10 (FC) - E9-1 (E1) 9 to 14 V REPLACE ECM (See page 10-9 ) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 541 05-352 DIAGNOSTICS 4 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS (ECM - CIRCUIT OPENING RELAY, CIRCUIT OPENING RELAY - IGNITION SWITCH) (a) E5 ECM FC R/B Sub-assy Check the wire harness between the ECM and circuit opening relay. (1) Disconnect the E5 ECM connector. (2) Remove the circuit opening relay from the R/B subassy. (3) Measure the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition E5-10 (FC) - R/B sub-assy circuit opening relay terminal 2 Below 1 Ω E5-10 (FC) or R/B sub-assy circuit opening relay terminal 2 - Body ground 10 kΩ or higher Circuit Opening Relay A67445 A90342 A92641 (b) Wire Harness Side R/B Sub-assy Circuit Opening Relay Instrument Panel J/B Assy Check the wire harness between the circuit opening relay and ignition switch. (1) Check the IGN fuse.
Remove the IGN fuse from the instrument panel J/B.
Measure the resistance of the IGN fuse. Standard: Below 1 Ω
Reinstall the IGN fuse. (2) Remove the circuit opening relay from the R/B subassy. (3) Disconnect the I15 ignition switch connector. (4) Measure the resistance of the wire harness side connectors. Standard: IGN fuse I15 Ignition Switch 1 5 A90342 A90344 A61075 IG2 2 6 3 7 Tester Connection Specified Condition R/B sub-assy circuit opening relay terminal 1 - I15-6 (IG2) Below 1 Ω I15-6 (IG2) or R/B sub-assy circuit opening relay terminal 1 - Body ground 10 kΩ or higher 4 8 A92642 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 542 05-353 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) REPLACE ECM (See page 10-9 ) 5 INSPECT FUEL PUMP ASSY (a) Measure the resistance of the fuel pump terminals. Standard: Tester Condition Condition Specified Condition 4-5 20C (68F) 0.2 to 0.3 Ω 3 2 1 5 (b) 4 F12 Fuel Pump A74356 Check operation of the fuel pump. (1) Apply battery voltage to both the terminals. Check that the pump operates. NOTICE:
These tests must be done quickly (within 10 seconds) to prevent the coil from burning out.
Keep the fuel pump as far away from the battery as possible.
Always turn ON and OFF the voltage on the battery side, not the fuel pump side. NG REPLACE FUEL PUMP ASSY (See page 11-16 ) OK 6 CHECK WIRE HARNESS (CIRCUIT OPENING RELAY - FUEL PUMP, FUEL PUMP BODY GROUND) (a) Wire Harness Side R/B Sub-assy Circuit Opening Relay F12 Fuel Pump A90342 A67586 Check the wire harness between the circuit opening relay and fuel pump. (1) Remove the circuit opening relay from the R/B subassy. (2) Disconnect the F12 fuel pump connector. (3) Measure the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition R/B sub-assy circuit opening relay terminal 3 - F12-4 Below 1 Ω F12-4 or R/B sub-assy circuit opening relay terminal 3 - Body ground 10 kΩ or higher A92648 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 543 05-354 DIAGNOSTICS (b) Wire Harness Side F12 Fuel Pump A67586 - SFI SYSTEM (2AZ-FE) Check the wire harness between the fuel pump and body ground. (1) Disconnect the F12 fuel pump connector. (2) Measure the resistance between the wire harness side connector and body ground. Standard: OK Tester Connection Specified Condition F12-5 - Body ground Below 1 Ω REPAIR OR CONNECTOR REPLACE HARNESS AND NG REPLACE ECM (See page 10-9 ) OBD II scan tool (excluding hand-held tester): 1 CHECK FUEL PUMP OPERATION (See Page 11-4 ) (a) Check if there is pressure in the fuel inlet hose. HINT: The pipe has fuel pressure if the sound of flowing fuel can be heard. OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN ON PROBLEM SYMPTOMS TABLE (See page 05-31 ) NG 2 CHECK RELAY OPERATION (CIRCUIT OPENING RELAY) (a) E5 ECM When connecting between terminal FC of the ECM connector and body ground, check relay operation. OK: Noise can be heard from the circuit opening relay. FC A53765 OK Go to step 6 NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 544 05-355 DIAGNOSTICS 3 1 SFI SYSTEM (2AZ-FE) INSPECT CIRCUIT OPENING RELAY 2 1 3 - 5 (a) (b) 5 2 Remove the circuit opening relay from the R/B sub-assy. Measure the resistance of the circuit opening relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 3 NG B60778 REPLACE CIRCUIT OPENING RELAY OK 4 INSPECT ECM (FC VOLTAGE) E1 (-) E9 ECM (a) (b) FC (+) E5 ECM A67446 Turn the ignition switch ON. Measure the voltage of the ECM connectors. Standard: OK Tester Connection Specified Condition E5-10 (FC) - E9-1 (E1) 9 to 14 V REPLACE ECM (See page 10-9 ) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 545 05-356 DIAGNOSTICS 5 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS (ECM - CIRCUIT OPENING RELAY, CIRCUIT OPENING RELAY - IGNITION SWITCH) (a) E5 ECM FC R/B Sub-assy Check the wire harness between the ECM and circuit opening relay. (1) Disconnect the E5 ECM connector. (2) Remove the circuit opening relay from the R/B subassy. (3) Measure the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition E5-10 (FC) - R/B sub-assy circuit opening relay terminal 2 Below 1 Ω E5-10 (FC) or R/B sub-assy circuit opening relay terminal 2 - Body ground 10 kΩ or higher Circuit Opening Relay A67445 A90342 A92641 (b) Wire Harness Side R/B Sub-assy Circuit Opening Relay Instrument Panel J/B Assy Check the wire harness between the circuit opening relay and ignition switch. (1) Check the IGN fuse.
Remove the IGN fuse from the instrument panel J/B Assy.
Check the resistance of the IGN fuse. Standard: Below 1 Ω
Reinstall the IGN fuse. (2) Remove the circuit opening relay from the R/B subassy. (3) Disconnect the I15 ignition switch connector. (4) Measure the resistance of the wire harness side connectors. Standard: IGN fuse I15 Ignition Switch 1 5 A90342 A90344 A61075 2 6 3 7 Tester Connection Specified Condition R/B sub-assy circuit opening relay terminal 1 - I15-6 (IG2) Below 1 Ω I15-6 (IG2) or R/B sub-assy circuit opening relay terminal 1 - Body ground 10 kΩ or higher 4 8 NG IG2 A92642 REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 546 05-357 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) REPLACE ECM (See page 10-9 ) 6 INSPECT FUEL PUMP ASSY (a) Measure the resistance of the fuel pump terminals. Standard: Tester Condition Condition Specified Condition 4-5 20C (68F) 0.2 to 0.3 Ω 3 2 1 5 (b) 4 F12 Fuel Pump A74356 Check operation of the fuel pump. (1) Apply battery voltage to both the terminals. Check that the pump operates. NOTICE:
These tests must be done quickly (within 10 seconds) to prevent the coil from burning out.
Keep the fuel pump as far away from the battery as possible.
Always turns ON and OFF the voltage on the battery side, not the fuel pump side. NG REPLACE FUEL PUMP ASSY (See page 11-16 ) OK 7 CHECK WIRE HARNESS (CIRCUIT OPENING RELAY - FUEL PUMP, FUEL PUMP BODY GROUND) (a) Wire Harness Side R/B Sub-assy Circuit Opening Relay F12 Fuel Pump A90342 A67586 Check the wire harness between the circuit opening relay and fuel pump. (1) Remove the circuit opening relay from the R/B SubAssy. (2) Disconnect the F12 fuel pump connector. (3) Measure the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition R/B sub-assy circuit opening relay terminal 3 - F12-4 Below 1 Ω F12-4 or R/B sub-assy circuit opening relay terminal 3 - Body ground 10 kΩ or higher A92648 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 547 05-358 DIAGNOSTICS (b) Wire Harness Side F12 Fuel Pump A67586 - SFI SYSTEM (2AZ-FE) Check the wire harness between the fuel pump and body ground. (1) Disconnect the F12 fuel pump connector. (2) Measure the resistance between the wire harness side connector and body ground. Standard: NG Tester Connection Specified Condition F12-5 - Body ground Below 1 Ω REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE ECM (See page 10-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 548 05-16 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05ITB-02 LIST OF DISABLE A MONITOR HINT: The table below shows the ECM monitoring status for the components listed in the top of the table when the DTCs on the left of the table are set. A92556 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 206 05-17 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) A92557 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 207 05-18 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) A92558 Note *1: Without input speed sensor Note *2: With input speed sensor 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 208 05-19 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) A92559 Note *1: Without input speed sensor Note *2: With input speed sensor 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 209 05-20 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) A92560 Note *1: Without input speed sensor Note *2: With input speed sensor 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 210 05-21 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) A92561 Note *1: Without input speed sensor Note *2: With input speed sensor 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 211 05-359 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05EW1-05 MIL CIRCUIT CIRCUIT DESCRIPTION The Malfunction Indicator Lamp (MIL) is used to indicate the ECM’s detection of a vehicle malfunction. The instrument panel IG2 fuse provides circuit power and the ECM provides the circuit ground that illuminates the MIL. MIL operations should be checked visually: The MIL should be illuminated when the ignition is first turned ON. If the MIL is always ON or OFF, use the hand-held tester or OBD II scan tool and follow the procedures to determine the cause of problem. WIRING DIAGRAM Passenger Side J/B Instrument Panel J/B Assy GR 1 6 IGN 1C W 1G 4 1 4M 4E ECM P 6 IG2 AM2 7 I15 Ignition Switch J6 J/C 9 IL1 P E E Y 1 SB IC1 Combination Meter L-Y 13 C11 10 4 C12 L 11 10 IL2 SB E5 W MIL AM2 F7 FL Block Assy 1 W FL Main Battery 2005 HIGHLANDER REPAIR MANUAL (RM1144U) A90349 Author
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: 549 05-360 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) INSPECTION PROCEDURE HINT: Troubleshoot each trouble symptom in accordance with the chart below. MIL remains on Start inspection from step 1 MIL is not illuminated Start inspection from step 3 1 (a) (b) (c) (d) (e) CLEAR DTC Connect the hand-held tester or the OBD II scan tool to the DLC3. Turn the ignition switch ON and push the hand-held tester or the OBD II scan tool main switch ON. Read the DTC. Clear the DTC (see page 05-38 ). Check that the MIL is not illuminated. OK: MIL is not illuminated OK REPAIR CIRCUIT INDICATED BY OUTPUT DTC (See page 05-48 ) NG 2 CHECK WIRE HARNESS (CHECK FOR SHORT IN WIRE HARNESS) E5 ECM (a) (b) (c) Disconnect the E5 ECM connector. Turn the ignition switch ON. Check that the MIL is not illuminated. OK: MIL is not illuminated W A67445 OK REPLACE ECM (See page 10-9 ) NG CHECK AND REPLACE HARNESS AND CONNECTOR 3 (a) CHECK THAT MIL IS ILLUMINATED Check that the MIL is illuminated when turning the ignition switch ON. OK: MIL is illuminated NG SYSTEM OK NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 550 05-361 DIAGNOSTICS 4 (a) - SFI SYSTEM (2AZ-FE) INSPECT COMBINATION METER ASSY (MIL CIRCUIT) See the combination meter troubleshooting on page 05-1889 . NG REPAIR OR REPLACE BULB OR COMBINATION METER ASSEMBLY OK CHECK AND REPAIR HARNESS AND CONNECTOR (COMBINATION METER - ECM) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 551 05-22 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05F45-05 O2S TEST RESULT 1. INTRODUCTION The O2S TEST RESULT refers to the results of the engine control module (ECM) when it monitors the oxygen sensor (O2S), and it can be read using the hand-held tester or the generic OBD II scan tool. Based on this, you can find the O2S’s conditions. The ECM monitors the O2S for various data. You can read the monitor result (TEST DATA) of each monitor item using the O2S TEST RESULT. However, the output value of the TEST DATA is the latest ”snapshot” value that is taken after monitoring and therefore it is not dynamic. In this repair manual, the description of the O2S TEST RESULT (for O2S related DTCs) are written in a table. This table consists of 5 items: (1) TEST ID (a code applied to each TEST DATA) (2) Description of TEST DATA (3) Conversion Factor (When conversion factor has a value written in the table, multiply the TEST DATA value appearing on the scan tool by the conversion factor value. The result will be the required value.) (4) Unit (5) Standard Value If the TEST DATA value appearing on the scan tool is out of the standard value, the O2S is malfunctioning. If it is within the standard value, the O2S is functioning normally. However, if the value is on the borderline of the standard value, the O2S may malfunction very soon. 2. HOW TO READ O2S TEST RESULT USING HANDHELD TESTER (a) Connect the hand-held tester to the DLC3. (b) O2S TEST RESULT Screen 01 BANK 1 - SENSOR 1 On the tester screen, select the following menus: DIAGNOSIS / CARB OBDII / O2S TEST RESULT. A list of the O2S equipped on the vehicle will be displayed. 01 BANK 1 - SENSOR 2 01 BANK 2 - SENSOR 1 01 BANK 2 - SENSOR 2 A21190 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 212 05-23 DIAGNOSTICS (c) TEST DATA Screen LOW SW V ⋅ ⋅ ⋅ HIGH SW V ⋅ ⋅ ⋅ MIN O2S V ⋅ ⋅ ⋅ MAX O2S V ⋅ ⋅ ⋅ TIME $81 ⋅ ⋅ ⋅ ⋅ (d) 0.400 V 0.550 V 0.100 V 0.900 V 17 (e) A21191 TEST ID $81 Description of TEST DATA Percentage of monitoring time when the O2S voltage is less than 0.05 V - SFI SYSTEM (2AZ-FE) Select the desired O2S and press ENTER. The following screen will appear. Press HELP and
simultaneously. More information will appear. Example: (1) The hand-held tester displays ”17” as a value of the ”TIME $81” (see the illustration on the left). (2) Find the conversion factor value of ”TIME $81” in the O2S TEST RESULT chart below. 0.3906 is specified for $81 in this chart. (3) Multiply ”17” in step (1) by 0.3906 (conversion factor) in the step (2). 17 x 0.3906 = 6.6 % (4) If the answer is within the standard value, the ”TIME $81” can be confirmed to be normal. O2S TEST RESULT Chart: Conversion Factor Multiply 0.3906 Unit % Standard Value Within 60 % 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 213 05-55 DIAGNOSTICS DTC P0010 - SFI SYSTEM (2AZ-FE) 05EST-05 CAMSHAFT POSITION ”A” ACTUATOR CIRCUIT (BANK 1) CIRCUIT DESCRIPTION The Variable Valve Timing (VVT) system includes the ECM, the Oil Control Valve (OCV) and the VVT controller. The ECM sends a target duty-cycle control signal to the OCV. This control signal, sent to the OCV, regulates the oil pressure applied to the VVT controller. Camshaft timing control is performed based on engine operation conditions such as intake air volume, throttle position and engine coolant temperature. The ECM controls the OCV based on the signals output from several sensors. The VVT controller regulates the intake camshaft angle using oil pressure through the OCV. As a result, the relative position between the camshaft and the crankshaft is optimized. Also, the engine torque and fuel economy improve, and exhaust emissions decrease. The ECM detects the actual valve timing using signals from the camshaft position sensor and the crankshaft position sensor. The ECM performs feedback control and verifies target valve timing. ECM Crankshaft Position Sensor MAF Meter OCV Target Valve Timing Throttle Position Sensor Feedback Duty Control ECT Sensor Correction Vehicle Speed Signal Camshaft Position Sensor Actual Valve Timing A71007 DTC No. P0010 DTC Detection Condition Open or short in OCV circuit Trouble Area
Open or short in OCV circuit
OCV
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: 245 05-56 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) MONITOR DESCRIPTION After the ECM sends the ”target” duty-cycle signal to the OCV, the ECM monitors the OCV current to establish an ”actual” duty-cycle. When the actual duty-cycle ratio varies from the target duty-cycle ratio, the ECM sets a DTC. MONITOR STRATEGY Related DTCs P0010: VVT OCV range check Required sensors / components (Main) VVT OCV Required sensors / components (Related) - Frequency of operation Continuous Duration 1 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present See page 05-16 Battery voltage 11 V or more Target duty ratio for the OCV 70 % or less Starter OFF Current cut status for the OCV Not cut TYPICAL MALFUNCTION THRESHOLDS Either of the following condition is met: OCV duty ratio 100 % (always ON) despite the target duty ratio is less than 70 % OCV duty ratio when ECM supplies current to OCV 3 % or less despite the ECM is supplying current to the OCV COMPONENT OPERATING RANGE VVT OCV duty ratio More than 3 % and less than 100 % 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 246 05-57 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) WIRING DIAGRAM ECM C2 OCV 1 G-W 16 OC1+ E9 2 G-R 15 OC1E9 A87978 INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. Hand-held tester: 1 (a) (b) (c) (d) (e) PERFORM ACTIVE TEST USING HAND-HELD TESTER (OCV OPERATION) Start the engine and warm it up. Connect the hand-held tester to the DLC3. Turn ON the ignition switch. Push the hand-held tester main switch. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1. Using the hand-held tester, operate the OCV and check the engine speed. Standard: Tester Operation Specified Condition OCV is OFF Normal engine speed OCV is ON Rough idle or engine stall OK CHECK FOR INTERMITTENT PROBLEMS (See page 05-9 ) NG 2 INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSY (OCV) (See page 10-2 ) OK: OCV has no contamination and moves smoothly. NG REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 247 05-58 DIAGNOSTICS 3 - SFI SYSTEM (2AZ-FE) CHECK ECM (OCV SIGNAL) (a) E9 ECM OC1 + During idling, check the waveform of the ECM connector using an oscilloscope. Standard: Tester Connection Specified Condition E9-16 (OC1+) - E9-15 (OC1-) Correct waveform is as shown OC1- OCV Signal Waveform 5 V/ Division GND 1 msec./Division NG A87357 A67528 REPLACE ECM (See page 10-9 ) OK 4 CHECK WIRE HARNESS (OCV - ECM) (a) (b) (c) Wire Harness Side C2 OCV OC1+ Disconnect the C2 OCV connector. Disconnect the E9 ECM connector. Measure the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition C2-1 (OCV) - E9-16 (OC1+) C2-2 (OCV) - E9-15 (OC1-) Below 1 Ω C2-1 (OCV) or E9-16 (OC1+) - Body ground C2-2 (OCV) or E9-15 (OC1-) - Body ground 10 kΩ or higher E9 ECM OC1Y A54386 A81698 A85431 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK CHECK FOR INTERMITTENT PROBLEMS 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 248 05-59 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) OBD II scan tool (excluding hand-held tester): 1 CHECK CAMSHAFT TIMING OIL CONTROL VALVE ASSY (OPERATE OCV) (a) (b) (c) (d) Wire Harness Side C2 OCV Start the engine and warm it up. Disconnect the OCV connector. Apply battery positive voltage to the terminals of the OCV. Check the engine speed. OK: Rough idle or engine stalled. NG A53155 REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSY OK 2 CHECK ECM (OCV SIGNAL) (a) E9 ECM OC1 + During idling, check the waveform of the ECM connector using an oscilloscope. Standard: Tester Connection Specified Condition E9-16 (OC1+) - E9-15 (OC1-) Correct waveform is as shown OC1- OCV Signal Waveform 5 V/ Division GND 1 msec./Division A67528 A87357 NG REPLACE ECM (See page 10-9 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 249 05-60 DIAGNOSTICS 3 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS (OCV - ECM) (a) (b) (c) Wire Harness Side C2 OCV OC1+ Disconnect the C2 OCV connector. Disconnect the E9 ECM connector. Measure the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition C2-1 (OCV) - E9-16 (OC1+) C2-2 (OCV) - E9-15 (OC1-) Below 1 Ω C2-1 (OCV) or E9-16 (OC1+) - Body ground C2-2 (OCV) or E9-15 (OC1-) - Body ground 10 kΩ or higher E9 ECM OC1Y A54386 A81698 NG A85431 REPAIR OR CONNECTOR REPLACE HARNESS AND OK CHECK FOR INTERMITTENT PROBLEMS 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 250 05-61 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05ESU-05 DTC P0011 CAMSHAFT POSITION ”A” -TIMING OVERADVANCED OR SYSTEM PERFORMANCE (BANK 1) DTC P0012 CAMSHAFT POSITION ”A” -TIMING OVERRETARDED (BANK 1) CIRCUIT DESCRIPTION Refer to DTC P0010 on page 05-55 . DTC No. DTC Detection Condition P0011 After engine is warmed up and engine speed is at 550 to 4,000 rpm, condition (a) continues (1 trip detection logic) (a) Valve timing does not change from current valve timing (Problem of advanced valve timing)
Valve timing
OCV
VVT controller assembly
ECM Trouble Area P0012 After engine is warmed up and engine speed is at 550 to 4,000 rpm, condition (a) continues (2 trip detection logic) (a) Valve timing does not change from current valve timing (Problem of retarded valve timing)
Same as DTC No. P0011 MONITOR DESCRIPTION The ECM optimizes the valve timing using the Variable Valve Timing (VVT) system to control the intake valve camshaft. The VVT system includes the ECM, the Oil Control Valve (OCV) and the VVT controller. The ECM sends a target duty-cycle control signal to the OCV. This control signal, sent to the OCV, regulates the oil pressure applied to the VVT controller. The VVT controller can advance or retard the intake valve camshaft. Example: A DTC will be set if: 1) the difference between the ”target” and ”actual” valve timing is more than 5 degrees of the camshaft angle (CA) and the condition continues for more than 4.5 seconds; or 2) the OCV is forcibly activated 63 times or more. Advanced cam DTCs are subject to ”1 trip” detection logic. Retarded cam DTCs are subject to ”2 trip” detection logic. MONITOR STRATEGY Related DTCs P0011: Advanced camshaft timing P0012: Retarded camshaft timing Required sensors / components (Main) VVT OCV and VVT Actuators Required sensors / components (Related) CKP, CMP and ECT sensors Frequency of operation Once per driving cycle Duration Within 10 sec. MIL operation P0011: Immediate P0012: 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-16 Battery voltage 11 V or more Throttle position learning Completed Engine RPM 550 to 4,000 rpm ECT 75 to 100C (167 to 212F) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 251 05-62 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) TYPICAL MALFUNCTION THRESHOLDS Deviation of valve timing More than 5CA (Crankshaft Angle) OCV activation 63 times or more Response of valve timing 1 sec./CA or more (valve timing does not change) If the difference between ”target” and ”actual” camshaft timing is larger than the specified value, the ECM operates the VVT actuator. The ECM then monitors the camshaft timing change for 5 seconds. WIRING DIAGRAM Refer to DTC P0010 on page 05-55 . INSPECTION PROCEDURE HINT: Abnormal bank Problem of advanced OCV Problem of retarded OCV Bank 1 P0011 P0012 Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. Hand-held tester: 1 (a) CHECK VALVE TIMING (See page 14-68 ) Check for a loose or jumped tooth of the timing chain. OK: The matchmarks of the crankshaft pulley and camshaft pulley are aligned. NG ADJUST VALVE TIMING (See page 14-68 ) OK 2 (a) (b) (c) (d) (e) PERFORM ACTIVE TEST USING HAND-HELD TESTER (OPERATE OF OCV) Connect the hand-held tester to the DLC3. Start the engine and warm it up. Turn ON the ignition switch. Push the hand-held tester main switch. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1. Using the hand-held tester, operate the OCV and check the engine speed. Standard: Tester Operation Specified Condition OCV is OFF Normal engine speed OCV is ON Rough idle or engine stall NG Go to step 4 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 252 05-63 DIAGNOSTICS 3 (a) - SFI SYSTEM (2AZ-FE) CHECK IF DTC OUTPUTS REOCCUR Erase the DTC(s) using one of the following methods: 1) use the hand-held tester, 2) disconnect the battery cable for more than 60 seconds, or 3) remove the EFI NO. 1 and ETCS fuses for more than 60 seconds. HINT: After disconnecting the battery cable, perform the ”INITIALIZE” procedure (see page 05-893 ). (b) Start and warm up the engine. (c) Drive the vehicle for 10 minutes or more. (d) Read output DTC using the hand-held tester. OK: No DTC is output. OK VVT SYSTEM OK* HINT: *: DTCs P0011 and P0012 are output when a foreign object in the engine oil enters the system. These codes will stay even if the system returns to normal after a short time. Foreign objects are filtered out by the oil filter. NG 4 CHECK ECM (OCV SIGNAL) (a) E9 ECM OC1 + During idling, check the waveform of the ECM connector using an oscilloscope. Standard: Tester Connection Specified Condition E9-16 (OC1+) - E9-15 (OC1-) Correct waveform is as shown OC1- OCV Signal Waveform 5 V/ Division GND 1 msec./Division A67528 A87357 NG REPLACE ECM (See page 10-9 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 253 05-64 DIAGNOSTICS 5 - SFI SYSTEM (2AZ-FE) CHECK OIL CONTROL VALVE FILTER OK: The filter is not clogged. NG REPLACE OIL CONTROL VALVE FILTER OK 6 CHECK CAMSHAFT TIMING OIL CONTROL VALVE ASSY (OCV) (See page 10-2 ) OK: OCV has no contamination and moves smoothly. OK Go to step 8 NG 7 REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSY (OCV) GO 8 CHECK CAMSHAFT TIMING GEAR ASSY (See page 14-79 ) OK: Camshaft timing gear rotates smoothly when pressure is applied. OK Go to step 10 NG 9 REPLACE CAMSHAFT TIMING GEAR ASSY GO 10 CHECK FOR BLOCKAGE (OCV, OIL CHECK VALVE AND OIL HOLE) OK: No blockage NG REPAIR OR REPLACE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 254 05-65 DIAGNOSTICS 11 (a) - SFI SYSTEM (2AZ-FE) CHECK IF DTC OUTPUTS REOCCUR Erase the DTC(s) using one of the following methods: 1) use the hand-held tester, 2) disconnect the battery cable for more than 60 seconds, or 3) remove the EFI NO. 1 and ETCS fuses for more than 60 seconds. HINT: After disconnecting the battery cable, perform the ”INITIALIZE” procedure (see page 05-893 ). (b) Start and warm up the engine. (c) Drive the vehicle for 10 minutes or more. (d) Read output DTC using the hand-held tester. OK: No DTC is output. OK VVT SYSTEM OK* HINT: *: DTCs P0011 and P0012 are output when a foreign object in the engine oil enters the system. These codes will stay even if the system returns to normal after a short time. Foreign objects are filtered out by the oil filter. NG REPLACE ECM (See page 10-9 ) OBD II scan tool (excluding hand-held tester): 1 (a) CHECK VALVE TIMING (See page 14-68 ) Check for loose or jumped tooth of timing chain. OK: The matchmarks of the crankshaft pulley and camshaft pulley are alined. NG ADJUST VALVE TIMING (See page 14-68 ) OK 2 INSPECT OPERATION OF OCV (a) (b) C2 OCV (-) Start the engine. Check the engine speed with (1) and (2). (1) Disconnect the C2 OCV connector. (2) Apply battery positive voltage between the terminals of the OCV. Result: (+) A76968 B Proceed to Check (1) Check (2) A Normal engine speed Rough idle or engine stall B Conditions other than A Conditions other than A Go to step 4 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 255 05-66 DIAGNOSTICS 3 (a) - SFI SYSTEM (2AZ-FE) CHECK IF DTC OUTPUTS REOCCUR Erase the DTC(s) using one of the following methods: 1) use the hand-held tester, 2) disconnect the battery cable for more than 60 seconds, or 3) remove the EFI NO. 1 and ETCS fuses for more than 60 seconds. HINT: After disconnecting the battery cable, perform the ”INITIALIZE” procedure (see page 05-893 ). (b) Start and warm up the engine. (c) Drive the vehicle for 10 minutes or more. (d) Read output DTC using the hand-held tester. OK: No DTC is output. OK VVT SYSTEM OK* HINT: *: DTCs P0011 and P0012 are output when a foreign object in the engine oil enters the system. These codes will stay even if the system returns to normal after a short time. Foreign objects are filtered out by the oil filter. NG 4 CHECK ECM (OCV SIGNAL) (a) E9 ECM OC1 + During idling, check the waveform of the ECM connector using an oscilloscope. Standard: Tester Connection Specified Condition E9-16 (OC1+) - E9-15 (OC1-) Correct waveform is as shown OC1- OCV Signal Waveform 5 V/ Division GND 1 msec./Division A67528 A87357 NG REPLACE ECM (See page 10-9 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 256 05-67 DIAGNOSTICS 5 - SFI SYSTEM (2AZ-FE) CHECK OIL CONTROL VALVE FILTER OK: The filter is not clogged. NG REPLACE OIL CONTROL VALVE FILTER OK 6 CHECK CAMSHAFT TIMING OIL CONTROL VALVE ASSY (OCV) (See page 10-2 ) OK: OCV has no contamination and moves smoothly. OK Go to step 8 NG 7 REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSY (OCV) GO 8 CHECK CAMSHAFT TIMING GEAR ASSY (See page 14-79 ) OK: Camshaft timing gear rotates smoothly when pressure is applied. OK Go to step 10 NG 9 REPLACE CAMSHAFT TIMING GEAR ASSY GO 10 CHECK FOR BLOCKAGE (OCV, OIL CHECK VALVE AND OIL HOLE) OK: No blockage NG REPAIR OR REPLACE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 257 05-68 DIAGNOSTICS 11 (a) - SFI SYSTEM (2AZ-FE) CHECK IF DTC OUTPUTS REOCCUR Erase the DTC(s) using one of the following methods: 1) use the hand-held tester, 2) disconnect the battery cable for more than 60 seconds, or 3) remove the EFI NO. 1 and ETCS fuses for more than 60 seconds. HINT: After disconnecting the battery cable, perform the ”INITIALIZE” procedure (see page 05-893 ). (b) Start and warm up the engine. (c) Drive the vehicle for 10 minutes or more. (d) Read output DTC using the hand-held tester. OK: No DTC is output. OK VVT SYSTEM OK* HINT: *: DTCs P0011 and P0012 are output when a foreign object in the engine oil enters the system. These codes will stay even if the system returns to normal after a short time. Foreign objects are filtered out by the oil filter. NG REPLACE ECM (See page 10-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 258 05-69 DIAGNOSTICS DTC P0016 - SFI SYSTEM (2AZ-FE) 0520A-16 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK 1 SENSOR A) CIRCUIT DESCRIPTION Refer to DTC P0335 and P0339 on page 05-166 . DTC No. P0016 DTC Detection Condition Trouble Area Deviation in crankshaft position sensor signal and VVT sensor (bank 1) signal (2 trip detection logic)
Mechanical system (jumped tooth of timing chain, chain stretched)
ECM MONITOR DESCRIPTION The ECM optimizes the valve timing using the Variable Valve Timing (VVT) system to control the intake valve camshaft. The VVT system includes the ECM, the Oil Control Valve (OCV) and the VVT controller. The ECM sends a target duty-cycle control signal to the OCV. This control signal, sent to the OCV, regulates the oil pressure applied to the VVT controller. The VVT controller can advance or retard the intake valve camshaft. The ECM calibrates the valve timing of the VVT system by setting the camshaft to the maximum retard angle when the engine is idling. The ECM closes the OCV to retard the cam. The ECM stores this value as a VVT learning value. When the difference between the target valve timing and the actual valve timing is 5 degrees or less, the ECM stores this in its memory. If the learning value meets both of the following conditions (”a” and ”b”), the ECM interprets this as a defect in the VVT system and sets a DTC. (a) The VVT learning value is less than 27CA or more than 49CA. (b) The Above condition continues for more than 18 seconds. MONITOR STRATEGY Related DTCs P0016: Camshaft timing misalignment at Idling Required sensors / components (Main) VVT actuator Required sensors / components (Related) CMP and CKP sensors Frequency of operation Once per driving cycle Duration Within 60 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present See page 05-16 Engine RPM 550 to 1,400 rpm TYPICAL MALFUNCTION THRESHOLDS Duration that either of the following conditions 1 or 2 is met 18 sec. or more 1. VVT angle when camshaft is retarded maximum Less than 27CA 2. VVT angle when camshaft is retarded maximum More than 49CA 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 259 05-70 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) WIRING DIAGRAM Refer to DTCs P0335 and P0339 on page 05-166 . INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 (a) CHECK VALVE TIMING (See page 14-68 ) Check for loose or jumped tooth of timing chain. OK: The matchmarks of the crankshaft pulley and camshaft pulley are alined. NG ADJUST VALVE TIMING (See page 14-68 ) OK REPLACE ECM (See page 10-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 260 05-71 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05ET1-06 DTC P0031 OXYGEN (A/F) SENSOR HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1) DTC P0032 OXYGEN SENSOR HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1) HINT: Although the title (DTC description) says ”oxygen sensor”, this DTC is related to the ”A/F sensor”. CIRCUIT DESCRIPTION Refer to DTC P2195 on page 05-269 . HINT: The ECM provides a pulse width modulated control circuit to adjust current through the heater. The A/F sensor heater circuit uses a relay on the +B side of the circuit. Reference A/F Sensor Heater HT +B EFI Relay From Battery EFI NO. 2 Sensor Fuse AFAF+ EFI NO. 1 Fuse ECM HA1A A1A+ Duty Control A1AMREL A90346 DTC No. DTC Detection Condition Trouble Area P0031 Heater current of 0.8 A or less when heater operates (1 trip detection logic)
Open in heater circuit of A/F sensor
A/F sensor heater
EFI relay
ECM P0032 Heater current exceeds 10 A when heater operates (1 trip detection logic)
Short in heater circuit of A/F sensor
A/F sensor heater
EFI relay
ECM HINT: Sensor 1 is the sensor closest to the engine assembly. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 261 05-72 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) MONITOR DESCRIPTION The ECM uses A/F sensor information to keep the air/fuel ratio close to the stoichiometric ratio. This maximizes the catalytic converter’s ability to purify exhaust gas. The sensor detects oxygen levels in the exhaust gas and sends this signal to the ECM. The inner surface of the sensor element is exposed to outside air. The outer surface of the sensor element is exposed to exhaust gas. The sensor element is made of platinum coated zirconia and includes an integrated heating element. The zirconia element generates small voltage when there is a large difference in the oxygen concentrations of the exhaust and the outside air. The platinum coating amplifies the voltage generation. When heated, the sensor becomes very efficient. If the temperature of the exhaust is low, the sensor will not generate useful voltage signals without supplemental heating. The ECM regulates the supplemental heating using a duty-cycle approach to regulate the average current in the heater element. If the heater current is out of the normal range, the sensor’s output signals will be inaccurate and the ECM cannot regulate the A/F ratio properly. When the heater current is out of the normal operating range, the ECM interprets this as a malfunction and sets a DTC. MONITOR STRATEGY Related DTCs P0031: A/F sensor heater range check (Low current) P0032: A/F sensor heater range check (High current) Required sensors / components (Main) A/F sensor heater Required sensors / components (Related) - Frequency of operation Continuous Duration 10 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present See page 05-16 P0031: Battery voltage Less than 10.5 V A/F sensor heater duty ratio 50 % or more Time after engine start 10 sec. or more P0032: Time after engine start 10 sec. or more TYPICAL MALFUNCTION THRESHOLDS P0031: A/F sensor heater current Less than 0.8 A P0032: A/F sensor heater current More than 10 A COMPONENT OPERATING RANGE A/F sensor heater current 1.8 to 3.4 A at 20°C (68°F) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 262 05-73 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) MONITOR RESULT Refer to page 05-24 for detailed information. The test value and test limit information are described as shown in the following table. Check the monitor result and test values after performing the monitor drive pattern (see page 05-26 ).
TID (Test Identification Data) is assigned to each emissions-related component.
TLT (Test Limit Type): If TLT is 0, the component is malfunctioning when the test value is higher than the test limit. If TLT is 1, the component is malfunctioning when the test value is lower than the test limit.
CID (Component Identification Data) is assigned to each test value.
Unit Conversion is used to calculate the test value indicated on generic OBD ll scan tools. TID $07: A/F sensor heater TLT CID 1 $01 Unit Conversion Description of Test Data Multiply by 0.00017 (A) Maximum heater current Description of Test Limit Malfunction criterion for A/F sensor heater WIRING DIAGRAM Refer to DTC P2195 on page 05-269 . INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) (b) A6 A/F sensor AF- AF+ Disconnect the A6 A/F sensor connector. Measure the resistance between the terminals of the A/F sensor. Standard: Tester Connection Condition Specified Condition 1 (HT) - 2 (+B) 20C (68F) 1.8 to 3.4 Ω 1 (HT) - 4 (AF-) - 10 kΩ or higher NG REPLACE AIR FUEL RATIO SENSOR A52607 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 263 05-74 DIAGNOSTICS 2 1 SFI SYSTEM (2AZ-FE) INSPECT RELAY (EFI) 2 1 3 - 5 (a) (b) 5 2 Remove the EFI relay from the engine room J/B. Measure the resistance of the EFI relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 3 NG B60778 REPLACE RELAY OK 3 CHECK ECM (HA1A VOLTAGE) HA1A (+) E8 ECM E9 ECM E1 (-) A76903 (a) (b) Turn the ignition switch ON. Measure the voltage of the ECM connectors. Standard: OK Tester Connection Specified Condition E8-5 (HA1A) - E9-1 (E1) 9 to 14 V REPLACE ECM (See page 10-9 ) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 264 05-75 DIAGNOSTICS 4 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS (ECM - A/F SENSOR, A/F SENSOR - EFI RELAY) (a) Wire Harness Side E8 ECM Check the wire harness between the ECM and A/F sensor. (1) Disconnect the E8 ECM connector. (2) Disconnect the A6 A/F sensor connector. (3) Measure the resistance of the wire harness side connectors. Standard: HA1A Tester Connection Specified Condition A6-1 (HT) - E8-5 (HA1A) Below 1 Ω A6-1 (HT) or E8-5 (HA1A) - Body ground 10 kΩ or higher A6 A/F Sensor HT 1 3 2 4 +B A81695 A76787 A85433 (b) Wire Harness Side A6 A/F Sensor HT 1 3 2 4 +B Check the wire harness between the A/F sensor and EFI relay. (1) Disconnect the A6 A/F sensor connector. (2) Remove the EFI relay from the engine room J/B. (3) Measure the resistance of the wire harness side connectors. Standard: Tester Connection Engine Room J/B A6-2 (+B) - J/B EFI relay terminal 3 Below 1 Ω A6-2 (+B) or J/B EFI relay terminal 3 - Body ground 10 kΩ or higher NG EFI Relay A90291 A76787 A90920 Specified Condition REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE ECM (See page 10-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 265 05-76 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05ETE-05 DTC P0037 OXYGEN SENSOR HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2) DTC P0038 OXYGEN SENSOR HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2) CIRCUIT DESCRIPTION Refer to DTC P0136 on page 05-1 18. HINT: The ECM provides a pulse width a modulated control circuit to adjust current through the heater. The oxygen sensor heater circuit uses a relay on the +B side of the circuit. Reference Heated Oxygen Sensor EFI Relay From Battery EFI NO. 1 Fuse ECM +B Heater HT HT1B EFI NO. 2 Sensor E1 Fuse OX OX1B Duty Control OB1MREL A90346 DTC No. DTC Detection Condition Trouble Area P0037 Heater current of less than 0.3 A when the heater operates with +B greater than 10.5 V (1 trip detection logic)
Open or short in heater circuit of heated oxygen sensor
Heated oxygen sensor heater
EFI relay
ECM P0038 Heater current exceeds 2 A when heater operates (1 trip detection logic)
Same as DTC No. P0037 HINT: Sensor 2 is the sensor farthest away from the engine assembly. MONITOR DESCRIPTION The sensing portion of the heated oxygen sensor has a zirconia element that is used to detect oxygen concentration in the exhaust. If the zirconia element is at the proper temperature and the difference of the oxygen concentration between the inside and outside surface of the sensor is large, the zirconia element will generate voltage signals. In order to increase the oxygen concentration detecting capacity in the zirconia element, the ECM supplements the heat from the exhaust with heat from a heating element inside the sensor. When current in the sensor is out of the standard operating range, the ECM interprets this as a fault in the heated oxygen sensor and sets a DTC. Example: The ECM will set a high current DTC if the current in the sensor is more than 2 A when the heater is OFF. Similarly, the ECM will set a low current DTC if the current is less than 0.25 A when the heater is ON. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 266 05-77 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) MONITOR STRATEGY Related DTCs P0037: HO2S heater range check (Low current) P0038: HO2S heater range check (High current) Required sensors / components (Main) Heated oxygen sensor (HO2S) heater Required sensors / components (Related) Vehicle speed sensor (VSS) Frequency of operation Continuous Duration 0.3 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present See page 05-16 P0037: Battery voltage 10.5 V or more Engine Running Starter OFF Intrusive heating Not operated P0038 (Case 1): Battery voltage 10.5 V or more Engine Running Starter OFF Intrusive heating Not operated P0038 (Case 2): Battery voltage 10.5 V or more All heater is turned OFF and intrusive heating is operated when the following conditions are met Condition 1 and 2 1. Heater ON 2. Heater current 2 A or more TYPICAL MALFUNCTION THRESHOLDS P0037: HO2S heater current intrusive heating Less than 0.3 A P0038 (Case 1): HO2S heater current 2 A or more P0038 (Case 2): HO2S heater current intrusive heating More than 2 A COMPONENT OPERATING RANGE HO2S heater current 0.4 to 1 A (when engine is idle, warmed-up and battery voltage is 11 to 14 V) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 267 05-78 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) MONITOR RESULT Refer to page 05-24 for detailed information. The test value and test limit information are described as shown in the following table. Check the monitor result and test values after performing the monitor drive pattern (see page 05-26 ).
TID (Test Identification Data) is assigned to each emissions-related component.
TLT (Test Limit Type): If TLT is 0, the component is malfunctioning when the test value is higher than the test limit. If TLT is 1, the component is malfunctioning when the test value is lower than the test limit.
CID (Component Identification Data) is assigned to each test value.
Unit Conversion is used to calculate the test value indicated on generic OBD ll scan tools. TID $04: HO2S heater TLT 1 CID $02 Unit Conversion Description of Test Data Multiply by 0.000076 (A) Description of Test Limit Maximum HO2S heater current (Bank 1 Sensor 2) Malfunction threshold for HO2S heater WIRING DIAGRAM Refer to DTC P0136 on page 05-1 18. INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 INSPECT HEATED OXYGEN SENSOR (HEATER RESISTANCE) (a) (b) H10 Heated Oxygen Sensor HT OX +B E1 Disconnect the H10 heated oxygen sensor connector. Measure the resistance of the heated oxygen sensor terminals. Standard: Tester Connection Condition H10-2 (HT) - H10-1 (+B) 20C (68F) 11 to 16 Ω H10-2 (HT) - H10-1 (+B) 800C (1,472F) 23 to 32 Ω NG Specified Condition REPLACE HEATED OXYGEN SENSOR A80018 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 268 05-79 DIAGNOSTICS 2 1 SFI SYSTEM (2AZ-FE) INSPECT RELAY (EFI) 2 1 3 - 5 5 2 (a) (b) Remove the EFI relay from the engine room J/B. Measure the resistance of the EFI relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 3 B60778 NG REPLACE RELAY OK 3 INSPECT ECM (HT1B VOLTAGE) HT1B (+) E1 (-) E8 ECM E9 ECM (a) (b) Turn the ignition switch ON. Measure the voltage of the ECM connectors. Standard: Tester Connection Specified Condition E8-21 (HT1B) - E9-1 (E1) 9 to 14 V OK REPLACE ECM (See page 10-9 ) A76903 NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 269 05-80 DIAGNOSTICS 4 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS (ECM - HEATED OXYGEN SENSOR, HEATED OXYGEN SENSOR - EFI RELAY) (a) Wire Harness Side E8 ECM Check the wire harness between the ECM and heated oxygen sensor. (1) Disconnect the E8 ECM connector. (2) Disconnect the H10 heated oxygen sensor connector. (3) Measure the resistance of the wire harness side connectors. Standard: Tester Connection HT1B H10 Heated Oxygen Sensor +B HT E1 OX A81695 A80019 Specified Condition H10-2 (HT) - E8-21 (HT1B) Below 1 Ω H10-2 (HT) or E8-21 (HT1B) - Body ground 10 kΩ or higher A91528 (b) Wire Harness Side H10 Heated Oxygen Sensor +B HT E1 OX Check the wire harness between the heated oxygen sensor and EFI relay. (1) Disconnect the H10 heated oxygen sensor connector. (2) Remove the EFI relay from the engine room J/B. (3) Measure the resistance of the wire harness side connectors. Standard: Tester Connection Below 1 Ω H10-1 (+B) or J/B EFI relay terminal 3 - Body ground 10 kΩ or higher Engine Room J/B EFI Relay A80019 A90291 NG A91529 Specified Condition H10-1 (+B) - J/B EFI relay terminal 3 REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE ECM (See page 10-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 270 05-81 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05ESV-05 DTC P0100 MASS OR VOLUME AIR FLOW CIRCUIT DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT CIRCUIT DESCRIPTION The Mass Air Flow (MAF) meter measures the amount of air flowing through the throttle valve. The ECM uses this information to determine the fuel injection time and provide a proper air fuel ratio. Inside the MAF meter, there is a heated platinum wire exposed to the flow of intake air. By applying a specific current to the wire, the ECM heats this wire to a given temperature. The flow of incoming air cools the wire and an internal thermistor, changing their resistance. To maintain a constant current value, the ECM varies the voltage applied to these components in the MAF meter. The voltage level is proportional to the air flow through the sensor. The ECM interprets this voltage as the intake air amount. The circuit is constructed so that the platinum hot wire and temperature sensor provide a bridge circuit, with the power transistor controlled so that the potential of A and B remains equal to maintain the set temperature. B+ Temperature Sensor Power Transistor Platinum Hot Wire (Heater) B A Output Voltage Temperature Sensor Platinum Hot Wire (Heater) A80089 DTC No. DTC Detection Condition Trouble Area P0100 When MAF meter circuit has an open or a short for more than 3 seconds
Open or short in MAF meter circuit
MAF meter
ECM P0102 When MAF meter circuit has an open for more than 3 seconds
Same as DTC No. P0100 P0103 When MAF meter circuit has a short for more than 3 seconds
Same as DTC No. P0100 HINT: After confirming DTC P0100, P0102 or P0103, use the hand-held tester or the OBD II scan tool to confirm the MAF ratio from the ALL menu (to reach the ALL menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL). Air Flow Value (g/s) Approximately 0.0 271.0 or more Malfunction
Open in MAF meter power source circuit
Open or short in VG circuit
Open in EVG circuit 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 271 05-82 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) MONITOR DESCRIPTION If there is a defect in the sensor, or an open or short circuit, the voltage level will deviate from the normal operating range. The ECM interprets this deviation as a defect in the MAF meter and sets a DTC. Example: The sensor voltage output is less than 0.2 V or more than 4.9 V and either condition continues for more than 3 seconds. MONITOR STRATEGY Related DTCs P0100: MAF meter range check (Chattering) P0102: MAF meter range check(Low voltage) P0103: MAF meter range check (High voltage) Required sensors / components (Main) MAF Meter Required sensors / components (Related) CKP (Crank shaft position) sensor Frequency of operation Continuous Duration 3 sec. MIL operation Immediate: Engine RPM is less than 4,000 rpm 2 driving cycles: Engine RPM is 4,000 rpm or more Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-16 TYPICAL MALFUNCTION THRESHOLDS P0100: MAF meter voltage Less than 0.2 V, or more than 4.9 V P0102: MAF meter voltage Less than 0.2 V P0103: MAF meter voltage More than 4.9 V COMPONENT OPERATING RANGE MAF meter voltage Between 0.4 and 2.2 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 272 05-83 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) WIRING DIAGRAM M1 MAF Meter Engine Room R/B No. 2 EFI NO. 2 2 B-W 2 1 EB1 B-R +B VG 1 1 2 ECM R 30 VG E7 L-W 29 EVG E7 3 E2G 2 Y 5V P-L 3 2D 13 B IK3 8 E5 MREL 2B 5 3 1 5 2 EFI Relay Engine Room J/B EFI NO. 1 1 2I 2F 4 W 3 F7 FL Block Assy 1 W W-B A J2 J/C FL Main Battery EH A90347 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 273 05-84 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 (a) (b) (c) (d) READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (MAF RATE) Connect the hand-held tester or the OBD II scan tool to the DLC3. Start the engine. Push the hand-held tester or the OBD II scan tool main switch ON. On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / MAF. Read the values. Result: Air Flow Rate (gm/second) Proceed to 0.0 A 271.0 or more B MAF rate greater than 1 but less than 270.0 * C HINT: *: The value must change when the throttle valve is opened or closed. B Go to step 6 C CHECK FOR INTERMITTENT PROBLEMS (See page 05-9 ) A 2 CHECK MASS AIR FLOW METER (POWER SOUCE VOLTAGE) (a) (b) (c) Wire Harness Side M1 MAF Meter Turn the ignition switch ON. Disconnect the M1 MAF meter connector. Measure the voltage of the wire harness side connector. Standard: Tester Connection Specified Condition M1-1 (+B) - Body ground 9 to 14 V +B (+) A54396 NG Go to step 5 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 274 05-85 DIAGNOSTICS 3 - SFI SYSTEM (2AZ-FE) INSPECT ECM (VG VOLTAGE) VG (+) (a) (b) EVG (-) Start the engine. Measure the voltage of the ECM connector. Standard: Tester Connection Condition Specified Condition E7-30 (VG) - E7-29 (EVG) Engine is idling 0.5 to 3.0 V HINT: The shift position should be P or N and the A/C switch should be turned OFF. E7 ECM A76903 OK REPLACE ECM (See page 10-9 ) NG 4 CHECK WIRE HARNESS (MAF METER - ECM) (a) (b) (c) Wire Harness Side M1 MAF Meter EVG Disconnect the M1 MAF meter connector. Disconnect the E7 ECM connector. Measure the resistance of the wire harness side connectors. Standard: VG E7 ECM Tester Connection Specified Condition M1-3 (VG) - E7-30 (VG) M1-2 (EVG) - E7-29 (EVG) Below 1 Ω M1-3 (VG) or E7-30 (VG) - Body ground 10 kΩ or higher EVG Y A54396 A81699 VG A85482 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE MASS AIR FLOW METER 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 275 05-86 DIAGNOSTICS 5 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS (MAF METER - EFI RELAY) (a) (b) (c) Wire Harness Side M1 MAF Meter Disconnect the M1 MAF meter connector. Remove the EFI relay from the engine room J/B. Measure the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition M1-1 (+B) - J/B EFI relay terminal 3 Below 1 Ω M1-1 (+B) or J/B EFI relay terminal 3 - Body ground 10 kΩ or higher +B (+) Engine Room J/B EFI Relay A54396 A90291 A90959 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK INSPECT ECM POWER SOURCE CIRCUIT (See page 05-312 ) 6 INSPECT ECM (SENSOR GROUND) (a) EVG E7 ECM A76903 Measure the resistance of the ECM connector. Standard: Tester Connection Specified Condition E7-29 (EVG) - Body ground Below 1 Ω NG REPLACE ECM (See page 10-9 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 276 05-87 DIAGNOSTICS 7 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS (MAF METER - ECM) (a) (b) (c) Wire Harness Side M1 MAF Meter EVG Disconnect the M1 MAF meter connector. Disconnect the E7 ECM connector. Measure the resistance of the wire harness side connectors. Standard: VG E7 ECM Tester Connection Specified Condition M1-3 (VG) - E7-30 (VG) M1-2 (EVG) - E7-29 (EVG) Below 1 Ω M1-3 (VG) or E7-30 (VG) - Body ground 10 kΩ or higher EVG Y A54396 A81699 VG A85482 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE MASS AIR FLOW METER 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 277 05-88 DIAGNOSTICS DTC P0101 - SFI SYSTEM (2AZ-FE) 051ZM-14 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE PROBLEM CIRCUIT DESCRIPTION Refer to DTC P0100 on page 05-81 . DTC No. DTC Detection Condition P0101
High voltage: Conditions (a), (b) and (c) continue for more than 10 seconds (2 trip detection logic): (a) Engine speed less than 2,000 rpm (b) Engine coolant temperature 70C (158F) or higher (c) Voltage output of Mass Air Flow (MAF) meter more than 2.2 V (varies with Throttle Position [TP] sensor voltage)
Low voltage: Conditions (a) and (b) continue for more than 10 seconds (2 trip detection logic): (a) Engine speed more than 300 rpm (b) Voltage output of MAF meter less than 0.65 V (varies with TP sensor voltage) Trouble Area
MAF meter MONITOR DESCRIPTION The MAF meter is a sensor that measures the amount of air flowing through the throttle valve. The ECM uses this information to determine the fuel injection time and to provide an appropriate air-fuel ratio. Inside the MAF meter, there is a heated platinum wire which is exposed to the flow of intake air. By applying a specific electrical current to the wire, the ECM heats it to a specific temperature. The flow of incoming air cools both the wire and an internal thermistor, changing their resistance. To maintain a constant current value, the ECM varies the voltage applied to these components of the MAF meter. The voltage level is proportional to the air flow through the sensor, and the ECM uses it to calculate the intake air volume. If there is a defect in the sensor, or an open or short in the circuit, the voltage level deviates from the normal operating range. The ECM interprets this deviation as a malfunction in the MAF meter and sets the DTC. Example: If the voltage is more than 2.2 V, or less than 0.65 V while idling, the ECM determines that there is a malfunction in the MAF meter and sets the DTC. MONITOR STRATEGY Related DTCs P0101: MAF Meter Rationality (Low voltage) P0101: MAF Meter Rationality (High voltage) Required sensors/ components (Main) MAF meter Required sensors/ components (Related) Crankshaft position sensor, ECT sensor, Throttle position sensor Frequency of operation Continuous Duration 10 seconds MIL operation 2 driving cycles Sequence of operation None 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 278 05-89 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present See page 05-16 MAF Meter Rationality (High Voltage): Engine RPM Less than 2,000 rpm ECT 70°C (158°F) or more MAF meter voltage 4.9 V or less MAF Meter Rationality (Low Voltage): Engine RPM More than 300 rpm MAF meter voltage 0.2 V or more Fuel cut OFF TYPICAL MALFUNCTION THRESHOLDS MAF Meter Rationality (High Voltage): MAF meter voltage More than 2.2 V (varies with throttle position sensor voltage) MAF Meter Rationality (Low Voltage): MAF meter voltage Less than 0.65 V (varies with throttle position sensor voltage) WIRING DIAGRAM Refer to DTC P0100 on page 05-81 . INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 (a) CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0101) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display (DTC Output) Proceed to P0101 and other DTCs are output A Only P0101 is output B HINT: If any other codes besides P0101 are output, perform the troubleshooting for those codes first. B REPLACE MASS AIR FLOW METER A GO TO RELEVANT DTC CHART (See page 05-48 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 279 05-90 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 0596B-07 DTC P0110 INTAKE AIR TEMPERATURE CIRCUIT DTC P0112 INTAKE AIR TEMPERATURE CIRCUIT LOW INPUT DTC P0113 INTAKE AIR TEMPERATURE CIRCUIT HIGH INPUT CIRCUIT DESCRIPTION Fig. 1 30 20 Resistance kΩ 10 Acceptable 5 3 2 1 0.5 0.3 0.2 0.1 - 20 (- 4) 0 32 20 68 40 104 60 140 80 176 100 212 The Intake Air Temperature (IAT) sensor, mounted on the Mass Air Flow (MAF) meter, monitors the intake air temperature. The IAT sensor has a thermistor that varies its resistance depending on the temperature of the intake air. When the air temperature is low, the resistance in the thermistor increases. When the temperature is high, the resistance drops. The variations in resistance are reflected as changes in voltage applied to the ECM terminal (see Fig. 1). The IAT sensor is connected to the ECM (see below). The 5 V power source voltage in the ECM is applied to the IAT sensor from terminal THA via resistor R. That is, the resistor R and the IAT sensor are connected in series. When the resistance value of the IAT sensor changes in accordance with changes in the IAT, the voltage at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve the driveability during cold engine operation. Temperature C (F) A67628 DTC No. Proceed to DTC Detection Condition Trouble Area P0110 Step 1 Open or short in IAT (Intake air temperature) sensor circuit for 0.5 seconds (1 trip detection logic) P0112 Step 4 Short in IAT sensor circuit for 0.5 seconds (1 trip detection logic)
Same as DTC No. P0110 P0113 Step 2 Open in IAT sensor circuit for 0.5 seconds (1 trip detection logic)
Same as DTC No. P0110
Open or short in IAT sensor circuit
IAT sensor (built-in MAF meter)
ECM HINT: After confirming DTC P0110, P0112 or P0113, use the hand-held tester or the OBD II scan tool to confirm the IAT from the ALL menu (to reach the ALL menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL). Temp. Displayed Malfunction -40 °C (-40°F) Open circuit 140°C (284°F) or more Short circuit 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 280 05-91 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) MONITOR DESCRIPTION The ECM monitors the sensor voltage and uses this value to calculate the intake air temperature. When the sensor output voltage deviates from the normal operating range, the ECM interprets this as a fault in the IAT sensor and sets a DTC. Example: The sensor voltage output is -40C (-40F), or more than 140C (284F) and either condition continues for 0.5 seconds or more. MONITOR STRATEGY Related DTCs P0110: IAT sensor range check (Chattering) P0112: IAT sensor range check (Low Resistance) P0113: IAT sensor range check (High Resistance) Required sensors / components (Main) IAT sensor Required sensors / components (Related) - Frequency of operation Continuous Duration 0.5 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-16 TYPICAL MALFUNCTION THRESHOLDS P0110: IAT sensor resistance Less than 98.5 Ω, or more than 156 kΩ P0112: IAT sensor resistance [IAT] Less than 98.5 Ω [More than 140C (284F)] P0113: IAT sensor resistance [IAT] More than 156 kΩ [-40C (-40F)] COMPONENT OPERATING RANGE IAT sensor resistance [IAT] 98.5 Ω to 156 kΩ [-39 to 140C (-40 to 284F)] 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 281 05-92 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) WIRING DIAGRAM M1 MAF Meter (IAT Sensor) ECM 5V 5 20 THA E7 L-B 4 G BR Short Connector 5 5 S29 S28 28 BR E7 E2 A90293 INSPECTION PROCEDURE HINT:
If DTCs that are related to different systems are output simultaneously while terminal E2 is used as a ground terminal, terminal E2 may have an open circuit. Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred.
1 (a) (b) (c) READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (INTAKE AIR TEMPERATURE) Connect the hand-held tester or the OBD II scan tool to the DLC3. Turn ON the ignition switch. Push the hand-held tester or the OBD II scan tool main switch ON. On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / INTAKE AIR. Read the values. Temperature: The same as actual intake air temperature. Result: Display Proceed to -40 °C (-40°F) A 140°C (284°F) or more B OK (same as present temperature) C HINT:

If there is an open circuit, the hand-held tester or the OBD II scan tool indicates -40°C (-40°F). If there is a short circuit, the hand-held tester or the OBD II scan tool indicates 140°C (284°F) or more. B Go to step 4 C CHECK FOR INTERMITTENT PROBLEMS (See page 05-9 ) A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 282 05-93 DIAGNOSTICS 2 - SFI SYSTEM (2AZ-FE) READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (CHECK FOR OPEN IN HARNESS) M1 MAF Meter (a) (b) ECM (c) (d) THA E2 Disconnect the M1 MAF meter connector. Connect terminals THA and E2 of the M1 MAF meter wire harness side connector. Turn the ignition switch ON. On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / INTAKE AIR. Read the values. OK: Temperature value: 140°C (284°F) or more Wire Harness Side M1 MAF Meter THA E2 OK Y A75743 A76903 A85506 REPLACE MASS AIR FLOW METER (IAT SENSOR) NG 3 READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (CHECK FOR OPEN IN ECM) M1 MAF Meter (a) Disconnect the M1 MAF meter connector. (b) Connect terminals THA and E2 of the E7 ECM connector. HINT: Before checking, do a visual and contact pressure check for the ECM connector. (c) Turn the ignition switch ON. (d) On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / INTAKE AIR. Read the values. OK: Temperature value: 140°C (284°F) or more ECM THA E2 THA Y A75742 A76903 E2 E7 ECM OK A85507 REPAIR OR CONNECTOR REPLACE HARNESS OR NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 283 05-94 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) CONFIRM GOOD CONNECTION AT ECM. IF OK, REPLACE ECM (See page 10-9 ) 4 READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (CHECK FOR SHORT IN HARNESS) M1 MAF Meter (a) (b) (c) ECM THA E2 A75766 Disconnect the M1 MAF meter connector. Turn the ignition switch ON. On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / INTAKE AIR. Read the values. OK: Temperature value: -40°C (-40°F) OK REPLACE MASS AIR FLOW METER NG 5 READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (CHECK FOR SHORT IN ECM) M1 MAF Meter (a) (b) (c) ECM THA E2 Disconnect the E7 ECM connector. Turn the ignition switch ON. On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / INTAKE AIR. Read the values. OK: Temperature value: -40°C (-40°F) E7 ECM Y A75744 A81699 OK A85508 REPAIR OR CONNECTOR REPLACE HARNESS OR NG REPLACE ECM (See page 10-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 284 05-95 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 0596C-07 DTC P0115 ENGINE COOLANT TEMPERATURE CIRCUIT DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW INPUT DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH INPUT CIRCUIT DESCRIPTION A thermistor is built into the Engine Coolant Temperature (ECT) sensor and changes the resistance value according to the engine coolant temperature. The structure of the sensor and connection to the ECM are the same as the Intake Air Temperature (IAT) sensor. HINT: If the ECM detects the DTC P0115, P0117 or P0118, it operates the fail-safe function in which the ECT is assumed to be 80C (176F). DTC No. Proceed to DTC Detection Condition Trouble Area P0115 Step 1 Open or short in ECT (Engine coolant temperature) sensor circuit for 0.5 seconds P0117 Step 4 Short in ECT sensor circuit for 0.5 seconds
Same as DTC No. P0115 P0118 Step 2 Open in ECT sensor circuit for 0.5 seconds
Same as DTC No. P0115
Open or short in ECT sensor circuit
ECT sensor
ECM HINT: After confirming DTC P0115, P0117 or P0118, use the hand-held tester or the OBD II scan tool to confirm the ECT from the ALL menu (to reach the ALL menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL). Temperature Displayed Malfunction -40 °C (-40°F) Open circuit 140°C (284°F) or more Short circuit MONITOR DESCRIPTION The ECT sensor is used to monitor the engine coolant temperature. The ECT sensor has a thermistor that varies its resistance depending on the temperature of the engine coolant. When the coolant temperature is low, the resistance in the thermistor increases. When the temperature is high, the resistance drops. The variations in resistance are reflected in the voltage output from the sensor. The ECM monitors the sensor voltage and uses this value to calculate the engine coolant temperature. When the sensor output voltage deviates from the normal operating range, the ECM interprets this as a fault in the ECT sensor and sets a DTC. Example: When the ECM calculates that the ECT is -40C (-40F) or more than 140C (284F) and if either condition continues for 0.5 seconds or more, the ECM will set a DTC. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 285 05-96 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) MONITOR STRATEGY Related DTCs P0115: ECT sensor range check (Chattering) P0117: ECT sensor range check (Low resistance) P0118: ECT sensor range check (High resistance) Required sensors / components (Main) ECT sensor Required sensors / components (Related) - Frequency of operation Continuous Duration 0.5 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-16 TYPICAL MALFUNCTION THRESHOLDS P0115: Less than 79 Ω or more than 156 kΩ ECT sensor resistance P0117: Less than 79 Ω [More than 140C (284F)] ECT sensor resistance [ECT] P0118: ECT sensor resistance [ECT] More than 156 kΩ [-40C (-40F)] COMPONENT OPERATING RANGE 79 Ω to 156 KΩ [-39 to 140C (-40 to 284F)] ECT sensor resistance [ECT] WIRING DIAGRAM ECM E2 ECT Sensor THW 5V E2 1 19 THW E7 G-B 2 BR BR Short Connector 5 5 S29 S28 BR 28 E7 R E2 A90294 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 286 05-97 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) INSPECTION PROCEDURE HINT:
If DTCs that are related to different systems are output simultaneously while terminal E2 is used as a ground terminal, terminal E2 may have an open circuit. Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred.
1 (a) (b) (c) READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (ENGINE COOLANT TEMPERATURE) Connect the hand-held tester or the OBD II scan tool to the DLC3. Turn ON the ignition switch. Push the hand-held tester or the OBD II scan tool main switch ON. On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / COOLANT TEMP. Read the values. Temperature: Same value as the actual engine coolant temperature. Result: Temperature Displayed Proceed to -40 °C (-40°F) A 140°C (284°F) or more B OK (same as present temperature) C HINT:

If there is an open circuit, the hand-held tester or the OBD II scan tool indicates -40°C (-40°F). If there is a short circuit, the hand-held tester or the OBD II scan tool indicates 140°C (284°F) or more. B Go to step 4 C CHECK FOR INTERMITTENT PROBLEMS (See page 05-9 ) A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 287 05-98 DIAGNOSTICS 2 - SFI SYSTEM (2AZ-FE) READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (CHECK FOR OPEN IN WIRE HARNESS) E2 ECT Sensor (a) (b) ECM (c) (d) THW E2 Disconnect the E2 ECT sensor connector. Connect terminals 1 and 2 of the E2 ECT sensor wire harness side connector. Turn the ignition switch ON. On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / COOLANT TEMP. Read the values. OK: Temperature value: 140°C (284°F) or more Wire Harness Side E2 ECT Sensor OK Y 75743 A66104 A85509 CONFIRM GOOD CONNECTION AT SENSOR. IF OK, REPLACE ENGINE COOLANT TEMP. SENSOR NG 3 READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (CHECK FOR OPEN IN ECM) E2 ECT Sensor (a) Disconnect the E2 ECT sensor connector. (b) Connect terminals THW and E2 of the E7 ECM connector. HINT: Before checking, do a visual and contact pressure check for the ECM connector. (c) Turn the ignition switch ON. (d) On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / COOLANT TEMP. Read the values. OK: Temperature value: 140°C (284°F) or more ECM THW E2 THW Y A75742 A76903 E2 E7 ECM A85507 OK REPAIR OR CONNECTOR REPLACE HARNESS AND NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 288 05-99 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) CONFIRM GOOD CONNECTION AT ECM. IF OK, REPLACE ECM (See page 10-9 ) 4 READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (CHECK FOR SHORT IN WIRE HARNESS) E2 ECT Sensor (a) (b) (c) ECM THW E2 Disconnect the E2 ECT sensor connector. Turn the ignition switch ON. On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / COOLANT TEMP. Read the values. OK: Temperature value: -40°C (-40°F) OK A75766 REPLACE ENGINE COOLANT TEMPERATURE SENSOR NG 5 READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (CHECK FOR SHORT IN ECM) E2 ECT Sensor (a) (b) (c) ECM THW E2 Disconnect the E7 ECM connector. Turn the ignition switch ON. On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / COOLANT TEMP. Read the values. OK: Temperature value: -40°C (-40°F) E7 ECM Y A75744 A81699 OK A85508 REPAIR OR CONNECTOR REPLACE HARNESS AND NG REPLACE ECM (See page 10-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 289 05-100 DIAGNOSTICS DTC P0116 - SFI SYSTEM (2AZ-FE) 051ZP-14 ENGINE COOLANT TEMP. CIRCUIT RANGE/PERFORMANCE PROBLEM CIRCUIT DESCRIPTION Refer to DTC P0115 on page 05-95 . DTC No. P0116 DTC Detection Condition Trouble Area ECT is between 35°C (95°F) and 60°C (140°F) when engine is started, and conditions (a) and (b) are met: (a) Vehicle has accelerated and decelerated (b) ECT remains within 3°C (5.4°F) of initial engine coolant temperature (2 trip detection logic)
ECT is more than 60°C (140°F) when engine is started and vehicle has accelerated and decelerated
ECT sensor records a temperature variation is within 1°C (1.8°F) successively 6 times (6 trip detection logic)
Cooling system
ECT sensor MONITOR DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to monitor the engine coolant temperature. The ECT sensor has a thermistor that varies its resistance depending on the temperature of the engine coolant. When the coolant temperature is low, the resistance in the thermistor increases. When the temperature is high, the resistance drops. The variations in resistance are reflected in the voltage output from the sensor. The ECM monitors the sensor voltage and uses this value to calculate the engine coolant temperature. When the sensor output voltage deviates from the normal operating range, the ECM interprets this as a fault in the ECT sensor and sets a DTC. Examples: 1) Upon starting the engine, the ECT is between 35C (95F) and 60C (140F). If, after driving for 250 seconds, the ECT still remains within 3C (5.4F) of the starting temperature, a DTC will be set (2 trip detection logic). 2) Upon starting the engine, the ECT is over 60C (140F). If, after driving for 250 seconds, the ECT still remains within 1C (1.8F) of the starting temperature, a DTC will be set (6 trip detection logic). MONITOR STRATEGY Related DTCs P0116: ECT sensor stuck P0116: ECT sensor stuck at high Required sensors / components (Main) ECT sensor Required sensors / components (Related) CKP sensor, IAT sensor, MAF meter Frequency of operation Continuous Duration 250 sec. or more MIL operation 2 driving cycles: ECT sensor stuck 6 driving cycles: ECT sensor stuck at high Sequence of operation None 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 290 05-101 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present See page 05-16 ECT Sensor Stuck at Low ECT: Cumulative idle off period 250 sec. or more Speed increase by 30 km/h (18.6 mph) or more 10 times or more ECT 35 to 60C (95 to 140F) IAT -6.7 C (20F) or more ECT Sensor Stuck at High ECT: ECT 60C (140F) or more IAT -6.7 C (20F) or more ”Stop and go”*1 Once or more ”Steady driving and stop*2 Once or more *1 Vehicle is stopped for 20 seconds or more and accelerated to more than 43.5 mph (70 km/h) within 40 seconds. *2 Vehicle is driven by 40.4 mph (65 km/h) or more for 30 seconds or more and the vehicle speed reaches 43.5 mph (70 km/h). The vehicle is decelerated from 40.4 mph (65 km/h) to 1.86 mph (3 km/h) or less within 35 seconds and stopped for 10 seconds. TYPICAL MALFUNCTION THRESHOLDS ECT Sensor Stuck at Low ECT: ECT change Less than 3C (5.4F) ECT sensor Stuck at High ECT: ECT change 1C (1.8F) or less COMPONENT OPERATING RANGE ECT Varies with actual ECT (Engine coolant temperature) INSPECTION PROCEDURE HINT:

If DTCs P0115, P0116, P0117, P0118 and P0125 are output simultaneously, the ECT sensor circuit may be open or shorted. Perform the troubleshooting of DTC P0115, P0117 or P0118 first. Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. REPLACE ENGINE COOLANT TEMPERATURE SENSOR 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 291 05-102 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 0596D-07 DTC P0120 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”A” CIRCUIT DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”A” CIRCUIT LOW INPUT DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”A” CIRCUIT HIGH INPUT DTC P0220 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”B” CIRCUIT DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”B” CIRCUIT HIGH INPUT DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”A”/”B” VOLTAGE CORRELATION 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 292 05-103 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) CIRCUIT DESCRIPTION HINT:

Throttle Position Sensor ECM Magnet IC No. 1 VC VTA1 Throttle Position Sensor Output Voltage (V) This Electronic Throttle Control System (ETCS) does not use a throttle cable. This throttle position sensor is a non-contact type. The throttle position sensor is mounted on the throttle body and it detects the opening angle of the throttle valve. This sensor is electronically controlled and uses Hall-effect elements, so that accurate control and reliability can be obtained. The throttle position sensor has 2 sensor elements/signal outputs: VTA1 and VTA2. VTA1 is used to detect the throttle opening angle and VTA2 is used to detect malfunctions in VTA1. Voltage applied to VTA1 and VTA2 change between 0 V and 5 V in proportion to the opening angle of the throttle valve. There are several checks that the ECM performs to confirm proper operation of the throttle position sensor and VTA1. The ECM judges the current opening angle of the throttle valve from these signals input from terminals VTA1 and VTA2, and the ECM controls the throttle motor to make the throttle valve angle properly in response to driver inputs. Fail-safe Angle *1 5 VTA2 VTA1 2.58 2.25 0.95 0.69 6.5 Usable Range 0 84 Throttle Valve Opening Angle (deg.) VTA2 E2 IC No. 2 Magnet Throttle Valve Fully Closed (Throttle Position expressed as percentage (VTA1) 10 to 24 %) Throttle Valve Fully Opened (Throttle Position expressed as percentage (VTA1) 64 to 96 %) *1: Fail-safe Angle 6.5° (Throttle Position expressed as percentage (VTA1) about 16 %) A19755 A19802 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 293 05-104 DIAGNOSTICS DTC No. - SFI SYSTEM (2AZ-FE) DTC Detection Condition Condition (a) of DTC P0120, P0122, P0123, P0220, P0222 or P0223 continues for 2 seconds (open or short in the throttle position sensor circuit) Trouble Area Detection conditions for DTCs P0122 and P0123 are not satisfied but condition (a) is satisfied (a) VTA1 is 0.2 V or less or VTA1 is 4.8 V or more
Throttle position sensor
ECM (a) VTA1 is 0.2 V or less
Throttle position sensor
Short in VTA1 circuit
Open in VC circuit
ECM P0123 (a) VTA1 is 4.8 V or more
Throttle position sensor
Open in VTA1 circuit
Open in E2 circuit
Short in VC and VTA1 circuits
ECM P0220 Detection conditions for DTCs P0222 and P0223 are not satisfied but condition (a) is satisfied (a) VTA2 is 0.5 V or less or VTA2 is 4.8 V or more and VTA1 is 0.2 V or more and VTA1 is 1.8 V or less
Throttle position sensor
ECM (a) VTA2 is 0.5 V or less
Throttle position sensor
Short in VTA2 circuit
Open in VC circuit
ECM P0223 (a) VTA2 is 4.8 V or more and VTA1 is 0.2 V or more and VTA1 is 1.8 V or less
Throttle position sensor
Open in VTA2 circuit
Open in E2 circuit
Short in VC and VTA2 circuits
ECM P2135 Condition (a) continues for 0.5 seconds or more, or condition (b) continues for 0.4 seconds or more: (a) Difference between VTA1 and VTA2 is 0.02 V or less (b) VTA1 is 0.2 V or less and VTA2 is 0.5 V or less
Short in VTA1 and VTA2 circuits
Throttle position sensor
ECM P0120 P0122 P0222 HINT:

After confirming DTCs, use the hand-held tester or the OBD II scan tool to confirm the throttle valve opening percentage and closed throttle position switch condition. ”THROTTLE POS” is the VTA1 signal. ”THROTTLE POS #2” is the VTA2 signal. Reference (Normal condition): Tester display Accelerator pedal released Accelerator pedal fully depressed THROTTLE POS 10 to 24 % 64 to 96 % THROTTLE POS #2 2.1 to 3.1 V 4.5 to 5.5 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 294 05-105 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) MONITOR DESCRIPTION The ECM uses the throttle position sensor to monitor the throttle valve opening angle. (a) There is a specific voltage difference between VTA1 and VTA2 for each throttle opening angle.
If the difference between VTA1 and VTA2 deviates from the specified range, the ECM interprets this as a fault and will set a DTC. (b) VTA1 and VTA2 have each specific voltage operating range.
If VTA1 or VTA2 is out of the normal operating range, the ECM interprets this as a fault and will set a DTC. (c) VTA1 and VTA2 should never be close to the same voltage levels.
If the difference between VTA1 and VTA2 is within 0.02 V, the ECM interprets this as a short circuit in the throttle position sensor system and will set a DTC. FAIL-SAFE If the Electronic Throttle Control System (ETCS) has a malfunction, the ECM cuts off current to the throttle control motor. The throttle control valve returns to a predetermined opening angle (approximately 16) by the force of the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue at a minimal speed. If the accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly. If a ”pass” condition is detected and then the ignition switch is turned OFF, the fail-safe operation will stop and the system will return to normal condition. MONITOR STRATEGY Related DTCs P0120: TP sensor 1 range check (Chattering) P0122: TP sensor 1 range check (Low voltage) P0123: TP sensor 1 range check (High voltage) P0220: TP sensor 2 range check (Chattering) P0222: TP sensor 2 range check (Low voltage) P0223: TP sensor 2 range check (High voltage) P2135: TP sensor range check (Correlation) Required sensors/components (Main) TP (Throttle position) sensor Required sensors/components (Related) - Frequency of operation Continuous Duration Accelerator pedal ON: 2 seconds Accelerator pedal OFF: 10 seconds 0.5 seconds or 0.4 seconds (P2135) MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-16 TYPICAL MALFUNCTION THRESHOLDS P0120: VTA1 voltage 0.2 V or less or 4.8 V or more P0122: VTA1 voltage 0.2 V or less P0123: VTA1 voltage 4.8 V or more P0220: VTA2 voltage 0.5 V or less or 4.8 V or more P0222: 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 295 05-106 DIAGNOSTICS VTA2 voltage - SFI SYSTEM (2AZ-FE) 0.5 V or less P0223: VTA2 voltage when the VTA1 is 0.2 to 1.8 V 4.8 V or more P2135: Either of the following condition(s) is met: Condition A or B Condition A - Difference between VTA1 and VTA2 voltages 0.02 V or less Condition B - VTA1 voltage 0.2 V or less VTA2 voltage 0.5 V or less COMPONENT OPERATING RANGE VTA1 voltage 0.6 to 3.96 V VTA2 voltage 2.25 to 4.8 V WIRING DIAGRAM T13 Throttle Position Sensor ECM 5V 18 VC 5 Y 6 B-W 4 B-R E7 VC 21 VTA1 VTA2 E7 31 E7 Short Connector 5 5 E2 3 BR BR S28 VTA1 VTA2 28 S29 BR E7 E2 A90295 INSPECTION PROCEDURE HINT:

If DTCs that are related to different systems are output simultaneously while terminal E2 is used as a ground terminal, terminal E2 may have an open circuit. Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 296 05-107 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) Hand-held tester: 1 READ VALUE OF HAND-HELD TESTER (THROTTLE POS AND THROTTLE POS #2) (a) On the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / THROTTLE POS and THROTTLE POS #2. Read the values. Result: Throttle position expressed as percentage and voltage Accelerator pedal released Accelerator pedal depressed Trouble Area Proceed to THROTTLE POS (VTA1) THROTTLE POS #2 (VTA2) THROTTLE POS (VTA1) THROTTLE POS #2 (VTA2) 0% 0 to 0.2 V 0% 0 to 0.2 V 100 % 4.5 to 5.5 V 100 % 4.5 to 5.5 V E2 circuit open 0 % or 100 % 2.1 to 3.1 V (fail safe) 0 % or 100 % 2.1 to 3.1 V (fail safe) VTA1 circuit open or ground short about 16 % (fail safe) 0 to 0.2 or 4.5 to 5.5 V about 16 % (fail safe) 0 to 0.2 or 4.5 to 5.5 V VTA2 circuit open or ground short 10 to 24 % 2.1 to 3.1 V 64 to 96 % (does not fail safe) 4.5 to 5.5 V (does not fail safe) Throttle position sensor circuit is normal B VC circuit open A B Go to step 5 A 2 CHECK WIRE HARNESS (THROTTLE POSITION SENSOR - ECM) (a) (b) (c) Wire Harness Side T13 Throttle Position Sensor Disconnect the T13 throttle position sensor connector. Disconnect the E7 ECM connector. Measure the resistance of the wire harness side connectors. Standard: Tester Connection E2 VTA2 VC T13-5 (VC) T13-6 (VTA1) T13-4 (VTA2) T13-3 (E2) - VTA1 E7 ECM VTA1 Y B53781 A81699 E7-18 E7-21 E7-31 E7-28 Specified Condition (VC) (VTA1) (VTA2) (E2) Below 1 Ω T13-5 (VC) or E7-18 (VC) - Body ground T13-6 (VTA1) or E7-21 (VTA1) - Body ground T13-4 (VTA2) or E7-31 (VTA2) - Body ground VC E2 VTA2 A85510 NG REPAIR OR CONNECTOR REPLACE 10 kΩ or higher HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 297 05-108 DIAGNOSTICS 3 - SFI SYSTEM (2AZ-FE) INSPECT ECM (VC VOLTAGE) E7 ECM (a) (b) (c) VC (+) Disconnect the T13 throttle position sensor connector. Turn the ignition switch ON. Measure the voltage of the ECM connector. Standard: Tester Connection Specified Condition E7-18 (VC) - E7-28 (E2) 4.5 to 5.5 V E2 (-) A76903 NG REPLACE ECM (See page 10-9 ) OK 4 REPLACE THROTTLE BODY ASSY (See page 10-6 ) GO 5 (a) (b) (c) (d) READ OUTPUT DTC (THROTTLE POSITION SENSOR DTCS ARE OUTPUT AGAIN) Clear the DTC (see page 05-38 ). Start the engine. Run the engine at idle for 15 seconds or more. Read the DTC. Result: Display (DTC Output) Proceed to P0120, P0122, P0123, P0220, P0222, P0223 and/or P2135 are output again A No DTC output B B SYSTEM OK A REPLACE ECM (See page 10-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 298 05-109 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) OBD II scan tool (excluding hand-held tester): 1 CHECK WIRE HARNESS (THROTTLE POSITION SENSOR - ECM) (a) (b) (c) Wire Harness Side T13 Throttle Position Sensor Disconnect the T13 throttle position sensor connector. Disconnect the E7 ECM connector. Measure the resistance of the wire harness side connectors. Standard: Tester Connection E2 VTA2 VC T13-5 (VC) T13-6 (VTA1) T13-4 (VTA2) T13-3 (E2) - VTA1 E7 ECM E7-18 E7-21 E7-31 E7-28 Specified Condition (VC) (VTA1) (VTA2) (E2) Below 1 Ω T13-5 (VC) or E7-18 (VC) - Body ground T13-6 (VTA1) or E7-21 (VTA1) - Body ground T13-4 (VTA2) or E7-31 (VTA2) - Body ground VC E2 VTA2 VTA1 Y B53781 A81699 NG A85510 REPAIR OR CONNECTOR REPLACE 10 kΩ or higher HARNESS AND OK 2 INSPECT ECM (VC VOLTAGE) E7 ECM (a) (b) (c) VC (+) E2 A76903 Disconnect the T13 throttle position sensor connector. Turn the ignition switch ON. Measure the voltage of the ECM connector. Standard: NG Tester Connection Specified Condition E7-18 (VC) - E7-28 (E2) 4.5 to 5.5 V REPLACE ECM (See page 10-9 ) OK 3 REPLACE THROTTLE BODY ASSY (See page 10-6 ) G0 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 299 05-1 10 DIAGNOSTICS 4 (a) (b) (c) (d) - SFI SYSTEM (2AZ-FE) READ OUTPUT DTC (THROTTLE POSITION SENSOR DTCS ARE OUTPUT AGAIN) Clear the DTC (see page 05-38 ). Start the engine. Run the engine at idle for 15 seconds or more. Read the DTC. Result: Display (DTC Output) Proceed to P0120, P0122, P0123, P0220, P0222, P0223 and/or P2135 are output again A No DTC output B B SYSTEM OK A REPLACE ECM (See page 10-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 300 05-1 11 DIAGNOSTICS DTC P0121 - SFI SYSTEM (2AZ-FE) 052NE-53 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”A” CIRCUIT RANGE/PERFORMANCE PROBLEM HINT: This is the purpose of the ”throttle position sensor”. CIRCUIT DESCRIPTION Refer to DTC P0120 on page 05-102 . DTC No. P0121 DTC Detection Condition Trouble Area Condition (a) continues for 2.0 seconds: (a) Difference between VTA1 and VTA2 deviates from threshold Throttle position sensor MONITOR DESCRIPTION The ECM uses the throttle position sensor to monitor the throttle valve opening angle. This sensor includes 2 signals: VTA1 and VTA2. VTA1 is used to detect the throttle opening angle and VTA2 is used to detect malfunctions in VTA1. There are several checks that the ECM performs to confirm proper operation of the throttle position sensor and VTA1. There is a specific voltage difference between VTA1 and VTA2 for each throttle opening angle. If the voltage output difference between the VTA1 and VTA2 deviates from the normal operating range, the ECM interprets this as a malfunction of the throttle position sensor. The ECM will turn on the MIL and will set a DTC. FAIL-SAFE If the Electronic Throttle Control System (ETCS) has a malfunction, the ECM cuts off current to the throttle control motor. The throttle control valve returns to a predetermined opening angle (approximately 16
) by the force of the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue at a minimal speed. If the accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly. If a ”pass” condition is detected and then the ignition switch is turned OFF, the fail-safe operation will stop and the system will return to normal condition. MONITOR STRATEGY Related DTCs P0121: TP (Throttle position) sensor rationality Required sensors / components (Main) TP sensor Required sensors / components (Related) - Frequency of operation Continuous Duration 2 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present See page 05-16 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 301 05-1 12 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) TYPICAL MALFUNCTION THRESHOLDS Difference in learning voltage value of (VTA1 - VTA2 × 0.8) Less than 0.8 V, or more than 1.6 V INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. REPLACE THROTTLE POSITION SENSOR (See page 10-6 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 302 05-1 13 DIAGNOSTICS DTC P0125 - SFI SYSTEM (2AZ-FE) 05ESW-05 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL CIRCUIT DESCRIPTION Refer to DTC P0115 on page 05-95 . DTC No. DTC Detection Condition P0125
If ECT (engine coolant temperature) or IAT (intake air temperature) is less than -19.45°C (-3°F) at engine start; 20 minutes or more after starting engine, ECT sensor value is 20°C (68°F) or less (2 trip detection logic)
If ECT and IAT are between -19.45°C (-3°F) and -8.34°C (17°F) at engine start; 5 minutes or more after starting engine, ECT sensor value is 20°C (68°F) or less (2 trip detecti logic) tion l i )
If ECT and IAT greater than -8.34°C (17°F) at engine start; 2 minutes or more after starting engine, ECT sensor value is 20°C (68°F) or less (2 trip detection logic) Trouble Area
Cooling system
ECT sensor
Thermostat MONITOR DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to monitor the temperature of the engine coolant. The resistance of the sensor varies with the actual coolant temperature. The ECM applies a voltage to the sensor and the varying resistance of the sensor causes the signal voltage to vary. The ECM monitors the ECT signal voltage after engine start-up. If, after sufficient time has passed, the sensor still reports that the engine is not warm enough for closed-loop fuel control, the ECM interprets this as a fault in the sensor or cooling system and sets a DTC. Example: The ECT is 0C (32F) at engine start. After 5 minutes running time, the ECT sensor still indicates that the engine is not warm enough to begin active feedback control of the air-fuel ratio. The ECM interprets this as a fault in the sensor or cooling system and sets a DTC. MONITOR STRATEGY Related DTCs P0125: Insufficient ECT (Engine coolant temperature) for closed loop Required sensors/components (Main) Thermostat, cooling sysem Required sensors/components (Related) ECT sensor, MAF meter Frequency of operation Continuous Duration 2 minutes: Engine start ECT is -8.34C (17F) or more 5 minutes: Engine start ECT is -19.45 to -8.34C (-3 to 17F) 20 minutes: Engine start ECT is less than -19.45C (-3F) MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever the following DTCs are not present See page 05-16 Fuel cut OFF Engine Running Idle OFF TYPICAL MALFUNCTION THRESHOLDS Time until ”actual ECT” reaches ”Closed Loop ECT” 2 minutes: Engine start ECT is -8.34C (17F) or more 5 minutes: Engine start ECT is -19.45 to -8.34C (-3 to 17F) 20 minutes: Engine start ECT is less than -19.45C (-3F) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 303 05-1 14 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) INSPECTION PROCEDURE HINT:
If DTCs P0115, P0116, P0117, P0118 and P0125 are output simultaneously, engine coolant temperature sensor circuit may be open or short. Perform the troubleshooting of DTC P0115, P0117 or P0118 first. Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred.
1 (a) CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0125) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display (DTC Output) Proceed to Only P0125 are output A P0125 and other DTCs are output B HINT: If any other codes besides P0125 is output, perform the troubleshooting for those codes first. B GO TO RELEVANT DTC CHART (See page 05-48 ) A 2 (a) INSPECT THERMOSTAT (See page 16-2 ) Check the valve opening temperature of the thermostat. OK: Valve opening temperature: 80 to 84C (176 to 183F) HINT: Also check that the valve is completely closed under opening temperature as above. NG REPLACE THERMOSTAT (See page 16-1 1) OK 3 (a) CHECK COOLING SYSTEM Check the cooling system for excessive cooling, such as abnormal radiator fan operation, modified cooling system and other defects. OK: There is no modification of cooling system. NG REPAIR OR REPLACE COOLING SYSTEM OK REPLACE ENGINE COOLANT TEMPERATURE SENSOR 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 304 05-1 15 DIAGNOSTICS DTC P0128 - SFI SYSTEM (2AZ-FE) 05ETK-05 COOLANT THERMOSTAT (COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE) CIRCUIT DESCRIPTION This DTC is output when the Engine Coolant Temperature (ECT) does not reach 75°C (167°F) despite sufficient engine warm-up time. DTC No. P0128 DTC Detection Condition Trouble Area
Thermostat
Cooling system
ECT sensor
ECM Conditions (a), (b) and (c) are met: (a) Cold start (b) Sufficient warm-up time has elapsed (c) ECT is less than 75°C (167°F) MONITOR DESCRIPTION 5 seconds Estimated ECT Threshold (75C (167F)) Indicated coolant temperature reading ECT Time DTC set (after 2 driving cycles) A82385 The ECM estimates the coolant temperature based on starting temperature, engine loads, and engine speeds. The ECM then compares the estimated temperature with the actual ECT. When the estimated coolant temperature reaches 75C (167F), the ECM checks the actual ECT. If the actual ECT is less than 75C (167F), the ECM will interpret this as a fault in the thermostat or the engine cooling system and set a DTC. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 305 05-1 16 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) MONITOR STRATEGY Related DTCs P0128: Coolant thermostat Required sensors/components (Main) Thermostat Required sensors/components (Related) ECT sensor, IAT sensor, VSS Frequency of operation Once per driving cycle Duration 500 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present See page 05-16 Battery voltage 11 V or more Throttle position learning Completed Either of the following conditions is met: Condition 1 or 2 1. All of the following conditions are met: Condition (a), (b) and (c) (a) ECT at engine start - IAT at engine start -15 to 7C (-27 to 12.6F) (b) ECT at engine start -10 to 56C (14 to 132.8F) (c) IAT at engine start -10 to 56C (14 to 132.8F) 2. All of the following conditions are met: Condition (a), (b) and (c) (a) ECT at engine start - IAT at engine start More than 7C (12.6F) (b) ECT at engine start 56C (132.8F) or less (c) IAT at engine start -10 C (14F) or more Accumulated time that vehicle speed is 80 mph (128 km/h) or more Less than 20 seconds TYPICAL MALFUNCTION THRESHOLDS Duration that both of the following conditions 1 and 2 are met: 5 seconds or more 1. Estimated ECT 120.5C (248.9F) or more 2. ECT sensor output Less than 120.5C (248.9F) MONITOR RESULT Refer to page 05-24 for detailed information. The test value and test limit information are described as shown in the following table. Check the monitor result and test values after performing the monitor drive pattern (see page 05-26 ).
TID (Test Identification Data) is assigned to each emissions-related component.
TLT (Test Limit Type): If TLT is 0, the component is malfunctioning when the test value is higher than the test limit. If TLT is 1, the component is malfunctioning when the test value is lower than the test limit.
CID (Component Identification Data) is assigned to each test value.
Unit Conversion is used to calculate the test value indicated on generic OBD ll scan tools. TID $08: Thermostat TLT 1 CID $01 Unit Conversion Multiply by 0.625 and subtract 40 (C) Description of Test Data ECT sensor output when estimated ECT has reached to malfunction criterion Description of Test Limit Malfunction criteria for thermostat 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 306 05-1 17 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 (a) CHECK COOLING SYSTEM Check the cooling system for excessive cooling, such as abnormal radiator fan operation, modified cooling system and other defects. NG REPAIR OR REPLACE COOLING SYSTEM OK 2 (a) INSPECT THERMOSTAT (See page 16-2 ) Check the valve opening temperature of the thermostat. OK: Valve opening temperature: 80 to 84C (176 to 183F) HINT: Also check that the valve is completely closed under opening temperature as above. NG REPLACE THERMOSTAT(See page 16-1 1) OK REPLACE ECM(See page 10-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 307 05-1 18 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05ITJ-02 DTC P0136 OXYGEN SENSOR CIRCUIT MALFUNCTION (BANK 1 SENSOR 2) DTC P0137 OXYGEN SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2) DTC P0138 OXYGEN SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2) CIRCUIT DESCRIPTION The heated oxygen sensor (HO2S) is used to monitor oxygen in the exhaust gas. For optimum catalyst operation, the air fuel mixture (air-fuel ratio) must be maintained near the ideal stoichiometric ratio. The HO2S output voltage changes suddenly in the vicinity of the stoichiometric ratio. The ECM adjusts the fuel injection time so that the air-fuel ratio is nearly stoichiometric. The HO2S generates a voltage between 0.1 and 0.9 V in response to oxygen in the exhaust gas. If the oxygen in the exhaust gas increases, the air-fuel ratio becomes Lean. The ECM interprets Lean when the HO2S voltage is below 0.45 V. If the oxygen in the exhaust gas decreases, the air-fuel ratio becomes Rich. The ECM interprets Rich when the HO2S voltage is above 0.45 V. Atmosphere Ideal Air-fuel Mixture Platinum Electrode Solid Electrolyte (Zirconia Element) Platinum Electrode Heater Coating (Ceramic) Cover Output Voltage Housing Richer - Air Fuel Ratio - Leaner Exhaust Gas A90870 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 308 05-1 19 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) DTC No. DTC Detection Condition Trouble Area P0136
Following condition (a) (b) or (c) is met: (a) During driving with engine warmed up, heated oxygen sensor output does not change for 8 minutes (b) Heated oxygen sensor output out ut is very low most of time for 220 seconds (c) The rear heated oxygen sensor voltage does not drop to below 0.2 V immediately when vehicle decelerates and fuel cut is o operating erating
Both (a) and (b) continue for more than 30 seconds: (a) Estimated rear oxygen sensor temperature is less than 800C (b) Rear oxygen sensor impedance is less than 5Ω
Open or short in heated oxygen sensor (bank 1 sensor 2) circuit i i
Heated oxygen sensor (bank 1 sensor 2)
Heated oxygen sensor heater (bank 1 sensor 2)
A/F sensor
A/F sensor heater
EFI relay P0137 Both (a) and (b) continue for more than 240 seconds: (a) Estimated rear oxygen sensor temperature is more than 450C (b) Rear oxygen sensor impedance is more than 15kΩ
Open or short in heated oxygen sensor (bank 1 sensor 2) circuit (sensor to ECM)
Open or short in heated oxygen sensor (bank 1 sensor 2) internal P0138 Rear oxygen sensor output voltage is over 1.2 V for more than 30 seconds
Short in heated oxygen sensor (bank 1 sensor 2) circuit
Short in heated oxygen sensor (bank 1 sensor 2) circuit
ECM internal circuit malfunction MONITOR DESCRIPTION The ECM monitors the rear heated oxygen sensor (HO2S) in the following 4 items: 1. The HO2S voltage changes between Rich (more than 0.45 V) and Lean (less than 0.45 V) while the vehicle is running (repeating acceleration and deceleration) for 8 minutes. If not, the ECM interprets this as a malfunction, illuminates the MIL, and then sets a DTC. 2. The HO2S voltage does not remain at less than 0.05 V for a long time while the vehicle is running (60 % of the time in the 220 second-monitor, the sensor output is less than 0.05 V). If it does, the ECM interprets this as a malfunction, illuminates the MIL, and then sets a DTC. 3. The sensor’s voltage drops to below 0.2 V (extremely Lean status) immediately when the vehicle decelerates and the fuel cut is working for 7 seconds. If not, the ECM interprets this to mean the sensor’s response feature has deteriorated, illuminates the MIL, and then sets a DTC. 4. The rear oxygen sensor impedance is 5 Ω or less, 15 kΩ or more, or output voltage is 1.2 V or more (normal voltage: 0 to 1.0 V). If so, the ECM will determine that the rear oxygen sensor or a related circuit has an open or short circuit, illuminates the MIL and sets a DTC. Impedance is detected by the IC inside the ECM. MONITOR STRATEGY Related DTCs P0136: Heated oxygen sensor output voltage (Output voltage) P0136: Heated oxygen sensor impedance (Low impedance) P0137: Heated oxygen sensor impedance (High impedance) P0138: Heated oxygen sensor output voltage (High voltage) P0138: Heated oxygen sensor output voltage (During fuel-cut) Required Sensors/Components (Main) Heated oxygen sensor Required Sensors/Components (Related) Crankshaft position sensor, engine coolant temperature sensor, mass air flow meter and throttle position sensor Frequency of Operation Once per driving cycle: Active air-fuel ratio control detection Continuous: Others Duration Within 480 seconds MIL Operation 2 driving cycles: P0136 (Rear HO2S output voltage - case 1) P0136 (Rear HO2S output voltage - case 2) P0138 (Rear HO2S voltage during fuel-cut) Immediate: Others Sequence of Operation None 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 309 05-120 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present See page 05-16 P0136 (Rear HO2S output voltage - case 1): All of the following conditions are met: Conditions 1, 2, 3 and 4 1. Malfunction determination in this driving cycle Not detected 2. Engine Running 3. Time after engine start 0 second or more 4. Either of the following conditions is met: Conditions (a) or (b) (a) Cumulative time while HO2S heater is operating 22 seconds or more (b) HO2S voltage Has reached to 0.2 V or more P0136 (Rear HO2S output voltage - case 2): Engine Running P0136 (Rear HO2S low impedance): Battery voltage 11 V or more Estimated HO2S temperature Less than 700C (1,292F) ECM monitor Completed P0606 Not set P0137 (Rear HO2S high impedance): Battery voltage 11 V or more Estimated HO2S temperature 450C (842F) or higher ECM monitor Completed P0606 Not set P0138 (Rear HO2S output voltage - case 3): Battery voltage 11 V or more Time after engine start 2 seconds or more P0138 (Rear HO2S output voltage during fuel-cut): Engine coolant temperature 70C (158F) or more Catalyst temperature 400C (752F) or more Fuel-cut Executing TYPICAL MALFUNCTION THRESHOLDS P0136 (Rear HO2S output voltage - case 1): Both of the following conditions are met: Conditions 1 and 2 1. Frequency that HO2S voltage changes between (a) and (b) 0 time (a) Maximum voltage 0.6 V or more (b) Minimum voltage 2. Cumulative monitor time Less than 0.45 V *1 of rear HO2S 320 seconds or more *1: Monitor time is counted when all of the following conditions are met: Conditions (a) and (b) (a) Fuel system status Closed-loop (b) Idle OFF P0136 (Rear HO2S output voltage - case 2): All of the following conditions are met: Conditions 1, 2, 3, 4 and 5 1. Cumulative monitor time *2 of HO2S 220 seconds or more 2. Duration while HO2S voltage is below 0.05 V 132 seconds or more 3. Duration while HO2S voltage is higher than 0.7 V Less than 44 seconds 4. Duration while HO2S voltage is 0.45 V to 0.7 V Less than 88 seconds 5. Duration while HO2S voltage is 0.45 V or more 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Less than 20 seconds Author
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: 310 05-121 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) *2: Monitor time is counted when all of the following conditions are met: Conditions 1, 2, 3 and 4 1. Intake air amount per revolution 0.32 g/rev or more 2. Vehicle speed 3 km/h (1.875 mph) or more 3. Idle OFF 4. Fuel-cut OFF P0136 (Rear HO2S low impedance): Duration of the following condition: 30 seconds or more Rear HO2S impedance Less than 5 Ω P0137 (Rear HO2S high impedance): Duration of the following condition: 90 seconds or more Rear HO2S impedance 15 kΩ or more P0138 (Rear HO2S output voltage - case 3): Duration of the following condition: 10 seconds or more Rear HO2S voltage 1.2 V or more P0138 (Rear HO2S output voltage during fuel-cut): Either of the following conditions is met: Conditions 1 or 2 1. Duration until rear HO2S voltage drops to 0.2 V after fuelcut start 7 seconds or more 2. Both of the following conditions are met: Conditions (a) and (b) (a) Rear HO2S voltage when fuel-cut starts 0.5 V or more (b) Duration that HO2S voltage is 0.2 to 0.35 V 1 second or more COMPONENT OPERATING RANGE HO2S voltage Varies between 0.1 and 0.9 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 311 05-122 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) O2S TEST RESULT Refer to page 05-22 for detailed information. HO2S Output voltage (Minimum and Maximum): TEST ID Description of TEST VALUE Conversion Factor (Unit) Unit Standard Value $07 Minimum HO2S voltage N/A V Less than TEST LIMIT $08 Maximum HO2S voltage N/A V More than TEST LIMIT $31 Minimum time per onecycle of HO2S frequency that HO2S switches Lean to Rich N/A Second Less than TEST LIMIT $32 Minimum time per onecycle of HO2S frequency that HO2S switches Rich to Lean N/A Second Less than TEST LIMIT $37 Time until HO2S voltage drops to 0.2 V during fuelcut N/A Second Less than TEST LIMIT $81 Percentage in monitoring time while HO2S voltage is lower than 0.05 V Multiply 0.39 % Less than TEST LIMIT $84 Percentage in monitoring time while HO2S voltage is higher than 0.7 V Multiply 0.39 % More than TEST LIMIT $85 Continuous time while HO2S voltage is higher than 0.45 V Multiply 0.262 Second More than TEST LIMIT $87 Percentage in monitoring time while HO2S voltage is higher than 0.45 V Multiply 0.39 % More than TEST LIMIT 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 312 05-123 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) WIRING DIAGRAM ECM H10 Heated Oxygen Sensor 5 B-R IM1 GR 1 EB1 1 +B HT 2 3 E OX 4 6 BR Shielded B IM1 R-Y 21 HT1B E8 G 29 E8 OX1B 3 IM1 B-W 2 2 W 2 EFI NO. 2 1 Engine Room R/B No. 2 P-L IM1 13 IK3 2 R E8 O1B8 MREL E5 B 2 Y 3 2D 5 3 2B Engine Room J/B 1 R EFI Relay 5 EFI NO. 1 2 4 IM1 BR 1 F7 FL Block Assy 2I W 3 4 2F A J7 J/C W-B A BR 1 E9 E1 A A 1 W J2 J/C BR FL Main Battery EH EE A90296 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 313 05-124 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) CONFIRMATION DRIVING PATTERN (P0136) Once 40 seconds or more Vehicle speed 60 km/h (38 mph) Twice 40 seconds or more (d) Idling (c) 12 times 40 seconds or more (d) (e) (d) (e) (f) Ignition Switch OFF Warm up 10 seconds (a), (b) (engine coolant or more temperature is more than 75C (167F)) 10 seconds or more 10 seconds or more A58686 (a) Connect the hand-held tester to the DLC3. (b) Switch the hand-held tester from normal mode to check (test) mode (see page 05-40 ). (c) Start the engine and warm it up until the engine coolant temperature becomes more than 75C. (d) Drive the vehicle at 60 km/h (38 mph) or more for 40 seconds or more. (e) Let the engine idle for 10 seconds or more. (f) Perform steps (d) to (e) 12 times. HINT: If a malfunction exists, the MIL will illuminate during step (f). NOTICE: If the conditions in this test are not strictly followed, detection of a malfunction will not occur. If you do not have a hand-held tester, turn the ignition switch OFF after performing steps from (c) to (f), then perform steps from (c) to (f) again. CONFIRMATION DRIVING PATTERN (P0137) Warm up the engine and run the engine at 60 km/h (38 mph) for 7 minutes. CONFIRMATION DRIVING PATTERN (P0138) Warm up the engine and run the engine at idle for 30 seconds. INSPECTION PROCEDURE HINT: Hand-held tester only: It is possible the malfunctioning area can be found using the ACTIVE TEST A/F CONTROL operation. The A/F CONTROL operation can determine if the A/F sensor, heated oxygen sensor or other potential trouble areas are malfunctioning or not. (a) Perform the ACTIVE TEST A/F CONTROL operation. HINT: The A/F CONTROL operation lowers the injection volume 12.5 % or increases the injection volume 25 %. (1) Connect the hand-held tester to the DLC3 on the vehicle. (2) Turn the ignition switch ON. (3) Warm up the engine by running the engine at 2,500 rpm for approximately 90 seconds. (4) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (5) Perform the A/F CONTROL operation with the engine idle (press the right or left button). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 314 05-125 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) Result: A/F sensor reacts in accordance with increase and decrease of injection volume: +25 % → rich output: Less than 3.0 V -12.5 % → lean output: More than 3.35 V Heated oxygen sensor reacts in accordance with increase and decrease of injection volume: +25 % → rich output: More than 0.55 V -12.5 % → lean output: Less than 0.4 V NOTICE: The A/F sensor output has a few seconds of delay and the heated oxygen sensor output has about 20 seconds of delay at maximum. Output voltage of A/F sensor (sensor 1) Output voltage of heated oxygen sensor (sensor 2) Injection volume Injection volume +25 % +25 % -12.5 % -12.5 % Case 1 Output voltage More than 3.35 V Less than 3.0 V OK More than 0.55 V Injection volume +25 % -12.5 % -12.5 % Case 2 Output voltage A/F sensor (A/F sensor, heater, A/F sensor circuit) Output voltage NG Injection volume More than 0.55 V OK Less than 0.4V Injection volume +25 % +25 % -12.5 % -12.5 % Case 3 Output voltage NG Heated oxygen sensor (heated oxygen sensor, heater, heated oxygen sensor circuit) NG Extremely rich or lean actual air-fuel ratio (Injector, fuel pressure, gas leakage in exhaust system, etc.) Output voltage More than 3.35 V OK Injection volume Almost No reaction Injection volume +25 % +25 % -12.5 % -12.5 % Case 4 Output voltage Almost No reaction OK Less than 0.4V +25 % Less than 3.0V  Output voltage Injection volume Almost No reaction Main suspect trouble area Output voltage NG Almost No reaction The following A/F CONTROL procedure enables a technician to check and graph the voltage outputs of both the A/F sensor and the heated oxygen sensor. For displaying the graph, enter ”ACTIVE TEST / A/F CONTROL / USER DATA”, select ”AFS B1S1 and O2S B1S2” by pressing ”YES” and push ”ENTER”. Then press ”F4”. HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 315 05-126 DIAGNOSTICS 1 - SFI SYSTEM (2AZ-FE) CHECK OTHER DTC OUTPUT (a) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display (DTC Output) Proceed to P0138 is output A P0137 is output B P0136 is output C HINT: If any other codes besides P0136, P0137 and/or P138 are output, perform the troubleshooting for those codes first. B Go to step 9 C Go to step 6 A 2 READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (OUTPUT VOLTAGE OF HEATED OXYGEN SENSOR) (a) (b) (c) (d) (e) Connect the hand-held tester or the OBD II scan tool to the DLC3. Turn ON the ignition switch. Push the hand-held tester or the OBD II scan tool main switch ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / O2S B1S2. Run the engine at idle. Read the output voltage of the heated oxygen sensor during idling. Heated oxygen sensor output voltage Proceed to More than 1.2 V A Less than 1.0 V B B READ OUTPUT DTC A 3 CHECK WIRE HARNESS (CHECK FOR SHORT) (a) (b) (c) E8 ECM Turn the ignition switch OFF and wait for 5 minutes. Disconnect the E8 ECM connector. Measure the resistance of the wire harness side connectors. Standard: O1BOX1B HT1B A81695 OK Tester Connection Specified Condition E8-21 (HT1B) - E8-29 (OX1B) 10 kΩ or higher E8-21 (HT1B) - E8-2 (O1B-) 10 kΩ or higher REPLACE ECM (See page 10-9 ) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 316 05-127 DIAGNOSTICS 4 - SFI SYSTEM (2AZ-FE) INSPECT HEATED OXYGEN SENSOR (CHECK FOR SHORT) (a) (b) H10 Heated Oxygen Sensor Disconnect the H10 heated oxygen sensor connector. Measure the resistance of the sensor side connectors. Standard: +B OX E1 OK A80018 Tester Connection Specified Condition H10-1 (+B) - H10-3 (E1) 10 kΩ or higher H10-1 (+B) - H10-4 (OX) 10 kΩ or higher REPAIR OR CONNECTOR REPLACE HARNESS AND NG REPLACE HEATED OXYGEN SENSOR 5 (a) READ OUTPUT DTC (CHECK MODE) Change the ECM to check mode with the hand-held tester. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / CHECK MODE. Warm up the engine and drive the vehicle at over 25 mph (40 km/h) for an accumulated total of 10 minutes. (b) HINT: The 10 minutes of driving should be driven in one instance, but it is not necessary to maintain a speed of 25 mph (40 km/h) for 10 minutes consecutively. (c) Read the DTC. Result: Display (DTC output) Proceed to P0136 is output A No DTC B B CHECK FOR INTERMITTENT PROBLEMS (See page 05-9 ) A REPLACE HEATED OXYGEN SENSOR 6 READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (OUTPUT VOLTAGE OF HEATED OXYGEN SENSOR) (a) After warming up the engine, run the engine at 2,500 rpm for 3 minutes. (b) Read the output voltage of the heated oxygen sensor when the engine rpm is suddenly increased. HINT: Quickly accelerate the engine to 4,000 rpm 3 times by using the accelerator pedal. Heated oxygen sensor output voltage: Alternates 0.4 V or less and 0.5 V or more. OK Go to step 10 NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 317 05-128 DIAGNOSTICS 7 - SFI SYSTEM (2AZ-FE) INSPECT HEATED OXYGEN SENSOR (HEATER RESISTANCE) (a) (b) H10 Heated Oxygen Sensor HT +B Disconnect the H10 heated oxygen sensor connector. Measure the resistance of the heated oxygen sensor terminals. Standard: Tester Connection OX E1 Condition Specified Condition H10-1 (+B) - H10-2 (HT) 20C (68F) 11 to 16 Ω H10-1 (+B) - H10-2 (HT) 800C (1,472F) 23 to 32 Ω NG REPLACE HEATED OXYGEN SENSOR A80018 OK 8 INSPECT RELAY (EFI) 1 3 1 5 2 2 5 (a) (b) Remove the EFI relay from the engine room J/B. Measure the resistance of the EFI relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 3 B60778 NG REPLACE RELAY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 318 05-129 DIAGNOSTICS 9 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS (a) Wire Harness Side H10 Heated Oxygen Sensor +B HT E1 OX Check the wire harness between the ECM and heated oxygen sensor. (1) Disconnect the H10 heated oxygen sensor connector. (2) Disconnect the E8 ECM connector. (3) Measure the resistance of the wire harness side connectors. Standard: E8 ECM OX1B Tester Connection Specified Condition H10-2 (HT) - E8-21 (HT1B) H10-4 (OX) - E8-29 (OX1B) Below 1 Ω H10-2 (HT) or E8-21 (HT1B) - Body ground H10-4 (OX) or E8-29 (OX1B) - Body ground 10 kΩ or higher HT1B A80019 A81695 A92146 Reference (Bank 1 Sensor 2 System Drawing) Heated Oxygen Sensor EFI Relay From Battery EFI NO. 1 Fuse ECM +B Heater HT HT1B EFI NO. 2 Sensor E1 Fuse OX OX1B Duty Control OB1MREL A90346 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 319 05-130 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) REPLACE HEATED OXYGEN SENSOR 10 PERFORM CONFIRMATION DRIVING PATTERN HINT: Clear all DTCs prior to performing the confirmation driving pattern. GO 11 (a) READ OUTPUT DTC (DTC P0136 IS OUTPUT AGAIN) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display (DTC Output) Proceed to P0136 is not output again A P0136 is output again B A CHECK FOR INTERMITTENT PROBLEMS B 12 REPLACE HEATED OXYGEN SENSOR GO 13 PERFORM CONFIRMATION DRIVING PATTERN HINT: Clear all DTCs prior to performing the confirmation driving pattern. GO 14 (a) READ OUTPUT DTC (DTC P0136 IS OUTPUT AGAIN) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display (DTC Output) Proceed to P0136 is not output again A P0136 is output again B A REPAIR COMPLETED B 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 320 05-131 DIAGNOSTICS 15 (a) (b) (c) (d) (e) - SFI SYSTEM (2AZ-FE) PERFORM ACTIVE TEST USING HAND-HELD TESTER Start the engine and warm it up. Connect the hand-held tester to the DLC3. Turn ON the ignition switch and the hand-held tester main switch. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / INJ VOL. Using the hand-held tester, change the injection volume to check the A/F sensor output and heated oxygen sensor output values below. HINT: Change the injection volume from -12.5 % to +12.5 %. Result: A/F sensor output remains more than 3.3 V or A/F sensor output remains less than 3.3 V (Heated oxygen sensor reacts in accordance with increase and decrease of injection volume) Injection Volume +12.5 % -12.5 % Malfunction A/F Sensor Output Normal 3.3 V Heated Oxygen Sensor Output Malfunction 1V 0 A87979 OK REPLACE AIR FUEL RATIO SENSOR NG CHECK AND REPLACE EXTREMLY RICH OR LEAN ACTUAL AIR FUEL RATIO (INJECTOR, FUEL PRESSURE, GAS LEAKAGE IN EXHAUST SYSTEM, ETC.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 321 05-132 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05ETQ-06 DTC P0171 SYSTEM TOO LEAN (BANK 1) DTC P0172 SYSTEM TOO RICH (BANK 1) CIRCUIT DESCRIPTION The fuel trim is related to the feedback compensation value, not to the basic injection time. The fuel trim includes the short-term fuel trim and the long-term fuel trim. The short-term fuel trim is the short-term fuel compensation used to maintain the ideal stoichiometric airfuel ratio. The signal from the A/F sensor indicates whether the air-fuel ratio is RICH or LEAN compared to the stoichiometric air-fuel ratio. This variance triggers a reduction in the fuel volume if the air-fuel ratio is RICH, and an increase in the fuel volume if it is LEAN. The short-term fuel trim varies from the central value due to individual engine differences, wear over time and changes in the operating environment. The long-term fuel trim, which controls overall fuel compensation, steadies long-term deviations of the short-term fuel trim from the central value. If both the short-term fuel trim and the long-term fuel trim are LEAN or RICH beyond a certain value, it is detected as a malfunction, the MIL is illuminated and a DTC is set. DTC No. P0171 P0172 DTC Detection Condition Trouble Area When air-fuel ratio feedback is stable after warming up engine, fuel trim is considerably in error on LEAN side (2 trip detection logic)
Air induction system
Injector blockage
MAF meter
ECT sensor
Fuel pressure
Gas leakage in exhaust system
Open or short in A/F sensor (bank 1 sensor 1) circuit
A/F sensor (bank 1 sensor 1)
A/F sensor heater (bank 1 sensor 1)
EFI relay
Open or short in A/F sensor heater and EFI relay circuits
PCV hose connection
PCV hose When air-fuel ratio feedback is stable after warming up engine, fuel trim is considerably in error on RICH side (2 trip detection logic)
Injector leak, blockage
MAF meter
ECT sensor
Ignition system
Fuel pressure
Gas leakage in exhaust system
Open or short in A/F sensor (bank 1 sensor 1) circuit
A/F sensor (bank 1 sensor 1)
A/F sensor heater
Open or short in A/F sensor heater and EFI relay circuits
EFI relay HINT:

When DTC P0171 is recorded, the actual air-fuel ratio is on the LEAN side. When DTC P0172 is recorded, the actual air-fuel ratio is on the RICH side. If the vehicle runs out of fuel, the air-fuel ratio is LEAN and DTC P0171 is recorded. The MIL then illuminates. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 322 05-133 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) MONITOR DESCRIPTION +34 (%): Threshold at LEAN 1.35 Fuel Compensation Amount 1.0 -34 (%): Threshold at RICH 0.65 A82386 Under closed-loop fuel control, fuel injection amounts that deviate from the ECM’s estimated fuel amount will cause a change in the long-term fuel trim compensation value. This long-term fuel trim is adjusted when there are persistent deviations in the short-term fuel trim values. And, the deviation from the simulated fuel injection amount by the ECM affects the smoothed fuel trim learning value. The smoothed fuel trim learning value is the combination of smoothed short-term fuel trim (fuel feedback compensation value) and smoothed long-term fuel trim (learning value of the air-fuel ratio). When the smoothed fuel trim learning value exceeds the DTC threshold, the ECM interprets this as a fault in the fuel system and sets a DTC. Example: The smoothed fuel trim learning value is more than +34 % or less than -34 %. The ECM interprets this as a failure in the fuel system. MONITOR STRATEGY Related DTCs P0171: Fuel System Lean P0172: Fuel System Rich Required sensors/ components (Main) Fuel system Required sensors / components (Related) A/F sensor, MAF meter, CKP sensor Frequency of operation Continuous Duration 10 sec. MIL operation 2 driving cycles Sequence of operation None 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 323 05-134 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-16 Fuel system status Closed Loop Battery voltage 11 V or more Throttle position learning Completed Either of the following conditions is met: Condition 1 or 2 1. Engine RPM Less than 1,100 rpm 2. Intake air amount per revolution 0.22 g/rev or more TYPICAL MALFUNCTION THRESHOLDS Purge-cut Excecuting Either of the following conditions is met: Condition 1 or 2 1. Average between short-term fuel trim and long-term fuel trim 34% or more (varies with ECT) 2. Average between short-term fuel trim and long-term fuel trim -34% or less (varies with ECT) WIRING DIAGRAM Refer to DTC P2195 on page 05-269 . INSPECTION PROCEDURE HINT: Hand-held tester only: It is possible the malfunctioning area can be found using the ACTIVE TEST A/F CONTROL operation. The A/F CONTROL operation can determine if the A/F sensor, heated oxygen sensor or other potential trouble areas are malfunctioning or not. (a) Perform the ACTIVE TEST A/F CONTROL operation. HINT: The A/F CONTROL operation lowers the injection volume by 12.5 % or increases the injection volume by 25 %. (1) Connect the hand-held tester to the DLC3 on the vehicle. (2) Turn the ignition switch ON. (3) Warm up the engine by running the engine at 2,500 rpm for approximately 90 seconds. (4) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (5) Perform the A/F CONTROL operation with the engine idling (press the right or left button). Result: A/F sensor reacts in accordance with increase and decrease of injection volume: +25 % → RICH output: Less than 3.0 V -12.5 % → LEAN output: More than 3.35 V Heated oxygen sensor reacts in accordance with increase and decrease of injection volume: +25 % → RICH output: More than 0.55 V -12.5 % → LEAN output: Less than 0.4 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 324 05-135 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) NOTICE: The A/F sensor output has a few seconds of delay and the heated oxygen sensor output has about 20 seconds of delay at maximum. Output voltage of A/F sensor (sensor 1) Output voltage of heated oxygen sensor (sensor 2) Injection volume Injection volume +25 % +25 % -12.5 % -12.5 % Case 1 Output voltage More than 3.35 V Less than 3.0 V OK More than 0.55 V Injection volume +25 % -12.5 % -12.5 % Case 2 Output voltage A/F sensor (A/F sensor, heater, A/F sensor circuit) Output voltage NG Injection volume More than 0.55 V OK Less than 0.4V Injection volume +25 % +25 % -12.5 % -12.5 % Case 3 Output voltage Output voltage More than 3.35 V OK Injection volume Almost No reaction NG Injection volume +25 % +25 % -12.5 % -12.5 % Case 4 Output voltage Almost No reaction OK Less than 0.4V +25 % Less than 3.0V  Output voltage Injection volume Almost No reaction Main suspect trouble area Output voltage NG Almost No reaction NG Heated oxygen sensor (heated oxygen sensor, heater, heated oxygen sensor circuit) Extremely rich or lean actual air-fuel ratio (Injector, fuel pressure, gas leakage in exhaust system, etc.) The following A/F CONTROL procedure enables a technician to check and graph the voltage outputs of both the A/F sensor and the heated oxygen sensor. For displaying the graph, enter ”ACTIVE TEST / A/F CONTROL / USER DATA”, select ”AFS B1S1 and O2S B1S2” by pressing ”YES” and push ”ENTER”. Then press ”F4”. HINT:
Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred.
A high A/F sensor voltage could be caused by a RICH air fuel mixture. Check the conditions that might cause the engine to run with a RICH air fuel mixture.
A low A/F sensor voltage could be caused by a LEAN air fuel mixture. Check the conditions that might cause the engine to run with a LEAN air fuel mixture. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 325 05-136 DIAGNOSTICS 1 (a) - SFI SYSTEM (2AZ-FE) CHECK AIR INDUCTION SYSTEM Check for vacuum leaks in air induction system. OK: No vacuum leak. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK 2 CHECK CONNECTION OF PCV HOSE OK: PCV hose is connected correctly and PCV hose is not damaged. NG REPAIR OR REPLACE PCV HOSE OK 3 INSPECT FUEL INJECTOR ASSY (INJECTION AND VOLUME) (See page 11-4 ) Standard: Injection Volume Difference Between Each Injector 76 to 91 cm3 (4.6 to 5.5 cu in.) / 15 seconds 15 cm3 (0.9 cu in.) or less NG REPLACE FUEL INJECTOR ASSY (See page 11-10 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 326 05-137 DIAGNOSTICS 4 - SFI SYSTEM (2AZ-FE) INSPECT MASS AIR FLOW METER (a) (b) Air E2 THA 5 VG +B EVG 4 3 2 1 (c) 30 20 10 Resistance kΩ 5 Remove the MAF meter. Check the output voltage. (1) Apply battery voltage across terminals +B and EVG. (2) Connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal EVG. (3) Blow air into the MAF meter, and check that the voltage fluctuates. Measure the resistance of the IAT terminals. Standard: Tester Connection Condition Specified Condition 4 (THA) - 5 (E2) -20 C (-4F) 13.6 to 18.4 kΩ 4 (THA) - 5 (E2) 20C (68F) 2.21 to 2.69 kΩ 4 (THA) - 5 (E2) 60C (140F) 0.49 to 0.67 kΩ 3 2 1 0.5 0.3 0.2 Acceptable 0.1 -20 (-4) 0 20 40 60 80 100 (32) (80) (104) (140)(176) (212) TemperatureC(F) A60548 NG REPLACE MASS AIR FLOW METER OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 327 05-138 DIAGNOSTICS 5 - SFI SYSTEM (2AZ-FE) INSPECT ENGINE COOLANT TEMPERATURE SENSOR (RESISTANCE) (a) (b) Ohmmeter Remove the ECT sensor. Measure the resistance of the ECT sensor terminals. Standard: Tester Connection Condition Specified Condition 1-2 20C (68F) 2.32 to 2.59 kΩ 1-2 80C (176F) 0.310 to 0.326 kΩ 30 20 10 5 Resistance kΩ Acceptable 3 2 1 0.5 0.3 0.2 0.1 -20 S01196 S01699 (-4) 0 20 40 60 80 100 (32) (68) (104) (140) (176) (212) Temperature C (F) NOTICE: When checking the ECT sensor in water, be careful not to allow water to go into the terminals. After the check, dry the sensor. HINT: Alternate procedure: Connect an ohmmeter to the installed ECT sensor and read the resistance. Use an infrared thermometer to measure the engine temperature in the immediate vicinity of the sensor. Compare these values to the resistance/temperature graph. Change the engine temperature (warm up or allow to cool down) and repeat the test. NG A81700 REPLACE ENGINE COOLANT TEMPERATURE SENSOR OK 6 CHECK FOR SPARK AND IGNITION (See page 18-1 ) OK: Spark occurs. NG REPAIR OR REPLACE OK 7 (a) CHECK FUEL PRESSURE (See page 11-4 ) Check the fuel pressure (high or low pressure). Standard: Item Specified Condition Fuel pressure 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 55 psi) NG REPLACE FUEL SYSTEM OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 328 05-139 DIAGNOSTICS 8 - SFI SYSTEM (2AZ-FE) CHECK FOR EXHAUST GAS LEAKS OK: No gas leak. NG REPAIR OR REPLACE EXHAUST LEAKAGE POINT (See page 15-2 ) GAS OK 9 (a) (b) (c) (d) (e) (f) (g) READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (OUTPUT VOLTAGE OF AIR FUEL RATIO SENSOR (BANK 1 SENSOR 1)) Connect the hand-held tester or the OBD II scan tool to the DLC3. Warm up the A/F sensor (bank 1 sensor 1) by running the engine at 2,500 rpm for approximately 90 seconds. Read A/F sensor voltage output on the hand-held tester or the OBD II scan tool. Hand-held tester only: Enter the following menus: ENHANCED OBD II / SNAPSHOT / MANUAL SNAPSHOT / USER DATA. Select ”AFS B1 S1 / ENGINE SPD” and press YES. Monitor the A/F sensor voltage carefully. Check the A/F sensor voltage output under the following conditions: (1) Allow the engine to idle for 30 seconds. (2) Running the engine at approximately 2,500 rpm (where engine RPM is not suddenly changed). (3) Raise the engine speed to 4,000 rpm and quickly release the accelerator pedal so that the throttle is fully closed. Standard: Condition (1) and (2) Voltage change of 3.3 V (0.66 V)* (between approximately 3.1 to 3.5 V), as shown in the illustration. Condition (3) A/F sensor voltage increases to 3.8 V (0.76 V)* or more when fuel is cut during engine deceleration, as shown in the illustration. *: Voltage when using the OBD II scan tool. Normal Condition Malfunction Condition (3) Approximately 4,000 rpm (3) Approximately 4,000 rpm (2) Approximately 2,500 rpm (1) Idle (2) Approximately 2,500 rpm A/F Sensor Voltage (1) Idle (1) Idle (1) Idle Engine RPM Engine RPM ”Condition (3)” 3.8 V or More A/F Sensor Voltage Fuel Cut ”Condition (1), (2)” Change of approximately 3.3 V Fuel Cut When A/F sensor circuit is malfunctioning, voltage output does not change 2005 HIGHLANDER REPAIR MANUAL (RM1144U) A72304 Author
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: 329 05-140 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) HINT:
Whenever the output voltage of the A/F sensor remains at approximately 3.3 V (0.660 V)* (see ”Malfunction Condition” graphic) under any condition as well as the above conditions, the A/F sensor may have an open circuit (this will happen also when the A/F sensor heater has an open circuit).
Whenever the output voltage of the A/F sensor remains at a certain value of approximately 3.8 V (0.76 V)* or more, or 2.8 V (0.56 V)* or less (see ”Malfunction Condition” graphic) under any condition as well as the above conditions, the A/F sensor may have a short circuit.
The ECM will stop fuel injection (fuel cut) during engine deceleration. This will cause a LEAN condition and should result in a momentary increase in A/F sensor voltage output.
The ECM must establish a closed throttle position learned value to perform fuel cut. If the battery terminal has been disconnected, the vehicle must be driven over 10 mph (16 km/h) to allow the ECM to learn the closed throttle position.
When the vehicle is driven: You may notice that the output voltage of the A/F sensor is below 2.8 V (0.76 V)* during fuel enrichment. For example, when the vehicle tries to overtake another vehicle on a highway, the vehicle speed is suddenly increased with the accelerator pedal fully depressed. The A/F sensor is functioning normally.
The A/F sensor is a current output element, and therefore the current is converted into voltage inside the ECM. If measuring voltage at connectors of A/F sensor or ECM, you will observe a constant voltage. *: Voltage when using the OBD II scan tool. OK Go to step 17 NG 10 INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) (b) A6 A/F sensor AF- AF+ A52607 Disconnect the A6 A/F sensor connector. Measure the resistance of the A/F sensor terminals. Standard: Tester Connection Condition 1 (HT) - 2 (+B) 20C (68F) 1.8 to 3.4 Ω 1 (HT) - 4 (AF-) - 10 kΩ or higher NG Specified Condition REPLACE AIR FUEL RATIO SENSOR OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 330 05-141 DIAGNOSTICS 11 1 SFI SYSTEM (2AZ-FE) INSPECT RELAY (EFI) 1 3 - 5 2 2 5 (a) (b) Remove the EFI relay from the engine room J/B. Measure the resistance of the EFI relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 3 B60778 NG REPLACE RELAY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 331 05-142 DIAGNOSTICS 12 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS (A/F SENSOR - ECM) (a) (b) (c) Wire Harness Side A6 A/F Sensor HT 1 3 2 4 AF+ +B Disconnect the A6 A/F sensor connector. Disconnect the E8 ECM connector. Measure the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition A6-3 (AF+) - E8-23 (A1A+) A6-4 (AF-) - E8-31 (A1A-) A6-1 (HT) - E8-5 (HA1A) Below 1 Ω A6-3 (AF+) or E8-23 (A1A+) - Body ground A6-4 (AF-) or E8-31 (A1A-) - Body ground A6-1 (HT) or E8-5 (HA1A) - Body ground 10 kΩ or higher AFE8 ECM A1A+ HA1A A1A- Y A76787 A81695 A85512 Reference (Bank 1 Sensor 1 System Drawing) EFI Relay From Battery EFI NO. 1 Fuse ECM A/F Sensor Heater HT +B HA1A EFI NO. 2 Sensor Fuse AFAF+ A1A+ Duty Control A1AMREL A90346 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 13 REPLACE AIR FUEL RATIO SENSOR GO 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 332 05-143 DIAGNOSTICS 14 - SFI SYSTEM (2AZ-FE) PERFORM CONFIRMATION DRIVING PATTERN Vehicle Speed (e) 38 to 75 mph (60 to 120 km/h) Idling IG SW OFF (d) 2 minutes 3 to 5 minutes (a), (b), (c) Time A79199 (a) Clear the DTCs. (1) Disconnect the battery cable or remove the EFI NO. 1 and ETCS fuses for 60 seconds or more. Connect the hand-held tester to the DLC3. Switch the hand-held tester from the normal mode to the check mode (see page 05-40 ). Start the engine and warm it up with all the accessory switches OFF. Drive the vehicle at 38 to 75 mph (60 to 120 km/h) and engine speed at 1,400 to 3,200 rpm for 3 to 5 minutes. (b) (c) (d) (e) HINT: If a malfunction exists, the MIL will be illuminated during step (e). NOTICE: If the conditions in this test are not strictly followed, detecting a malfunction may be difficult. If you do not have a hand-held tester, turn the ignition switch OFF after performing steps (d) to (e), and then do step (e) again. GO 15 (a) READ OUTPUT DTC (DTC P0171, P0172 ARE OUTPUT AGAIN) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display (DTC Output) Proceed to DTC P0171, P0172 are not output again A DTC P0171, P0172 are output again B B REPLACE ECM (See page 10-9 ) AND PERFORM CONFIRMATION DRIVING PATTERN (Refer to step 14) A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 333 05-144 DIAGNOSTICS 16 - SFI SYSTEM (2AZ-FE) CONFIRM IF VEHICLE HAS RUN OUT OF FUEL IN PAST NO CHECK FOR INTERMITTENT PROBLEMS (See page 05-9 ) YES DTC IS CAUSED BY RUNNING OUT OF FUEL (DTCS P0171, P0172) 17 PERFORM CONFIRMATION DRIVING PATTERN HINT: Clear all DTCs prior to performing the confirmation driving pattern (refer to step 14). GO 18 (a) READ OUTPUT DTC (DTC P0171, P0172 ARE OUTPUT AGAIN) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display (DTC Output) Proceed to DTC P0171, P0172 are output again A DTC P0171, P0172 are not output again B B Go to step 22 A 19 REPLACE AIR FUEL RATIO SENSOR GO 20 PERFORM CONFIRMATION DRIVING PATTERN HINT: Clear all DTCs prior to performing the confirmation driving pattern (refer to step 14). GO 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 334 05-145 DIAGNOSTICS 21 (a) - SFI SYSTEM (2AZ-FE) READ OUTPUT DTC (DTC P0171, P0172 ARE OUTPUT AGAIN) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display (DTC Output) Proceed to DTC P0171, P0172 are not output again A DTC P0171, P0172 are output again B B REPLACE ECM (See page 10-9 ) AND PERFORM CONFIRMATION DRIVING PATTERN (Refer to step 14) A 22 CONFIRM IF VEHICLE HAS RUN OUT OF FUEL IN PAST NO CHECK FOR INTERMITTENT PROBLEMS (See page 05-9 ) YES DTC IS CAUSED SHORTAGE OF FUEL (DTCS P0171, P0172) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 335 05-146 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05ETT-05 DTC P0300 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED DTC P0301 CYLINDER 1 MISFIRE DETECTED DTC P0302 CYLINDER 2 MISFIRE DETECTED DTC P0303 CYLINDER 3 MISFIRE DETECTED DTC P0304 CYLINDER 4 MISFIRE DETECTED CIRCUIT DESCRIPTION When a misfire occurs in the engine, hydrocarbons (HC) are output in high concentrations. If this HC concentration is high enough, there could be an increase in exhaust emission levels. High concentrations of HC can also cause the temperature of the catalyst to increase, possibly damaging the catalyst. To prevent increases in emissions and limit the possibility of thermal damage, the ECM monitors the misfire rate. When the temperature of the catalyst reaches a point of thermal degradation, the ECM will blink the MIL. For monitoring misfires, the ECM uses both the camshaft position sensor and the crankshaft position sensor. The camshaft position sensor is used to identify misfiring cylinders and the crankshaft position sensor is used to measure variations in the crankshaft rotation speed. A misfire is counted when crankshaft rotation speed variations exceed threshold values. If the misfiring rate exceeds the threshold value and could cause emission deterioration, the ECM illuminates the MIL. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 336 05-147 DIAGNOSTICS DTC No. - SFI SYSTEM (2AZ-FE) DTC Detection Condition Trouble Area P0300 Misfiring of random cylinders is detected
Open or short in engine wire
Connector connection
Vacuum hose connection
Ignition system
Injector
Fuel pressure
MAF meter
ECT sensor
Compression pressure
Valve clearance
Valve timing
PCV hose connection
PCV hose
ECM P0301 P0302 P0303 P0304 Misfiring of each cylinder is detected
Same as DTC No. No P0300 HINT: When several codes for a misfiring cylinder are recorded repeatedly but no random misfire code is recorded, the misfires have been detected and recorded at different times. MONITOR DESCRIPTION ECM Camshaft Position Sensor Crankshaft Position Sensor (36-2 teeth or 12 teeth) A90871 The ECM illuminates the MIL (2 trip detection logic) if:
The misfiring rate exceeds a threshold value and could cause emission deterioration.
During the first 1,000 engine revolutions after the engine starts, an excessive misfire rate (approximately 20 to 50 misfires per 1,000 engine revolutions) occurs 1 time.
After the first 1,000 engine revolutions after the engine starts, an excessive misfire rate (approximately 20 to 50 misfires per 1,000 engine revolutions) occurs 4 times. The ECM blinks the MIL (MIL blinks immediately) if:
Within 200 engine revolutions at a high rpm, the threshold for ”percentage of misfire causing catalyst damage” is reached 1 time.
Within 200 engine revolutions at a normal rpm, the threshold for ”percentage of misfire causing catalyst damage” is reached 3 times. (for the 2nd trip, reaching the threshold once will cause the MIL to flash) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 337 05-148 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) MONITOR STRATEGY Related DTCs P0300: Multiple cylinder misfire P0301: cylinder 1 misfire P0302: cylinder 2 misfire P0303: cylinder 3 misfire P0304: cylinder 4 misfire Required sensors / components (Main) Injector, ignition coil, spark plug Required sensors / components (Related) CKP, CMP, ECT, IAT and MAF meter Frequency of operation Continuous Duration 1,000 revolutions: Emission-related-misfire 200 revolutions: Catalyst-damaged-misfire MIL operation 2 driving cycles (MIL flashes immediately when Catalyst-damaged-misfire occurs) Sequence of operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present See page 05-16 Battery voltage 8 V or more Throttle position learning Completed VVT system Not operated by scan tool Engine RPM 400 to 6,200 rpm All of the following conditions are met: Condition 1 and 2 1. Engine Coolant Temperature (ECT) -10 C (14F) or more 2. Either of the following conditions is met: Condition (a) or (b) (a) ECT at engine start More than -7C (19.4F) (b) ECT More than 20C (68F) Fuel-cut OFF Monitor Period of Emission-related-misfire: First 1,000 revolutions after engine start, or check mode Crankshaft 1,000 revolutions Except above Crankshaft 1,000 revolutions × 4 Monitor Period of Catalyst-damage-misfire (MIL blinks): All of the following conditions 1, 2 and 3 met: Crankshaft 200 revolutions 1. Driving cycles 1st 2. Check Mode OFF 3. Engine RPM Less than 3,800 rpm Except above Crankshaft 200 revolutions x 3 TYPICAL MALFUNCTION THRESHOLDS Monitor Period of Emission-related-misfire: Misfire rate 4.0 % or more Monitor Period of Catalyst-damage-misfire (MIL blinks): Number of misfire per 200 revolutions 129 or more (varies with intake air amount and engine RPM) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 338 05-149 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) WIRING DIAGRAM Refer to DTC P0351 on page 05-174 for the wiring diagram of the ignition system. ECM 5 6 R IC3 LG EB1 I8 Injector No. 1 R L 1 2 R Instrument Panel J/B Assy 9 1G IG2 R 4 1C 1 1 1C 1G B R I15 Ignition Switch GR E7 #1 2 E7 #2 3 E7 #3 4 E7 #4 W-B 7 E7 E01 W-B 6 E02 E7 I10 Injector No. 3 R B 2 1 AM2 7 6 IG2 R Y 1 L-Y I9 Injector No. 2 R Y 1 2 1 IC1 I11 Injector No. 4 R W 1 2 10 AM2 F7 FL Block Assy 1 W FL Main Battery EF A90297 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 339 05-150 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) CONFIRMATION DRIVING PATTERN (a) (b) (c) (d) Connect the hand-held tester to the DLC3. Record the DTCs, freeze frame data and misfire counter data. Set the hand-held tester to check mode (see page 05-40 ). Read the value on the misfire counter for each cylinder when idling. If the value is displayed on the misfire counter, skip the following procedure of confirmation driving. (e) Drive the vehicle several times with the engine speed, load and its surrounding range shown with ENGINE SPD, CALC LOAD in the freeze frame data or MISFIRE RPM, MISFIRE LOAD in the DATA LIST. If you have no hand-held tester, turn the ignition switch OFF after the symptom is simulated once. Then repeat the simulation process again. HINT: In order to memorize the misfire DTC, it is necessary to drive with MISFIRE RPM, MISFIRE LOAD in the DATA LIST for the period of time in the chart below. Take care not to turn the ignition switch OFF. Turning the ignition switch OFF switches the diagnosis system from check mode to normal mode and all DTCs, freeze frame data and other data are erased. (f) (g) Engine Speed Time Idling 3 minutes 30 seconds or more 1,000 rpm 3 minutes or more 2,000 rpm 1 minute 30 seconds or more 3,000 rpm 1 minute or more Check if there is misfire or not by monitoring, DTC and the freeze frame data. Record the DTCs, freeze frame data and misfire counter data. Turn the ignition switch OFF and wait for at least 5 seconds. INSPECTION PROCEDURE HINT:





If DTCs besides misfire DTCs are memorized simultaneously, troubleshoot the non-misfire DTCs first. Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. If the misfire does not occur when the vehicle is brought to the workshop, the misfire can be confirmed by reproducing the condition of the freeze frame data. Also, after finishing the repair, confirm that there is no misfire (see confirmation driving pattern). On 6 and 8 cylinder engines, cylinder specific misfire fault codes are disabled at high engine speeds. If the misfire starts in a high engine speed area or the misfire occurs only in a high engine speed area, only the general fault code P0300 will be stored. When only a general misfire fault code like P0300 is stored: (1) Erase the general misfire fault code from the ECM using the hand-held tester or OBD II scan tool. (2) Start the engine and drive the confirmation pattern. (3) Read the value of the misfire ratio for each cylinder. Or read the DTC. (4) Perform repairs on the cylinder that has a high misfire ratio. Or repair the cylinder indicated by the DTC. (5) After finishing repairs, drive the confirmation pattern again and confirm that no misfire occurs. When either of SHORT FT #1, LONG FT #1 in the freeze frame data is over the range of ±20 %, there is a possibility that the air-fuel ratio is becoming to RICH (-20 % or less) or LEAN (+20 % or more). When COOLANT TEMP in the freeze frame data is less than 80°C (176°F), there is a possibility of misfire only during engine warm-up. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 340 05-151 DIAGNOSTICS
- SFI SYSTEM (2AZ-FE) If the misfire cannot be reproduced, the following reasons may apply: 1) the vehicle has low fuel, 2) improper fuel is being used, and 3) the ignition plug is contaminated. Be sure to check the value on the misfire counter after the repair.
1 CHECK OTHER DTC OUTPUT (IN ADDITION TO MISFIRE DTCS) (a) Read the DTC using the hand-held tester to the OBD II scan tool. Result: Display (DTC Output) Proceed to Only P0300, P0301, P0302, P0303, P0304 are output A P0300, P0301, P0302, P0303, P0304 and other DTCs are output B HINT: If any other codes besides P0300, P0301, P0302, P0303, P0304 are output, perform the troubleshooting for those codes first. B GO TO RELEVANT DTC CHART (See page 05-48 ) A 2 (a) (b) CHECK WIRE HARNESS, CONNECTOR AND VACUUM HOSE IN ENGINE ROOM Check the connection conditions of the wire harness and connector. Check for the disconnection, piping and break of the vacuum hose. OK: Connected correctly and no damage on wire harness. NG REPAIR OR REPLACE, THEN CONFIRM THAT THERE IS NO MISFIRE OK 3 CHECK CONNECTION OF PCV HOSE OK: PCV hose is connected correctly and PCV hose has no damage. NG REPAIR OR REPLACE PCV HOSE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 341 05-152 DIAGNOSTICS 4 - SFI SYSTEM (2AZ-FE) READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (NUMBER OF MISFIRE) (a) Connect the hand-held tester or the OBD II scan tool to the DLC3. (b) Turn ON the ignition switch. Push the hand-held tester or the OBD II scan tool main switch ON. (c) Start the engine. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / CYL#1 to CYL#4. (e) Read the number of misfires on the hand-held tester or the OBD II scan tool. HINT: When a misfire is not reproduced, be sure to branch below based on the stored DTC. Result: High Misfire Rate Cylinder Proceed to 1 or 2 cylinders A More than 3 cylinders B B Go to step 15 A 5 CHECK SPARK PLUG AND SPARK OF MISFIRING CYLINDER Base of the Ground Electrode (a) (b) (c) Remove the ignition coil. Remove the spark plug. Check the spark plug type. Recommended spark plug: DENSO made SK20R11 NGK made IFR6A11 (d) 1.0 to 1.1 mm A85380 Measure the spark plug electrode gap. Standard: 1.0 to 1.1 mm (0.039 to 0.043 in.) Maximum: 1.3 mm (0.051 in.) NOTICE: If adjusting the gap of a new spark plug, bend only the base of the ground electrode. Do not touch the tip. Never attempt to adjust the gap on a used plug. (e) Check the electrode for carbon deposits. (f) Perform a spark test. CAUTION: Always disconnect each injector connector. NOTICE: Do not crank the engine for more than 2 seconds. (1) Install the spark plug to the ignition coil and connect the ignition coil connector. (2) Disconnect the injector connector. (3) Ground the spark plug. (4) Check if spark occurs while the engine is being cranked. OK: Spark jumps across electrode gap. OK Go to step 8 NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 342 05-153 DIAGNOSTICS 6 - SFI SYSTEM (2AZ-FE) CHANGE NORMAL SPARK PLUG AND CHECK SPARK OF MISFIRING CYLINDER (a) Change to a normal spark plug. (b) Perform a spark test. CAUTION: Always disconnect each injector connector. NOTICE: Do not crank the engine for more than 2 seconds. (1) Install the spark plug to the ignition coil and connect the ignition coil connector. (2) Disconnect the injector connector. (3) Ground the spark plug. (4) Check if spark occurs while the engine is being cranked. OK: Spark jumps across electrode gap. OK REPLACE SPARK PLUG NG 7 CHECK WIRE HARNESS OF MISFIRING CYLINDER (IGNITION COIL - ECM) (a) Wire Harness Side I2 I3 I4 I5 Ignition Coil Check the wire harness between the ignition coil and ECM. (1) Disconnect the I2, I3, I4 and I5 ignition coil connectors. (2) Disconnect the E7 ECM connector. (3) Measure the resistance of the wire harness side connectors. Standard: E7 ECM Tester Connection I2-2 I3-2 I4-2 I5-2 I2-2 I3-2 I4-2 I5-2 (4) IGF1 Y A54393 A81699 or or or or - E7-24 E7-24 E7-24 E7-24 (IGF1) (IGF1) (IGF1) (IGF1) E7-24 E7-24 E7-24 E7-24 (IGF1) (IGF1) (IGF1) (IGF1) - Body Body Body Body Specified Condition Below 1 Ω ground ground ground ground 10 kΩ or higher Disconnect the I2, I3, I4 and I5 ignition coil connectors. A85513 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 343 05-154 DIAGNOSTICS (b) Wire Harness Side I2 I3 I4 I5 Ignition Coil - SFI SYSTEM (2AZ-FE) Check the wire harness between the ignition coil and ECM. (1) Disconnect the I2, I3, I4 and I5 ignition coil connectors. (2) Disconnect the E7 ECM connector. (3) Measure the resistance of the wire harness side connectors. Standard: E7 ECM Y A54393 A81699 IGT1 IGT2 IGT3 IGT4 OK A85513 Tester Connection Specified Condition I2-3 - E7-8 (IGT1) I3-3 - E7-9 (IGT2) I4-3 - E7-10 (IGT3) I5-3 - E7-11 (IGT4) Below 1 Ω I2-3 or E7-8 (IGT1) - Body ground I3-3 or E7-9 (IGT2) - Body ground I4-3 or E7-10 (IGT3) - Body ground I5-3 or E7-11 (IGT4) - Body ground 10 kΩ or higher REPLACE IGNITION COIL ASSY (THEN CONFIRM THAT THERE IS NO MISFIRE) NG REPAIR OR REPLACE HARNESS AND CONNECTOR 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 344 05-155 DIAGNOSTICS 8 - SFI SYSTEM (2AZ-FE) INSPECT ECM TERMINAL OF MISFIRING CYLINDER (#1, #2, #3, #4 VOLTAGE) #4 (+) #3 (+) #2 (+) (a) (b) #1 (+) Turn the ignition switch ON. Measure the voltage of the ECM connectors. Standard: Tester Connection E01 (-) E7-1 E7-2 E7-3 E7-4 E7 ECM (#1) (#2) (#3) (#4) - E7-7 E7-7 E7-7 E7-7 Specified Condition (E01) (E01) (E01) (E01) 9 to 14 V A76903 HINT: Reference: Inspection using an oscilloscope. Check the waveform of the ECM connectors. Standard: Tester Connection Condition Specified Condition #1 to #4 - E01 Engine idling Connect waveform is as shown Injector Signal Waveform (Magnification) 20 V /Division 20 V /Division GND GND 100 msec./Division (Idling) Injection duration 1 msec./Division (Idling) A78423 OK Go to step 11 NG 9 INSPECT FUEL INJECTOR RESISTANCE OF MISFIRING CYLINDER (See page 11-7 ) NG REPLACE FUEL INJECTOR ASSY (See page 11-10 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 345 05-156 DIAGNOSTICS 10 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS OF MISFIRING CYLINDER (INJECTOR - ECM, INJECTOR - IGNITION SWITCH) (a) Wire Harness Side I8 I9 I10 I11 Injector E7 ECM #1 (+) Check the wire harness between the injector and ECM. (1) Disconnect the I8, I9, I10 and I11 injector connectors. (2) Disconnect the E7 ECM connector. (3) Measure the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition I8-1 - E7-1 (#1) I9-1 - E7-2 (#2) I10-1 - E7-3 (#3) I11-1 - E7-4 (#4) Below 1 Ω I8-1 or E7-1 (#1) - Body ground I9-1 or E7-2 (#2) - Body ground I10-1 or E7-3 (#3) - Body ground I11-1 or E7-4 (#4) - Body ground 10 kΩ or higher #2 (+) #4(+) A85366 A81699 #3 (+) A85514 (b) Instrument Panel J/B Assy Check the IG2 fuse. (1) Remove the IG2 fuse from the instrument panel J/B. (2) Measure the resistance of the IG2 fuse. Standard: Below 1 Ω IG2 Fuse A90345 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 346 05-157 DIAGNOSTICS (c) Wire Harness Side I8 I9 I10 I11 Injector 2 6 3 7 4 8 NG IG2 A85366 A61075 SFI SYSTEM (2AZ-FE) Check the wire harness between the injector and ignition switch. (1) Disconnect the I8, I9, I10 and I11 injector connectors. (2) Disconnect the I15 ignition switch connector. (3) Measure the resistance of the wire harness side connectors. Standard: I15 Ignition Switch 1 5 - A90538 Tester Connection Specified Condition I8-2 - I15-6 (IG2) I9-2 - I15-6 (IG2) I10-2 - I15-6 (IG2) I11-2 - I15-6 (IG2) Below 1 Ω I8-2 or I15-6 (IG2) - Body ground I9-2 or I15-6 (IG2) - Body ground I10-2 or I15-6 (IG2) - Body ground I11-2 or I15-6 (IG2) - Body ground 10 kΩ or higher REPAIR OR CONNECTOR REPLACE HARNESS AND OK 11 INSPECT FUEL INJECTOR INJECTION AND VOLUME OF MISFIRING CYLINDER (See page 11-7 ) Standard: Injection Volume 76 to 91 cm3 Difference Between Each Injector 15 cm3 (0.9 cu in.) or less (4.6 to 5.5 cu in.) / 15 seconds NG REPLACE FUEL INJECTOR ASSY OK 12 CHECK CYLINDER COMPRESSION PRESSURE OF MISFIRING CYLINDER (See page 14-1 ) Standard: Item Specified Condition Compression pressure 1.360 MPa (13.9 kgf/cm2, 198 psi) Minimum pressure 0.98 MPa (10 kgf/cm2, 142 psi) Difference between each cylinder 0.1 MPa (1.0 kgf/cm2, 14 psi) NG REPAIR OR REPLACE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 347 05-158 DIAGNOSTICS 13 - SFI SYSTEM (2AZ-FE) CHECK VALVE CLEARANCE OF MISFIRING CYLINDER (See page 14-6 ) Standard (cold): Item Specified Condition Intake 0.19 to 0.29 mm (0.0075 to 0.0114 in.) Exhaust 0.30 to 0.40 mm (0.0118 to 0.0157 in.) NG ADJUST VALVE CLEARANCE (See page 14-6 ) OK 14 SWITCH STEP BY NUMBER OF MISFIRE CYLINDER (REFER TO RESULTS OF STEP 4) HINT:

If the result of step 4 is ”1 or 2 cylinders”, proceed to A. If the result of step 4 is ”more than 3 cylinders”, proceed to B. B CHECK FOR INTERMITTENT PROBLEMS (See page 05-9 ) A 15 (a) CHECK VALVE TIMING (See page 14-68 ) Check for loose or jumped tooth of the timing chain. OK: The matchmarks of the crankshaft pulley and camshaft pulley are alined. NG ADJUST VALVE TIMING (See page 14-68 ) OK 16 CHECK FUEL PRESSURE (See page 11-4 ) Standard: Item Specified Condition Fuel pressure 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 55 psi) NG CHECK AND REPLACE FUEL PUMP, PRESSURE REGULATOR, FUEL PIPE LINE AND FILTER OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 348 05-159 DIAGNOSTICS 17 (a) (b) (c) - SFI SYSTEM (2AZ-FE) READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (INTAKE AIR TEMPERATURE AND MASS AIR FLOW RATE) Connect the hand-held tester or the OBD II scan tool to the DLC3. Turn the ignition switch ON. Check the intake air temperature. (1) On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / INTAKE AIR. Read the values. Temperature: Equivalent to ambient temperature Check the air flow rate. (1) On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / MAF. Read the values. Standard: (d) Condition Air Flow Rate (gm/s) Ignition switch ON (do not start engine) 0 Idling 0.5 to 5 Running without load (2,500 rpm) 3 to 10 Idling to quickly accelerating Air flow rate fluctuates NG REPLACE MASS AIR FLOW METER OK 18 INSPECT ENGINE COOLANT TEMPERATURE SENSOR (RESISTANCE) (a) (b) Ohmmeter Remove the ECT sensor. Measure the resistance between the terminals. Standard: Tester Connection 30 20 Resistance kΩ 10 5 Acceptable 3 2 1 0.5 0.3 0.2 0.1 -20 S01196 S01699 (-4) 0 20 40 60 80 100 (32) (68) (104) (140) (176) (212) Temperature C (F) A81700 Condition Specified Condition 1-2 20C (68F) 2.32 to 2.59 kΩ 1-2 80C (176F) 0.310 to 0.326 kΩ NOTICE: If checking the ECT sensor in water, be careful not to allow water to contact the terminals. After the check, dry the sensor. HINT: Alternate procedure: Connect an ohmmeter to the installed ECT sensor and read the resistance. Use an infrared thermometer to measure the engine temperature in the immediate vicinity of the sensor. Compare these values to the resistance/temperature graph. Change the engine temperature (warm up or allow to cool down) and repeat the test. NG REPLACE ENGINE COOLANT TEMPERATURE SENSOR OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 349 05-160 DIAGNOSTICS 19 - SFI SYSTEM (2AZ-FE) SWITCH STEP BY NUMBER OF MISFIRE CYLINDER (REFER TO RESULTS OF STEP 4) HINT:

If the result of step 4 is ”1 or 2 cylinders”, proceed to A. If the result of step 4 is ”more than 3 cylinders”, proceed to B. B AGAIN GO TO STEP 5 A CHECK FOR INTERMITTENT PROBLEMS (See page 05-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 350 05-161 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05ESX-04 DTC P0325 KNOCK SENSOR 1 CIRCUIT (BANK 1 OR SINGLE SENSOR) DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW INPUT (BANK 1 OR SINGLE SENSOR) DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH INPUT (BANK 1 OR SINGLE SENSOR) CIRCUIT DESCRIPTION A flat type knock sensor (non-resonant type) can detect vibrations in a wide band of frequency (about 6 kHz to 15 kHz) and has the following features:
Knock sensors is fitted on the cylinder block to detect the engine knocking.
The sensor contains a piezoelectric element which generates a voltage when the cylinder block vibrates. If engine knocking occurs, the ignition timing is retarded to suppress it. DTC No. DTC Detection Condition Trouble Area P0325 Open or short in knock sensor circuit (1 trip detection logic)
Open or short in knock sensor circuit
Knock sensor
ECM P0327 Output voltage of the knock sensor is 0.5 V or less (1 trip detection logic)
Short in knock sensor circuit
Knock sensor
ECM P0328 Output voltage of the knock sensor is 4.5 V or more (1 trip detection logic)
Open in knock sensor circuit
Knock sensor
ECM HINT: If the ECM detects the DTC P0325, it enters the fail-safe mode in which the corrective retarded angle value is set to the maximum value. MONITOR DESCRIPTION The knock sensor, located on the cylinder block, detects spark knock. When a spark knock occurs, the sensor vibrates in a specific frequency range. When the ECM detects the voltage in this frequency range, it retards the ignition timing to suppress the spark knock. The ECM also senses background engine noise with the knock sensor and uses this noise to check for faults in the sensor. If the knock sensor signal level is too low for more than 10 seconds, and if the knock sensor output voltage is out of normal range, the ECM interprets this as a fault in the knock sensor and sets a DTC. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 351 05-162 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) MONITOR STRATEGY Related DTCs P0325: Knock sensor range check (chattering) P0327: Knock sensor range check (low voltage) P0328: Knock sensor range check (high voltage) Required sensors / components (Main) Knock sensor Required sensors / components (Related) MAF meter, CKP sensor, ECT sensor Frequency of operation Continuous Duration 1 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-16 Battery voltage 10.5 V or more Time after engine start 5 sec. or more TYPICAL MALFUNCTION THRESHOLDS Knock Sensor Range Check (Chattering) P0325: Knock sensor voltage Less than 0.5 V, or more than 4.5 V Knock Sensor Range Check (Low voltage) P0327: Knock sensor voltage Less than 0.5 V Knock Sensor Range Check (High voltage) P0328: Knock sensor voltage More than 4.5 V WIRING DIAGRAM ECM 5V Shielded 1 B E8 K1 Knock Sensor 2 1 KNK1 28 W E8 BR A J7 J/C BR A FKNK1 1 E9 E1 BR A EE A90298 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 352 05-163 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 (a) (b) (c) (d) (e) (f) (g) READ OUTPUT DTC Clear the DTC (see page 05-38 ). Warm up the engine. Run the engine at 3,000 rpm for 10 seconds or more. Connect the hand-held tester or the OBD II scan tool to the DLC3. Turn ON the ignition switch. Push the hand-held tester or the OBD II scan tool main switch ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. Read the DTC. Result: Display (DTC output) Proceed to Only P0325 is output again A P0325, P0327 and/or P0328 are output again B P0325, P0327 and/or P0328 are not output again C B Go to step 3 C CHECK FOR INTERMITTENT PROBLEMS (See page 05-9 ) A 2 INSPECT KNOCK SENSOR (a) A85381 Check the knock sensor installation. OK: Torque is 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) NG TIGHTEN SENSOR OK REPLACE KNOCK SENSOR 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 353 05-164 DIAGNOSTICS 3 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS (ECM - KNOCK SENSOR) (a) (b) Disconnect the E8 ECM connector. Measure the resistance of the wire harness side connector. Standard: Tester Connection Condition Specified Condition E8-1 (KNK1) - E8-28 (FKNK1) 20C (68F) 120 to 280 kΩ KNK1 E8 ECM FKNK1 A81695 NG Go to step 5 OK 4 INSPECT ECM (KNK1 VOLTAGE) (a) (b) (c) Disconnect the E8 ECM connector. Turn the ignition switch ON. Measure the voltage of the ECM terminals. Voltage: Tester Connection Specified Condition E8-1 (KNK1) - E8-28 (FKNK1) 4.5 to 5.5 V KNK1 E8 ECM KNK1 Signal Waveform FKNK1 A81695 1 V / DIV GND 1 msec./ Division HINT: Reference: Inspection using an oscilloscope. After warming up, run the engine at 4,000 rpm. Check the waveform between terminal KNK1 and FKNK1 of the ECM connector. Standard: Tester Connection Specified Condition E8-1 (KNK1) - E8-28 (FKNK1) Correct waveform is as shown A85286 NG REPLACE ECM (See Page 10-9 ) OK CHECK FOR INTERMITTENT PROBLEMS NOTICE: Fault may be intermittent. Check the harness and connectors carefully. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 354 05-165 DIAGNOSTICS 5 - SFI SYSTEM (2AZ-FE) INSPECT KNOCK SENSOR (a) (b) Ohmmeter A65174 Remove the knock sensor. Measure the resistance between the terminals. OK: Resistance is 120 to 280 kΩ at 20C (68F) NG REPLACE KNOCK SENSOR OK REPAIR OR REPLACE HARNESS AND CONNECTOR 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 355 05-166 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05ESY-05 DTC P0335 CRANKSHAFT POSITION SENSOR ”A” CIRCUIT DTC P0339 CRANKSHAFT POSITION SENSOR ”A” CIRCUIT INTERMITTENT CIRCUIT DESCRIPTION The crankshaft position sensor (CKP) system consists of a crankshaft position sensor plate and a pickup coil. The sensor plate has 34 teeth and is installed on the crankshaft. The pickup coil is made of an iron core and magnet. The sensor plate rotates and as each tooth passes through the pickup coil, a pulse signal is generated. The pickup coil generates 34 signals for each engine revolution. Based on these signals, the ECM calculates the crankshaft position and engine RPM. Using these calculations, the fuel injection time and ignition timing are controlled. DTC No. DTC Detection Condition Trouble Area P0335
No crankshaft position sensor signal to ECM during cranking (2 trip detection logic)
No crankshaft position sensor signal to ECM with engine speed 600 rpm or more (2 trip detection logic)
Open or short in crankshaft position sensor circuit
Crankshaft position sensor
Signal plate (Crankshaft position sensor plate No. 1)
ECM P0339 No crankshaft position sensor signal is input to ECM for 0.05 seconds or more, and conditions (a), (b) and (c) are met: (a) Engine is at 1,000 rpm or more (b) STA signal is OFF (c) 3 seconds or more have elapsed after STA signal is switched from ON to OFF
Same as DTC No. P0355 MONITOR DESCRIPTION If there is no signal from the crankshaft sensor even though the engine is cranking, the ECM interprets this as a malfunction of the sensor. MONITOR STRATEGY Related DTCs P0335: CKP sensor range check during cranking P0335: CKP sensor range check during engine running Required sensors/ components (Main) CKP (Crankshaft position) sensor Required sensors / components (Related) - Frequency of operation Continuous Duration 4.7 sec.: CKP Sensor Range Check during Cranking 0.5 sec.: CKP Sensor Range Check during Engine Running MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-16 CKP Sensor Range Check during Cranking P0335: Starter ON Minimum battery voltage while starter is ON Less than 11 V CKP Sensor Range Check during Engine Running P0335: Engine RPM 600 rpm or more Starter OFF Time after starter turns from ON to OFF 3 sec. or more 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 356 05-167 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) TYPICAL MALFUNCTION THRESHOLDS CKP signal No signal COMPONENT OPERATING RANGE CKP sensor voltage fluctuates when the crankshaft rotates 34 CKP signals per 1 revolution crankshaft CKP signal WIRING DIAGRAM C1 Camshaft Position Sensor ECM Shielded 27 1 Y 2 L E9 G2+ Signal Rotor on Intake Camshaft Shielded 25 1 R 2 G Crankshaft Angle Sensor Plate C7 Crankshaft Position Sensor E9 G J7 J/C A BR A A 24 E9 NE+ NE- 1 E9 E1 A BR EE A90299 INSPECTION PROCEDURE HINT:


Read values on the hand-held tester or OBD II scan tool. (a) Connect the hand-held tester or the OBD II scan tool to the DLC3. (b) Start the engine and push the hand-held tester or the OBD II scan tool main switch ON. (c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / ENGINE SPD. The engine speed can be confirmed in DATA LIST using the hand-held tester or OBD II scan tool. If there are no NE signals from the crankshaft position sensor despite the engine revolving, the engine speed will be indicated as zero. If voltage output of the crankshaft position sensor is insufficient, the engine speed will be indicated as lower than the actual rpm. Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 357 05-168 DIAGNOSTICS 1 - SFI SYSTEM (2AZ-FE) INSPECT CRANKSHAFT POSITION SENSOR (RESISTANCE) (a) (b) A64984 Tester Connection Condition Specified Condition 1-2 Cold 985 to 1,600 Ω 1-2 Hot 1,265 to 1,890 Ω NOTICE: In the above section, the terms ”cold” and ”hot” refer to the temperature of the coils. ”Cold” means approximately -10 C to 50C (14F to 122F). ”Hot” means approximately 50C to 100C (122F to 212F). HINT: Reference: Inspection using an oscilloscope. During cranking or idling, check the waveform between the terminals of the ECM connector. Standard: E9 ECM G2+ NE+ Disconnect the C7 sensor connector. Measure the resistance between the terminals of the sensor. Standard: Tester Connection Specified Condition E9-27 (G2+) - E9-24 (NE-) E9-25 (NE+) - E9-24 (NE-) Correct waveform is as shown NE- G2+ and NE+ Signal Waveforms 2 V/ Division G2+ NE+ A81699 A76903 20 msec./Division (Idling) A87927 NG REPLACE CRANKSHAFT POSITION SENSOR (See page 18-6 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 358 05-169 DIAGNOSTICS 2 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS (CRANKSHAFT POSITION SENSOR - ECM) (a) (b) (c) Wire Harness Side C7 Crankshaft Position Sensor Disconnect the C7 sensor connector. Disconnect the E9 ECM connector. Measure the resistance of the wire harness side connectors. Standard: E9 ECM NE+ Tester Connection Specified Condition C7-1 - E9-25 (NE+) C7-2 - E9-24 (NE-) Below 1 Ω C7-1 or E9-25 (NE+) - Body ground C7-2 or E9-24 (NE-) - Body ground 10 kΩ or higher NE- Y A54385 A81699 A85533 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 3 (a) CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR) Check the crankshaft position sensor installation. OK: Sensor is installed correctly. NG TIGHTEN SENSOR OK 4 (a) (b) INSPECT CRANKSHAFT POSITION SENSOR PLATE NO.1 (TEETH OF SIGNAL PLATE) Remove the crankshaft position sensor plate No. 1 (see page 14-41 ). Check the teeth of the signal plate. OK: The pulley does not have any cracks or deformation. NG REPLACE CRANKSHAFT POSITION SENSOR PLATE NO.1 OK REPLACE ECM (See page 10-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 359 05-170 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05EVD-05 DTC P0340 CAMSHAFT POSITION SENSOR ”A” CIRCUIT (BANK 1 OR SINGLE SENSOR) DTC P0341 CAMSHAFT POSITION SENSOR ”A” CIRCUIT RANGE/PERFORMANCE (BANK 1 OR SINGLE SENSOR) CIRCUIT DESCRIPTION The Camshaft Position (CMP) sensor, like the Crankshaft Position (CKP) sensor, consists of a magnet and an iron core wrapped in copper wire. The camshaft has 3 teeth and the CMP sensor is installed so that it can detect these teeth passing by. When the camshaft rotates and the teeth pass by the CMP sensor, the magnet on the CMP sensor creates a magnetic field and voltage is generated in the copper wire. When the crankshaft makes two rotation, voltage will be generated in the CMP sensor 3 times. The CKP sensor is roughly the same. When the crankshaft makes one rotation, its 34 teeth pass by the CKP sensor and voltage is generated 34 times. The camshaft rotates at half the speed of the crankshaft. Therefore, the CMP sensor generates voltage 3 times in the time the crankshaft takes to make 2 rotations. The ECM detects generation of these voltages to locate the camshaft position, which are used to indicate the cylinder. DTC No. DTC Detection Condition Trouble Area P0340
No camshaft position sensor signal to ECM during cranking (2 trip detection logic)
No camshaft position sensor signal to ECM with engine speed 600 rpm or more (1 trip detection logic)
Open or short in camshaft position sensor circuit
Camshaft position sensor
Timing chain has a jumped tooth
ECM P0341 While crankshaft rotates twice, camshaft position sensor signal is input to ECM 12 times or more (1 trip detection logic)
Same as DTC No. P0340 HINT:

DTC P0340 indicates a malfunction related to the camshaft position sensor (+) circuit (Wire harness (ECM - camshaft position sensor) and camshaft position sensor). DTC P0341 indicates a malfunction related to the camshaft position sensor (-) circuit (Wire harness (ECM - camshaft position sensor) and camshaft position sensor). MONITOR DESCRIPTION If there is no signal from the camshaft position sensor even though the engine is cranking, or if the rotations of the camshaft and the crankshaft are not synchronized, the ECM interprets this as a malfunction of the sensor. MONITOR STRATEGY Related DTCs P0340: CMP sensor range check P0340: CMP/CKP misalignment P0341: CMP sensor malfunction Required sensors/ components (Main) CMP (Camshaft position) sensor and VVT sensor Required sensors / components (Related) CKP sensor Frequency of operation Continuous Duration 5 sec. MIL operation 2 driving cycles: CMP sensor range check Immediate: CMP/CKP misalignment and CMP malfunction CMP sensor malfunction Sequence of operation None 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 360 05-171 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-16 CMP Sensor Range Check P0340: Starter ON Minimal battery voltage while starter is ON Less than 11 V CMP/CKP Misalignment and CMP Sensor Malfunction P0340: Engine RPM 600 rpm or more Starter OFF CMP Sensor Malfunction P0341: Starter After OFF to ON timing TYPICAL MALFUNCTION THRESHOLDS CMP Sensor Range Check P0340: CMP signal No signal CMP/CKP Misalignment P0340: CMP and CKP phase Misaligned CMP Sensor Malfunction P0341: CMP and CKP phase Misaligned CMP signal per 2 revolutions of crankshaft 12 CMP signals or more COMPONENT OPERATING RANGE CMP sensor signal CMP sensor voltage fluctuates when the camshaft rotates 3 CMP signals per 2 revolutions of crankshaft WIRING DIAGRAM Refer to DTC P0335 on page 05-166 . INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 361 05-172 DIAGNOSTICS 1 - SFI SYSTEM (2AZ-FE) INSPECT CAMSHAFT POSITION SENSOR (RESISTANCE) (a) (b) A64984 E9 ECM G2+ Disconnect the C1 sensor connector. Measure the resistance between the terminals of the sensor. Standard: Tester Connection Condition Specified Condition 1-2 Cold 835 to 1,400 Ω 1-2 Hot 1,060 to 1,645 Ω NOTICE: In the above section, the terms ”cold” and ”hot” refer to the temperature of the coils. ”Cold” means approximately -10 C to 50C (14F to 122F). ”Hot” means approximately 50C to 100C (122F to 212F). HINT: Reference: Inspection using an oscilloscope. During cranking or idling, check the waveform between the terminals of the ECM connector. Standard: Tester Connection Specified Condition E9-27 (G2+) - E9-24 (NE-) E9-25 (NE+) - E9-24 (NE-) Correct waveform is as shown NE+ NE- G2+ and NE+ Signal Waveforms 2 V/ Division G2+ NE+ A81699 A76903 20 msec./Division (Idling) A87927 NG REPLACE CAMSHAFT POSITION SENSOR (See page 18-5 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 362 05-173 DIAGNOSTICS 2 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS (CAMSHAFT POSITION SENSOR - ECM) (a) (b) (c) Wire Harness Side C1 Camshaft Position Sensor Disconnect the C1 sensor connector. Disconnect the E9 ECM connector. Measure the resistance of the wire harness side connectors. Standard: E9 ECM G2+ Tester Connection Specified Condition C1-1 - E9-27 (G2+) C1-2 - E9-24 (NE-) Below 1 Ω C1-1 or E9-27 (G2+) - Body ground C1-2 or E9-24 (NE-) - Body ground 10 kΩ or higher NE- Y A54385 A81699 A85533 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 3 (a) CHECK SENSOR INSTALLATION (CAMSHAFT POSITION SENSOR) Check the sensor installation. OK: Sensor is installed correctly. NG TIGHTEN SENSOR OK 4 (a) (b) INSPECT CAMSHAFT Remove the camshafts (see page 14-79 ). Check the camshaft lobes. OK: The camshaft lobes do not have any cracks or deformation. NG REPLACE CAMSHAFT OK REPLACE ECM (See page 10-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 363 05-174 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05EVG-05 DTC P0351 IGNITION COIL ”A” PRIMARY/SECONDARY CIRCUIT DTC P0352 IGNITION COIL ”B” PRIMARY/SECONDARY CIRCUIT DTC P0353 IGNITION COIL ”C” PRIMARY/SECONDARY CIRCUIT DTC P0354 IGNITION COIL ”D” PRIMARY/SECONDARY CIRCUIT HINT:      These DTCs indicate a malfunction related to primary circuit. If DTC P0351 is displayed, check No. 1 ignition coil with igniter If DTC P0352 is displayed, check No. 2 ignition coil with igniter If DTC P0353 is displayed, check No. 3 ignition coil with igniter If DTC P0354 is displayed, check No. 4 ignition coil with igniter circuit. circuit. circuit. circuit. CIRCUIT DESCRIPTION A Direct Ignition System (DIS) is used on this vehicle. The DIS is a 1-cylinder ignition system which ignites one cylinder with one ignition coil. In the 1-cylinder ignition system, one spark plug is connected to the end of the secondary winding. High-voltage is generated in the secondary winding and is applied directly to the spark plug. The spark of the spark plug passes from the center electrode to the ground electrode. The ECM determines the ignition timing and outputs the ignition signals (IGTs) for each cylinder. Using the IGT, the ECM turns on and off the power transistor inside the igniter, which switches on and off current to the primary coil. When current to the primary coil is cut off, high-voltage is generated in the secondary coil and this voltage is applied to the spark plugs to create sparks inside the cylinders. As the ECM cuts the current to the primary coil, the igniter sends back the ignition confirmation signal (IGF) for each cylinder ignition to the ECM. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 364 05-175 DIAGNOSTICS ECM - SFI SYSTEM (2AZ-FE) From Battery Igniter No. 1 Ignition Coil with Igniter IGT1 Crankshaft Position Sensor No. 1 Spark Plug IGF1 Ignition Coil Camshaft Position Sensor Other Sensors  ECT Sensor  MAF Meter  Throttle Position Sensor  Others IGT2 No. 2 Ignition Coil with Igniter No. 2 Spark Plug IGT3 No. 3 Ignition Coil with Igniter No. 3 Spark Plug IGT4 No. 4 Ignition Coil with Igniter No. 4 Spark Plug TAC To Tachometer A90874 DTC No. P0351 P0352 P0353 P0354 DTC Detection Condition No IGF signal to ECM while engine is running (1 trip detection logic) Trouble Area  Ignition system  Open or short in IGF1 and IGT circuits (1 throught 4) from ignition coil assy to ECM  Ignition coil assy (No. 1 throught No. 4)  ECM 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 365 05-176 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) MONITOR DESCRIPTION Ignition Coil with Igniter IGT ECM Ignition Coil Igniter IGF Ignition Signal (IGT) Ignition Confirmation Signal (IGF) Normal Malfunction Circuit Open Time A82388 If the ECM does not receive the IGF after sending the IGT, it interprets this as a fault in the igniter and sets a DTC. MONITOR STRATEGY Related DTCs P0351: Igniter (Cylinder 1) malfunction P0352: Igniter (Cylinder 2) malfunction P0353: Igniter (Cylinder 3) malfunction P0354: Igniter (Cylinder 4) malfunction Required sensors/ components (Main) Igniter Required sensors / components (Related) CKP sensor Frequency of operation Continuous Duration 0.256 sec. + 4 sparks MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-16 Either of the following condition is met: Condition 1 or 2 1. Engine RPM 1,500 rpm or less 2. Starter OFF TYPICAL MALFUNCTION THRESHOLDS IGF signal ECM does not receive any IGF signal when ECM sends IGT signal to igniter 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 366 05-177 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) COMPONENT OPERATING RANGE IGF signal Igniter outputs IGF signal when it receives IGT signal from ECM WIRING DIAGRAM ECM 2 BR I2 Ignition Coil with Igniter No. 1 3 4 BR EB1 R 1 5V R-W 2 W-R 4 S28 1 IC3 I3 Ignition Coil with W-R Igniter No. 2 3 1 R W-B GR O 6 1F R 4 W-B 1 1C R IG2 1 1G R Instrument Panel J/B Assy B 4 W-B AM2 1 IGF1 Short Connector P 9 E7 IGT2 Y-B 10 E7 IGT3 2 W-R I5 Ignition Coil with W-R Igniter No. 4 3 1 W-B IG2 6 7 IGT1 R I15 Ignition Switch Y E7 4 24 W-R E7 S29 2 W-R I4 Ignition Coil with W-R Igniter No. 3 1 3 W-B 4 1C 8 R 4 W-B IC1 L-Y 11 E7 IGT4 2 L-Y 10 AM2 1 F7 FL Block Assy R 1 BR W-B W FL Main Battery E9 E1 A N1 Noise Filter J7 J/C 1 BR EF A EE A90300 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 367 05-178 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK SPARK PLUG AND SPARK OF MISFIRING CYLINDER (See page 18-3 ) OK: Spark occurs. NG Go to step 4 OK 2 CHECK WIRE HARNESS (IGNITION COIL ASSY - ECM (IGF TERMINAL)) (a) (b) (c) Wire Harness Side I2 I3 I4 I5 Ignition Coil Disconnect the I2, I3, I4 and I5 ignition coil connectors. Disconnect the E7 ECM connector. Measure the resistance of the wire harness side connectors. Standard: Tester Connection I2-2 I3-2 I4-2 I5-2 E7 ECM I2-2 I3-2 I4-2 I5-2 Y A54393 A81699 - E7-24 E7-24 E7-24 E7-24 Specified Condition (IGF1) (IGF1) (IGF1) (IGF1) or E7-24 (IGF1) or E7-24 (IGF1) or E7-24 (IGF1) or E7-24 (IGF1) - Below 1 Ω Body ground Body ground Body ground Body ground 10 kΩ or higher IGF1 A85848 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 368 05-179 DIAGNOSTICS 3 - SFI SYSTEM (2AZ-FE) CHECK ECM (IGF1 VOLTAGE) IGF1 (+) E7 ECM E1 (-) E9 ECM (a) (b) (c) Disconnect the I2, I3, I4 and I5 ignition coil connectors. Turn the ignition switch ON. Measure the voltage of the ECM connectors. Standard: Tester Connection Specified Condition E7-24 (IGF1) - E9-1 (E1) 4.5 to 5.5 V A76903 HINT: Reference: Inspection using the oscilloscope. During cranking or idling, check the waveform of the ECM connectors. Standard: IGF1 (+) Tester Connection Specified Condition E7-24 (IGF1) - E9-1 (E1) Correct waveform is as shown E1 (-) E7 ECM E9 ECM IGT and IGF Signal Waveform 2 V/ Division CH1 (IGT1 to 4) GND CH2 (IGF1) 20 msec./Division GND A76903 A35500 A87928 NG REPLACE ECM (See page 10-9 ) OK REPLACE IGNITION COIL ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 369 05-180 DIAGNOSTICS 4 (a) (b) (c) I2 I3 I4 I5 Ignition Coil IGT4 (+) Y A54393 A81699 SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS (IGNITION COIL ASSY - ECM (IGT TERMINAL)) Wire Harness Side E7 ECM - Disconnect the I2, I3, I4 and I5 ignition coil connectors. Disconnect the E7 ECM connector. Measure the resistance of the wire harness side connectors. Standard: IGT3 (+) Tester Connection Specified Condition I2-3 - E7-8 (IGT1) I3-3 - E7-9 (IGT2) I4-3 - E7-10 (IGT3) I5-3 - E7-11 (IGT4) Below 1 Ω I2-3 or E7-8 (IGT1) - Body ground I3-3 or E7-9 (IGT2) - Body ground I4-3 or E7-10 (IGT3) - Body ground I5-3 or E7-11 (IGT4) - Body ground 10 kΩ or higher IGT1 (+) IGT2 (+) A85848 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 370 05-181 DIAGNOSTICS 5 - SFI SYSTEM (2AZ-FE) CHECK ECM (a) IGT3 (+) IGT4 (+) IGT2 (+) IGT1 (+) Measure the voltage of the ECM connectors when the engine is cranked. Standard: E1 (-) E9 ECM E7 ECM IGT2 (+) IGT1 (+) (b) (c) E9 ECM Tester Connection Specified Condition E7-8 (IGT1) - E9-1 (E1) E7-9 (IGT2) - E9-1 (E1) E7-10 (IGT3) - E9-1 (E1) E7-1 1 (IGT4) - E9-1 (E1) 4.5 V or more A76903 IGT3 (+) IGT4 (+) IGT2 (+) IGT1 (+) HINT: Reference: Inspection using an oscilloscope. During cranking or idling, check the waveform of the ECM connectors. Standard: E1 (-) E7 ECM More than 0.1 V or less than 4.5 V Disconnect the I2, I3, I4 and I5 ignition coil connectors. Measure the voltage of the ECM connectors when the engine is cranked. Standard: E1 (-) E7 ECM Specified Condition A76903 IGT3 (+) IGT4 (+) Tester Connection E7-8 (IGT1) - E9-1 (E1) E7-9 (IGT2) - E9-1 (E1) E7-10 (IGT3) - E9-1 (E1) E7-1 1 (IGT4) - E9-1 (E1) E9 ECM Tester Connection Specified Condition E7-8 (IGT1) - E9-1 (E1) E7-9 (IGT2) - E9-1 (E1) E7-10 (IGT3) - E9-1 (E1) E7-1 1 (IGT4) - E9-1 (E1) Correct waveform is as shown IGT and IGF Signal Waveform 2 V/ Division CH1 (IGT1 to 4) GND CH2 (IGF1) 20 msec./Division A76903 A35500 GND A87928 NG REPLACE ECM (See page 10-9 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 371 05-182 DIAGNOSTICS 6 - SFI SYSTEM (2AZ-FE) CHECK IGNITION COIL ASSY (POWER SOURCE) Wire Harness Side I2 I3 I4 I5 Ignition Coil (a) (b) (c) Disconnect the I2, I3, I4 and I5 ignition coil connectors. Turn the ignition switch ON. Measure the voltage of the wire harness side connector and body ground. Standard: Tester Connection I2-1 I3-1 I4-1 I5-1 A54393 OK - Body Body Body Body Specified Condition ground ground ground ground 9 to 14 V REPLACE IGNITION COIL ASSY NG 7 CHECK WIRE HARNESS (IGNITION COIL ASSY - IGNITION SWITCH) (a) Check the IG2 fuse. (1) Remove the IG2 fuse from the instrument panel J/B Assy. (2) Measure the resistance of the IG2 fuse. Standard: Below 1 Ω (b) (c) (d) Disconnect the I2, I3, I4 and I5 ignition coil connectors. Disconnect the I15 ignition switch connector. Measure the resistance of the wire harness side connectors. Standard: Instrument Panel J/B Assy IG2 fuse A90345 Wire Harness Side I2 I3 I4 I5 Ignition Coil Tester Connection I15 Ignition Switch 1 5 Y A54393 A61075 2 6 3 7 IG2 I2-1 I3-1 I4-1 I5-1 or or or or I2-1 I3-1 I4-1 I5-1 - I15-6 I15-6 I15-6 I15-6 I15-6 I15-6 I15-6 I15-6 (IG2) (IG2) (IG2) (IG2) - Specified Condition (IG2) (IG2) (IG2) (IG2) Body Body Body Body Below 1 Ω ground ground ground ground 10 kΩ or higher 4 8 A85536 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 372 05-183 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) REPLACE IGNITION COIL ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 373 05-184 DIAGNOSTICS DTC P0420 - SFI SYSTEM (2AZ-FE) 05EW2-05 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1) MONITOR DESCRIPTION The ECM uses sensors mounted before and after the three-way catalyst (TWC) to monitor its efficiency. The first sensor, an Air Fuel ratio (A/F) sensor, sends pre-catalyst A/F ratio information to the ECM. The second sensor, a heated oxygen sensor (O2S), sends post-catalyst information to the ECM. The ECM compares these two signals to judge the efficiency of the catalyst and the catalyst’s ability to store oxygen. During normal operation, the TWC stores and releases oxygen as needed. The capacity to store oxygen results in a low variation in the post-TWC exhaust stream as shown below. If the catalyst is functioning normally, the waveform of the heated oxygen sensor slowly switches between RICH and LEAN. If the catalyst is deteriorated, the waveform will alternate frequently between RICH and LEAN. As the catalyst efficiency degrades, its ability to store oxygen is reduced and the catalyst output becomes more variable. When running the monitor, the ECM compares sensor 1 signals (A/F sensor) over a specific amount of time to determine catalyst efficiency. The ECM begins by calculating the signal length for both sensors (for the rear oxygen sensor, the ECM uses the output voltage signal length). If the oxygen sensor output voltage signal length is greater than the threshold (threshold is calculated based on the A/F sensor signal length), the ECM concludes that the catalyst is malfunctioning. The ECM will turn on the MIL and a DTC will be set. Normal Catalyst Waveform of Heated Oxygen Sensor After Catalyst Waveform of A/F Sensor Before Catalyst 3.5 V 1.0 V 3.0 V 0.5 V 0V 10 seconds Waveform of A/F Sensor Before Catalyst Waveform of Heated Oxygen Sensor After Catalyst Deteriorated Catalyst 3.5 V 1.0 V 3.0 V 0.5 V 0V 10 seconds A85838 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 374 05-185 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) Heated Oxygen Sensor Signal Length Signal Length Sensor Output Voltage Time A82718 DTC No. P0420 DTC Detection Condition Trouble Area After engine and catalyst are warmed up, and while vehicle is driven within set vehicle and engine speed, waveform of heated oxygen sensor (bank 1 sensor 2) alternates frequently between RICH and LEAN (2 trip detection logic)
Gas leakage in exhaust system
A/F sensor (bank 1 sensor 1)
Heated oxygen sensor (bank 1 sensor 2)
Three-way catalytic converter (Exhaust manifold) HINT:

Sensor 1 is the sensor closest to the engine assembly. Sensor 2 is the sensor farthest away from the engine assembly. MONITOR STRATEGY Related DTCs P0420: Catalyst deterioration Required sensors / components (Main) Catalyst Required sensors / components (Related) A/F sensor, Heated oxygen sensor (HO2S), IAT sensor, MAF meter, CKP sensor, ECT sensor Frequency of operation Once per driving cycle Duration 150 sec. (30 sec. x 5) MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present See page 05-16 Accumulated time that the following conditions are met: 30 sec. Battery voltage 11 V or more IAT -10 C (14F) or more Idle status OFF MAF 8 to 35 g/sec. Engine RPM Less than 4,500 rpm ECT 75C (167F) or more Rich experience after fuel cut Yes Fuel system status Closed Loop A/F sensor Activated Rear HO2S Activated Estimated catalyst temperature Both of the following conditions 1 and 2 are met: 1. Upstream catalyst temperature 500 to 900C (932 to 1,652F) 2. Downstream catalyst temperature 350 to 900C (662 to 1,652F) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 375 05-186 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) TYPICAL MALFUNCTION THRESHOLDS Rear HO2S locus length 13 V or more (Varies with A/F sensor locus length) Frequency of the monitor 4 times MONITOR RESULT Refer to page 05-24 for detailed information. The test value and test limit information are described as shown in the following table. Check the monitor result and test values after performing the monitor drive pattern (see page 05-26 ).
TID (Test Identification Data) is assigned to each emissions-related component.
TLT (Test Limit Type): If TLT is 0, the component is malfunctioning when the test value is higher than the test limit. If TLT is 1, the component is malfunctioning when the test value is lower than the test limit.
CID (Component Identification Data) is assigned to each test value.
Unit Conversion is used to calculate the test value indicated on generic OBD ll scan tools. TID $01: Catalyst - Sensor 1 A/F sensor, Sensor 2 HO2S TLT 0 CID $01 Unit Conversion Description of Test Data Description of Test Limit Catalyst deterioration level: Determined by waveforms of A/F sensor and HO2S Multiply by 0.0078 (no dimension) Malfunction criteria for catalyst deterioration CONDITIONING A/F SENSOR AND HEATED OXYGEN SENSOR FOR TESTING Engine Speed (c) (d) 3,000 rpm 2,000 rpm Idling (a) IG SW OFF (b) Time Warmed up 3 minutes or so 2 seconds 2 seconds Check (a) (b) (c) (d) A90911 Connect the hand-held tester or the OBD II scan tool to the DLC3. Start the engine and warm it up with all the accessories switched OFF until the Engine Coolant Temperature (ECT) is stable. Run the engine at 2,500 to 3,000 rpm for about 3 minutes. When alternating the engine between 3,000 rpm and 2,000 rpm for 2 seconds respectively, check the waveform of the oxygen sensor (bank 1 sensor 2). INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 376 05-187 DIAGNOSTICS 1 (a) - SFI SYSTEM (2AZ-FE) CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0420) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display (DTC Output) Proceed to Only P0420 is output A P0420 and other DTCs are output B HINT: If any other codes besides P0420 are output, perform the troubleshooting for those codes first. B GO TO RELEVANT DTC CHART (See page 05-48 ) A 2 CHECK FOR EXHAUST GAS LEAKAGE NG REPAIR OR REPLACE LEAKAGE POINT EXHAUST GAS OK 3 INSPECT AIR FUEL RATIO SENSOR (BANK 1 SENSOR 1) (See page 12-6 ) NG REPLACE AIR FUEL RATIO SENSOR OK 4 INSPECT HEATED OXYGEN SENSOR (See page 05-1 18) OK: During air-fuel ratio feedback, the O2S’s output alternates between rich and lean. NG REPLACE HEATED OXYGEN SENSOR OK REPLACE EXHAUST MANIFOLD AND FRONT EXHAUST PIPE 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 377 05-188 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) HINT: Hand-held tester only:
The following procedure enables a technician to identify a trouble area if there is a malfunction in front A/F sensor or rear heated oxygen sensors other than the catalyst converter, or the malfunction that indicates the actual air-fuel ratio extremely RICH or LEAN. It is possible the malfunctioning area can be found using the ACTIVE TEST A/F CONTROL operation. The A/F CONTROL operation can determine if the A/F sensor, heated oxygen sensor or other potential trouble areas are malfunctioning or not. (a) Perform the ACTIVE TEST A/F CONTROL operation. HINT: The A/F CONTROL operation lowers the injection volume 12.5 % or increases the injection volume 25 %. (1) Connect the hand-held tester to the DLC3 on the vehicle. (2) Turn the ignition switch ON. (3) Warm up the engine by running the engine speed at 2,500 rpm for approximately 90 seconds. (4) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (5) Perform the A/F CONTROL operation with the engine idle (press the right or left button). Result: Heated oxygen sensor reacts in accordance with increase and decrease of injection volume +25 % → rich output: More than 0.5 V -12.5 % → lean output: Less than 0.4 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 378 05-189 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) NOTICE: The A/F sensor output has a few seconds of delay and the heated oxygen sensor output has about 20 seconds of delay at maximum. Output voltage of A/F sensor (sensor 1) Output voltage of heated oxygen sensor (sensor 2) Injection volume Injection volume +25 % +25 % -12.5 % -12.5 % Case 1 Output voltage More than 3.35 V Less than 3.0 V OK More than 0.55 V Injection volume +25 % -12.5 % -12.5 % Case 2 Output voltage A/F sensor (A/F sensor, heater, A/F sensor circuit) Output voltage NG Injection volume More than 0.55 V OK Less than 0.4V Injection volume +25 % +25 % -12.5 % -12.5 % Case 3 Output voltage Output voltage More than 3.35 V OK Injection volume Almost No reaction NG Injection volume +25 % +25 % -12.5 % -12.5 % Case 4 Output voltage Almost No reaction OK Less than 0.4V +25 % Less than 3.0V  Output voltage Injection volume Almost No reaction Main suspect trouble area Output voltage NG Almost No reaction NG Heated oxygen sensor (heated oxygen sensor, heater, heated oxygen sensor circuit) Extremely rich or lean actual air-fuel ratio (Injector, fuel pressure, gas leakage in exhaust system, etc.) The following of A/F CONTROL procedure enables a technician to check and graph the voltage outputs of both the heated oxygen sensors. For displaying the graph, enter ”ACTIVE TEST / A/F CONTROL / USER DATA”, select ”AFS B1S1 and O2S B1S2” by pressing ”YES” and push ”ENTER”. Then press ”F4”. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 379 05-190 DIAGNOSTICS - SFI SYSTEM (2AZ-FE)(From August, 2004) 05PGO-01 DTC P043E EVAPORATIVE EMISSION SYSTEM REFERENCE ORIFICE CLOG UP DTC P043F EVAPORATIVE EMISSION SYSTEM REFERENCE ORIFICE HIGH FLOW CIRCUIT DESCRIPTION Refer to EVAP Inspection Procedure (see page 05-317). DTCs P043E P043F Monitoring Item 0.02 inch orifice clogged (built-in pump module) 0.02 inch orifice high-flow (built-in pump module) Detection Condition Trouble Area To determine leak criterion (Reference pressure), vacuum pump creates negative pressure in canister pump module through 0.02 inch orifice and pressure is measured.
Pump module If one of following conditions is met, ECM
Connector / wire harness sets pump module related DTCs: P043E, P043E (Pump module - ECM) P043F, P2401, P2402 and P2419:
ECM
Reference pressure is -1 kPa or higher
Reference pressure is -4.85 kPa or lower
Reference pressure is not saturated within 60 seconds Detection Timing Detection Period Ignition OFF 2 trips WIRING DIAGRAM Refer to EVAP Inspection Procedure (see page 05-317). INSPECTION PROCEDURE Refer to EVAP Inspection Procedure (see page 05-317). Author
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: 380 05-191 DIAGNOSTICS - SFI SYSTEM (2AZ-FE)(From August, 2004) MONITOR DESCRIPTION 5 hours* after the ignition switch is turned OFF, the electric vacuum pump creates negative pressure (vacuum) in the EVAP (Evaporative Emission) system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35C (95F) after 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later. If it is still not below 35C (95F) 7 hours after the ignition switch is turned off, the monitor check starts 2.5 hours later. Sequence - Operations Descriptions Duration ECM activation Activated by soak timer, 5 hours (7 or 9.5 hours) after ignition switch turned to OFF. A Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If EVAP pressure is not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM cancels EVAP system monitor. - 10 seconds B First 0.02 inch leak pressure measurement In order to determine 0.02 inch leak pressure standard, vacuum pump creates negative pressure (vacuum) through 0.02 inch orifice and then ECM checks if vacuum pump and vent valve operate normally. 60 seconds C EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) created in EVAP system, and EVAP system pressure then measured. Write down the measured value as it will be used in the leak check. If EVAP pressure does not stabilize within 15 minutes, ECM cancels EVAP system monitor. 15 minutes* D Purge VSV monitor Purge VSV opened and then EVAP system pressure measured by ECM. Large increase indicates normal. 10 seconds E Second 0.02 inch leak pressure measurement Leak check is performed after second 0.02 inch leak pressure standard is measured. If stabilized system pressure higher than second 0.02 inch leak pressure standard, ECM determines that EVAP system leaking. 60 seconds F Final check Atmospheric pressure measured and then monitoring result recorded by ECM. - * If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize. Operation A: Atmospheric Pressure Measurement Operation B, E: 0.02 Inch Leak Pressure Measurement Canister Fuel Tank OFF Vent Valve: OFF (vent) OFF (vent) Purge VSV: OFF 0.02 Inch Orifice Pressure Sensor Air Filter ON Pump Module Operation C: EVAP System Pressure Measurement Vacuum Pump: OFF OFF Operation D: Purge VSV monitor ON ON (closed) ON (closed) Atmospheric Pressure ON Negative Pressure ON A96746 Author
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: 381 05-192 DIAGNOSTICS - SFI SYSTEM (2AZ-FE)(From August, 2004) In sequence B and E, to determine the leak criterion, the vacuum pump creates negative pressure in the canister pump module through the 0.02 inch orifice. If the pressure is out of specified range or is not saturated, the ECM illuminates the MIL and sets DTCs P043E, P043F, P2401, P2402 and P2419 (2-trip detection logic). EVAP Pressure during EVAP Monitor Purge VSV OFF OFF ON: Open OFF: Closed Vent Valve OFF OFF ON: Closed OFF: Vent ON ON Vacuum Pump Malfunction Malfunction EVAP Pressure -1 kPa Specified OK OK Malfunction Malfunction Range -4.85 kPa Sequence Time A B 10 sec 60 sec C D E Within 15 minutes 10 sec 60 sec A85217 Author
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: 382 05-193 DIAGNOSTICS - SFI SYSTEM (2AZ-FE)(From August, 2004) OBD II MONITOR SPECIFICATIONS Monitor Strategy Required Sensors/Components Pump module Frequency of Operation Once per driving cycle Duration Within 15 minutes (varies with amount of fuel in tank) MIL Operation 2 driving cycles Sequence of Operation None Typical Enabling Conditions The monitor will run whenever these DTCs are not present See page 05-16. EVAP key-off monitor runs when all of the following conditions met: - Atmospheric pressure 525 to 825 mmHg (70 to 110 kPa) Battery voltage 10.5 V or more Vehicle speed Below 4 km/h (2.5 mph) Ignition switch OFF Engine condition Not running Time after engine stopped 5 hours FTP sensor malfunction (P0450, P0452, P0453) Not detected Purge VSV Not operated by scan tool Vent valve Not operated by scan tool Leak detection pump Not operated by scan tool Both of the following conditions are met before IG switch OFF: Condition 1 and 2 1. Duration that vehicle is driven 5 min. or more 2. Purge flow Executed ECT 4.4 to 35C (40 to 95F) IAT 4.4 to 35C (40 to 95F) Example of re-start time First time 7 hours Second time 9 hours and 30 min. Key-of f monitor sequence: 1 to 8 1. Atmospheric pressure Next sequence is run if following condition met - Atmospheric pressure change for 10 sec. Within 2.25 mmHg (0.3 kPa) for 1 sec. 2. First reference pressure Next sequence is run if all of following conditions met Condition 1, 2 and 3 1. FTP when 4 sec. after reference pressure measurement -7.5 mmHg (-1 kPa) or less 2. Reference pressure -36.47 to -7.93 mmHg (-4.85 to -1.057 kPa) 3. Reference pressure Saturated 3. Vent valve stuck closed check Next sequence is run if following condition met - FTP change for 10 sec. after vent valve ON (closed) 2.25 mmHg (0.3 kPa) or more 4. Vacuum introduction and leak Next sequence is run if both of following conditions met Condition 1 and 2 1. Vacuum introduction time Within 15 min. 2. FTP FTP was saturated 5. Purge VSV stuck closed check Next sequence is run if following condition met - FTP change for 10 sec. after purge VSV ON (open) 2.25 mmHg (0.3 kPa) or more Author
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: 383 05-194 DIAGNOSTICS - SFI SYSTEM (2AZ-FE)(From August, 2004) 6. Second reference pressure measurement Next sequence is run if all of following conditions met Condition 1, 2, 3 and 4 1. FTP when 4 sec. after reference pressure measurement -7.5 mmHg (-1 kPa) or less 2. Reference pressure -36.47 to -7.93 mmHg (-4.85 to -1.057 kPa) 3. Reference pressure Saturated 4. Reference pressure difference between first and second Less than 5.25 mmHg (0.7 kPa) 7. Leak check Next sequence is run if following condition met - FTP when vacuum introduction was complete Lower than second reference pressure 8. Atmospheric pressure Monitor is complete if following - Atmospheric pressure difference between sequence 1 and 8 Within 2.25 mmHg (0.3 kPa) Typical Malfunction Thresholds Following values are when atmosperic pressure is 760 mmHg (100 kPa) - One of the following conditions is met: Condition 1, 2, 3, 4 or 5 1. FTP when 4 seconds after reference pressure measurement began More than -7.5 mmHg (-1 kPa) 2. Reference pressure Less than -36.4 mmHg (-4.85 kPa) 3. Reference pressure -7.9 mmHg (-1.057 kPa) or more 4. Reference pressure Not saturated 5. Reference pressure difference between first and second 5.3 mmHg (0.7 kPa) or more MONITOR RESULT (MODE 06) Refer to page 05-317 for detailed information on Monitor Result. Author
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: 384 05-195 DIAGNOSTICS - SFI SYSTEM (2AZ-FE)(From August, 2004) -MEMO- Author
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: 385 05-196 DIAGNOSTICS DTC P0441 - SFI SYSTEM (2AZ-FE) 05HB6-02 EVAPORATIVE EMISSION CONTROL SYSTEM INCORRECT PURGE FLOW DTC SUMMARY DTCs P0441 P0441 P0441 Monitoring Items Malfunction Detection Conditions Detection Timings Trouble Areas Detection Logic Purge VSV (Vacuum Switching Valve) stuck open Vacuum pump creates negative pressure (vacuum) in EVAP system and EVAP system pressure measured. 0.02 inch leak pressure standard is measured at the start and at the end of the leak check. If stabilized pressure higher than [second 0.02 inch leak pressure standard x 0.2], ECM determines that purge VSV stuck open
Purge VSV
Connector/wire harness (Purge VSV - ECM)
ECM
Pump module
Leakage from EVAP system While ignition Switch OFF 2 trip Purge VSV stuck closed After EVAP leak check performed, purge VSV turned ON (open), and atmospheric air introduced into EVAP system. 0.02 inch leak pressure standard is measured at the start and at the end of the leak check. If pressure does not return to near atmospheric pressure, ECM determines that purge valve stuck closed
Purge VSV
Connector/wire harness (Purge VSV - ECM)
ECM
Pump module
Leakage from EVAP system While ignition Switch OFF 2 trip Purge flow While engine running, following conditions successively met:
Negative pressure not created in EVAP system when purge VSV turned ON (open)
EVAP system pressure change less than 0.5 kPa (3.75 mmHg) when vent valve turned ON (closed)
Atmospheric pressure change before and after purge flow monitor less than 0.1 kPa (0.75 mmHg)
Purge VSV
Connector/wire harness (Purge VSV - ECM)
Leakage from EVAP line (Purge VSV - Intake manifold)
ECM While engine running 2 trip CIRCUIT DESCRIPTION The circuit description can be found in the EVAP (Evaporative Emission) Inspection Procedure (see page 05-317 ). INSPECTION PROCEDURE Refer to the EVAP Inspection Procedure (see page 05-317 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 386 05-197 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) MONITOR DESCRIPTION The two monitors, Key-Off and Purge Flow, are used to detect malfunctions relating to DTC P0441. The Key-Of f monitor is initiated by the ECM internal timer, known as the soak timer, 5 hours* after the ignition switch is turned to OFF. The purge flow monitor runs while the engine is running. 1. KEY-OFF MONITOR 5 hours* after the ignition switch is turned OFF, the electric vacuum pump creates negative pressure (vacuum) in the EVAP (Evaporative Emission) system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35C (95F) 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later. If it is still not below 35C (95F) 7 hours after the ignition switch is turned off, the monitor check starts 2.5 hours later. Sequence - Operations Descriptions Duration ECM activation Activated by soak timer, 5 hours (7 or 9.5 hours) after ignition switch turned to OFF. A Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If EVAP pressure is not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM cancels EVAP system monitor. - 10 seconds B First 0.02 inch leak pressure measurement In order to determine 0.02 inch leak pressure standard, vacuum pump creates negative pressure (vacuum) through 0.02 inch orifice and then ECM checks if vacuum pump and vent valve operate normally. 60 seconds C EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) created in EVAP system, and EVAP system pressure then measured. Write down the measured value as it will be used in the leak check. If EVAP pressure does not stabilize within 15 minutes, ECM cancels EVAP system monitor. 15 minutes* D Purge VSV monitor Purge VSV opened and then EVAP system pressure measured by ECM. Large increase indicates normal. 10 seconds E Second 0.02 inch leak pressure measurement Leak check is performed after second 0.02 inch leak pressure standard is measured. If stabilized system pressure higher than second 0.02 inch leak pressure standard, ECM determines that EVAP system leaking. 60 seconds F Final check Atmospheric pressure measured and then monitoring result recorded by ECM. - * If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 387 05-198 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) Operation A: Atmospheric Pressure Measurement Operation B, E: 0.02 Inch Leak Pressure Measurement Canister Fuel Tank OFF Vent Valve: OFF (vent) OFF (vent) Purge VSV: OFF 0.02 Inch Orifice Pressure Sensor Air Filter ON Pump Module Operation C: EVAP System Pressure Measurement Vacuum Pump: OFF OFF Operation D: Purge VSV monitor ON ON (closed) ON (closed) Atmospheric Pressure Negative Pressure ON ON A96746 (a) Purge VSV stuck open In operation C, the vacuum pump creates negative pressure (vacuum) in the EVAP (Evaporative Emission) system. The EVAP system pressure is then measured by the ECM using the pressure sensor. If the stabilized system pressure is higher than [second 0.02 inch leak pressure standard x 0.2], the ECM interprets this as the purge VSV (Vacuum Switching Valve) being stuck open. The ECM illuminates the MIL and sets the DTC (2 trip detection logic). EVAP Pressure when Purge VSV Stuck Open: ON: Open OFF: Closed ON Purge VSV ON Vent Valve ON: Closed OFF: Vent ON Vacuum Pump Malfunction EVAP Pressure Positive Negative Second 0.02 inch Leak Pressure Standard x 0.2 OK First 0.02 inch Leak Pressure Standard Sequence Time A B 10 sec 60 sec C D E Within 15 minutes 10 sec 60 sec G36775 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 388 05-199 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) (b) Purge VSV stuck closed In operation D, the pressure sensor measures the EVAP system pressure. The pressure measurement for purge VSV monitor is begun when the purge VSV is turned ON (open) after the EVAP leak check. When the measured pressure indicates an increase of 0.3 kPa (2.25 mmHg) or more, the purge VSV is functioning normally. If the pressure does not increase, the ECM interprets this as the purge VSV being stuck closed. The ECM illuminates the MIL and sets the DTC (2 trip detection logic). EVAP Pressure when Purge VSV Stuck Closed: ON: Open OFF: Closed ON Purge VSV ON Vent Valve ON: Closed OFF: Vent ON Vacuum Pump EVAP Pressure OK Positive Negative Malfunction First 0.02 inch Leak Pressure Standard Sequence Time A B 10 sec 60 sec C D E Within 15 minutes 10 60 sec G36776 EVAP Pressure During Purge Flow Monitor: Purge VSV Open Vent Valve ON (closed) Malfunction EVAP Pressure 0.1 kPa OK OK 1st Monitor 0.5 kPa 2nd Monitor A71563 2. PURGE FLOW MONITOR The purge flow monitor consists of the two step monitors. The 1st monitor is conducted every time and the 2nd monitor is activated if necessary.
The 1st monitor While the engine is running and the purge VSV (Vacuum Switching Valve) is ON (open), the ECM monitors the purge flow by measuring the EVAP pressure change. If negative pressure is not created, the ECM begins the 2nd monitor.
The 2nd monitor The vent valve is turned ON (closed) and the EVAP pressure is then measured. If the variation in the pressure is less than 0.5 kPa (3.75 mmHg), the ECM interprets this as the purge VSV being stuck closed, and illuminates the MIL and sets DTC P0441 (2 trip detection logic). Atmospheric pressure check: In order to ensure reliable malfunction detection, the variation between the atmospheric pressures, before and after conduction of the purge flow monitor, is measured by the ECM. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 389 05-200 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) OBD II MONITOR SPECIFICATIONS (Key-off Monitor) Monitor Strategy Required Sensors/Components Purge VSV and pump module Frequency of Operation Once per driving cycle Duration Within 15 minutes (varies with fuel in tank) MIL Operation 2 driving cycles Sequence of Operation None Typical Enabling Conditions The monitor will run whenever these DTCs are not present See page 05-16 EVAP key-off monitor runs when all of the following conditions met - Atmospheric pressure 525 to 825 mmHg (70 to 110 kPa) Battery voltage 10.5 V or more Vehicle speed Below 4 km/h (2.5 mph) Ignition switch OFF Engine condition Not running Time after engine stopped 5 hours FTP sensor malfunction (P0450, P0452, P0453) Not detected Purge VSV Not operated by scan tool Vent valve Not operated by scan tool Leak detection pump Not operated by scan tool Both of the following conditions are met before IG switch OFF: Condition 1 and 2 1. Duration that vehicle is driven 5 min. or more 2. Purge flow Executed ECT 4.4 to 35C (40 to 95F) IAT 4.4 to 35C (40 to 95F) Example of re-start time First time 7 hours Second time 9 hours and 30 min. Key-of f monitor sequence: 1 to 8 1. Atmospheric pressure Next sequence is run if following condition met - Atmospheric pressure change for 10 sec. Within 2.25 mmHg (0.3 kPa) for 1 sec. 2. First reference pressure Next sequence is run if all of following conditions met Condition 1, 2 and 3 1. FTP when 4 sec. after reference pressure measurement -7.5 mmHg (-1 kPa) or less 2. Reference pressure -36.47 to -7.93 mmHg (-4.85 to -1.057 kPa) 3. Reference pressure Saturated 3. Vent valve stuck closed check Next sequence is run if following condition met - FTP change for 10 sec. after vent valve ON (closed) 2.25 mmHg (0.3 kPa) or more 4. Vacuum introduction and leak Next sequence is run if both of following conditions met Condition 1 and 2 1. Vacuum introduction time Within 15 min. 2. FTP FTP was saturated 5. Purge VSV stuck closed check Next sequence is run if following condition met - FTP change for 10 sec. after purge VSV ON (open) 2.25 mmHg (0.3 kPa) or more 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 390 05-201 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 6. Second reference pressure measurement Next sequence is run if all of following conditions met Condition 1, 2, 3 and 4 1. FTP when 4 sec. after reference pressure measurement -7.5 mmHg (-1 kPa) or less 2. Reference pressure -36.47 to -7.93 mmHg (-4.85 to -1.057 kPa) 3. Reference pressure Saturated 4. Reference pressure difference between first and second Less than 5.25 mmHg (0.7 kPa) 7. Leak check Next sequence is run if following condition met - FTP when vacuum introduction was complete Lower than second reference pressure 8. Atmospheric pressure Monitor is complete if following - Atmospheric pressure difference between sequence 1 and 8 Within 2.25 mmHg (0.3 kPa) Typical Malfunction Thresholds Purge VSV stuck open FTP when vacuum introduction was complete Higher than reference pressure x 0.2 Purge VSV stuck closed FTP change for 10 seconds after purge VSV ON (open) Less than 2.25 mmHg (0.3 kPa) OBD II MONITOR SPECIFICATIONS (Purge Flow Monitor) Monitor Strategy Required Sensors/Components Purge VSV and pump module Frequency of Operation Once per driving cycle Duration Within 30 seconds MIL Operation 2 driving cycles Sequence Operation None Typical Enabling Conditions The monitor will run whenever these DTCs are not present See page 05-16 Engine Running ECT 4.4C (40F) or more IAT 4.4C (40F) or more FTP sensor malfunction Not detected Purge VSV Not operated by scan tool EVAP system check Not operated by scan tool Battery voltage 10 V or more Purge duty cycle 8 % or more Typical Malfunction Thresholds Both of the following conditions are met: Condition 1 or 2 1. FTP change when purge operation is started Less than 0.75 mmHg (0.1 kPa) 2. FTP change during purge operation when vent valve is closed Less than 3.75 mmHg (0.5 kPa) MONITOR RESULT (MODE 06) Refer to page 05-317 for detailed information on Monitor Result. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 391 05-202 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05IR9-02 DTC P0450 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR/SWITCH DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR RANGE/PERFORMANCE DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR/SWITCH LOW INPUT DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR/SWITCH HIGH INPUT DTC SUMMARY Detection Logic Monitoring Items Malfunction Detection Conditions P0450 Pressure sensor voltage abnormal fluctuation Sensor output voltage rapidly fluctuates beyond upper and lower malfunction thresholds for 0.5 seconds.
Pump module
Connector/Wire harness (Pump module - ECM)
ECM
EVAP monitoring (ignition OFF)
Ignition ON 1 trip Pressure sensor noising Sensor output voltage fluctuates frequently in certain time period.
Pump module
Connector/Wire harness (Pump module - ECM)
ECM
EVAP monitoring (ignition OFF)
Engine running 2 trip Pressure sensor stuck Sensor output voltage does vary in certain time period.
Pump module
Connector/Wire harness (Pump module - ECM)
ECM
EVAP monitoring (ignition OFF) 2 trip P0452 Pressure sensor voltage low Sensor output voltage is less than 0.45 V for 0.5 seconds.
Pump module
Connector/Wire harness (Pump module - ECM)
ECM
Ignition ON
EVAP monitoring (ignition OFF) 1 trip P0453 Sensor output voltage is more than 4.9 Pressure sensor voltage high V for 0.5 seconds.
Pump module
Connector/Wire harness (Pump module - ECM)
ECM
Ignition ON
EVAP monitoring (ignition OFF) 1 trip P0451 P0451 Trouble Areas Detection Timings DTC HINT: The pressure sensor is built into the pump module. CIRCUIT DESCRIPTION The circuit description can be found in the EVAP (Evaporative Emission) Inspection Procedure (see page 05-317 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 392 05-203 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) MONITOR DESCRIPTION (a) Pressure Sensor Specification: Malfunction Area Output Voltage 4.900 V 4.150 V Usable Range 1.425 V Malfunction Area 0.450 V 60 kPa 110 kPa (b) Pressure HINT: Standard atmospheric pressure is 101.3 kPa A71562 (c) (d) DTC P0450: Pressure sensor voltage abnormal fluctuation. If the pressure sensor voltage output rapidly fluctuates between less than 0.45 V and more than 4.9 V, the ECM interprets this as an open or short circuit malfunction in the pressure sensor or its circuit, and stops the EVAP (Evaporative Emission) system monitor. The ECM then illuminates the MIL and sets the DTC (1 trip detection logic). DTC P0451: Pressure sensor noising or stuck If the pressure sensor voltage output fluctuates rapidly for 10 seconds, the ECM stops the EVAP system monitor. The ECM interprets this as noise from the pressure sensor, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC. Alternatively, if the sensor voltage output does not change for 10 seconds, the ECM interprets this as the sensor being stuck, and stops the monitor. The ECM then illuminates the MIL and sets the DTC. (Both the malfunctions are detected by 2 trip detection logic) DTC P0452: Pressure sensor voltage low If the pressure sensor voltage output is below 0.45 V, the ECM interprets this as an open or short circuit malfunction in the pressure sensor or its circuit, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC (1 trip detection logic). DTC P0453: Pressure sensor voltage high If the pressure sensor voltage output is 4.9 V or more, the ECM interprets this as an open or short circuit malfunction in the pressure sensor or its circuit, and stops the EVAP system monitor. The ECM then illuminates the MIL and sets the DTC (1 trip detection logic). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 393 05-204 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) OBD II MONITOR SPECIFICATIONS Monitor Strategy Required Sensors/Components Pump module Frequency of Operation Once per driving cycle: P0451 FTP sensor output ”Stuck” Continuous: P0451 FTP sensor ”Noise”, P0450, P0452 and P0453 Duration 0.5 sec.: P0450, P0452 and P0453 10 sec.: P0451 MIL Operation Immediate: P0450, P0452 and P0453 2 driving cycles: P0451 Sequence of Operation None Typical Enabling Conditions P0451: FTP sensor ”Noise” Monitor runs whenever these DTCs are not present See page 05-16 Atmospheric pressure (absolute pressure) 70 kPa (525 mmHg) or more, less than 110 kPa (825 mmHg) Battery voltage 10.5 V or more Intake air temperature 4.4 to 35C (40 to 95F) FTP sensor malfunction (P0450, P0452, P0453) Not detected Either of following conditions is met: Condition 1 or 2 1. Engine Running 2. Time after engine stopped 5 hours Example of re-start time First time 7 hours Second time 9 hours and 30 min. P0451: FTP sensor output ”Stuck” Monitor runs whenever these DTCs are not present See page 05-16 Battery voltage 10.5 V or more Intake air temperature 4.4 to 35C (40 to 95F) FTP sensor malfunction (P0450, P0452, P0453) Not detected Atmospheric pressure (absolute pressure) Less than 70 kPa (525 mmHg), or 110 kPa (825 mmHg) or more Time after engine stopped 5 hours Example of re-start time First time 7 hours Second time 9 hours and 30 min. P0450, P0452 and P0453: Monitor runs whenever these DTCs are not present See page 05-16 Ignition switch ON Battery voltage 8 V or more Starter OFF Typical Malfunction Thresholds P0450: Pressure sensor chattering Pressure sensor voltage Less than 0.45 V, or more than 4.9 V P0451: FTP sensor ”Noise” Frequency that FTP change is 2.25 mmHg (0.3 kPa) or more 10 times or more in 10 sec. P0451: FTP sensor output ”Stuck” FTP change for 10 sec. during EVAP monitor (Reference pressure) Less than 4.88 mmHg (0.65 kPa) P0452: Pressure sensor low voltage Pressure sensor voltage Less than 0.45 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 394 05-205 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) P0453: Pressure sensor high voltage Pressure sensor voltage More than 4.9 V WIRING DIAGRAM C17 Pump Module Pressure Sensor ECM 16 BJ1 4 L 12 BJ1 3 Y BR Vacuum Pump 1 W 8 B W-B Y 17 BJ1 BR 13 BJ1 W 14 BJ1 R 18 BJ1 V 2 6 L Vent Valve 9 R 7 IO1 P 15 IO1 BR 16 IO1 B-R SB GR 5 IM1 1 2I W FL MAIN A Battery BR B-R 28 E2 E7 4 MPMP E5 27 VPMP E5 Y-G 1 G 34 PRG E7 B 8 MREL E5 2 V4 Purge VSV B-R 2 BF 5 S29 LG 14 IM1 5V Engine Room J/B EFI No. 2 W-B J19 J/C 5 S28 BR VC 21 PPMP E5 L 12 IM1 4 IO1 5 IO1 18 E7 Y 3 IO1 1 EB1 BJ1 15 13 IM1 2 EFI No. 1 4 2F W-B A EFI Relay 5 3 3 2D 2 1 5 2B Y P-L 13 IK3 J2 J/C EH A85256 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 395 05-206 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) INSPECTION PROCEDURE NOTICE:
When a vehicle is brought into the workshop, leave it as it is. Do not change the vehicle condition. For example, do not tighten the fuel tank cap.
Do not disassemble the pump module.
A hand-held tester is required to conduct the following diagnostic troubleshooting procedure. 1 (a) (b) (c) (d) (e) (f) CONFIRM DTC AND EVAP PRESSURE Connect a hand-held tester to the DLC3. Turn the ignition switch to ON (do not start the engine). Turn the tester ON. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODES. Read DTCs. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / VAPOR PRESS. Read the EVAP (Evaporative Emission) pressure displayed on the tester. Result: (g) Display (DTC Output) Test Results P0451  P0452 P0453 Suspected Trouble Areas Proceed To
Pressure sensor C Less than 45 kpa (430 mmHg)
Wire harness/connector (ECM - pressure sensor)
Pressure sensor
Short in ECM circuit A More than 120 kPa (900 mmHg)
Wire harness/connector (ECM - pressure sensor)
Pressure sensor
Open in ECM circuit B B Go to step 4 C Go to EVAP INSPECTION PROCEDURE (See page 05-317 ) A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 396 05-207 DIAGNOSTICS 2 - SFI SYSTEM (2AZ-FE) CHECK HARNESS AND CONNECTOR(PUMP MODULE - ECM) (a) (b) (c) ECM Turn the ignition switch to OFF. Disconnect the E5 ECM connector. Measure the resistance between PPMP terminal of the ECM connector and the body ground. E5 21 (PPMP) A54404 Result: Test Results Suspected Trouble Areas Proceed To 10 Ω or less
Wire harness/connector (ECM - pressure sensor)
Short in pressure sensor circuit A 10 kΩ or more
Wire harness/connector (ECM - pressure sensor)
Short in ECM circuit B (d) Reconnect the ECM connector. B Go to step 7 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 397 05-208 DIAGNOSTICS 3 - SFI SYSTEM (2AZ-FE) CHECK HARNESS AND CONNECTOR(PUMP MODULE - ECM) (a) (b) (c) (d) (e) Remove the exhaust tail pipe. Remove the heat insulator under the canister. Disconnect the canister connector. Disconnect the E5 ECM connector. Check the resistance between PPMP terminal of the ECM connector and the body ground. A85252 ECM E5 21 A54404 Result: Test Results Suspected Trouble Areas Proceed To 10 kΩ or more
Short in pressure sensor circuit A 10 Ω or less
Short in wire harness/connector (ECM - pressure sensor) B (f) (g) Reconnect the canister connector. Reconnect the ECM connector. A Go to step 5 B Go to step 6 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 398 05-209 DIAGNOSTICS 4 - SFI SYSTEM (2AZ-FE) CHECK HARNESS AND CONNECTOR(PUMP MODULE - ECM) (a) (b) (c) (d) (e) (f) Turn the ignition switch to OFF. Remove the exhaust tail pipe. Remove the heat insulator under the canister. Disconnect the canister connector. Turn the ignition switch to ON. Measure the voltage and resistance of the C17 connector. Standard: A85252 Wire Harness Side Terminal No. Specified Condition C17-4 - Body ground Between 4.5 V and 5.5 V C17-3 - Body ground Between 4.5 V and 5.5 V C17-2 - Body ground Below 1 Ω C17 Canister A85258 Result: Test Results Suspected Trouble Areas Proceed To Voltage and resistance within standard ranges
Open in pressure sensor circuit A Voltage and resistance outside standard ranges
Open in wire harness/connector (ECM - pressure sensor) B (g) Reconnect the canister connector. A Go to step 5 B Go to step 6 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 399 05-210 DIAGNOSTICS 5 - SFI SYSTEM (2AZ-FE) REPLACE PUMP MODULE (a) (b) (c) (d) A85252 (e) (f) (g) (h) Remove the exhaust tail pipe. Remove the heat insulator under the canister. Disconnect the hoses and the connector. Remove the 3 bolts and the pump module with the Oring. Install a new pump module with a new O-ring. Install the 3 bolts. Connect the hoses and the connector. Go to the next step before installing the exhaust tail pipe. NEXT 6 Go to step 8 REPAIR OR REPLACE WIRE HARNESS AND CONNECTOR HINT: If the exhaust tail pipe has been removed, go to the next step before reinstalling it. NEXT 7 REPLACE ECM (see page 10-9 ) NEXT 8 (a) (b) (c) (d) Go to step 8 Go to step 8 CONFIRM DTC (AFTER REPAIR) Connect the hand-held tester to the DLC3. Turn the ignition switch to ON and turn the tester ON. Wait for at least 60 seconds. On the tester, select the following menu items: DIAGNOSIS /ENHANCED OBD II /DTC INFO /PENDING CODES. HINT: If no pending DTC is displayed on the tester, the repair has been successfully completed. NEXT COMPLETED 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 400 05-21 1 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05IRA-02 DTC P0455 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (GROSS LEAK) DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK) DTC SUMMARY DTC P0455 P0456 Monitoring Items Detection Timings Detection Logic
Fuel tank cap (loose)
Leakage from EVAP line (Canister - Fuel tank)
Leakage from EVAP line (Purge VSV - Canister)
Pump module
Leakage from fuel tank
Leakage from canister While ignition switch OFF 2 trip Same above While ignition switch OFF 2 trip Malfunction Detection Conditions EVAP gross leak Vacuum pump creates negative pressure (vacuum) in EVAP system and EVAP system pressure measured. 0.02 inch leak pressure standard is measured at the start and at the end of the leak check. If stabilized pressure higher than [second 0.02 inch leak pressure standard x 0.2], ECM determines that EVAP system has large leakage. EVAP small leak Vacuum pump creates negative pressure (vacuum) in EVAP system and EVAP system pressure measured. 0.02 inch leak pressure standard is measured at the start and at the end of the leak check. If stabilized pressure larger than second 0.02 inch leak pressure, ECM determines that EVAP system has small leakage. Trouble Areas CIRCUIT DESCRIPTION The circuit description can be found in the EVAP (Evaporative Emission) Inspection Procedure (see page 05-317 ). INSPECTION PROCEDURE Refer to the EVAP Inspection Procedure (see page 05-317 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 401 05-212 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) MONITOR DESCRIPTION 5 hours* after the ignition switch is turned OFF, the electric vacuum pump creates negative pressure (vacuum) in the EVAP (Evaporative Emission) system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35C (95F) 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later. If it is still not below 35C (95F) 7 hours after the ignition switch is turned off, the monitor check starts 2.5 hours later. Sequence - Operations Descriptions Duration ECM activation Activated by soak timer, 5 hours (7 or 9.5 hours) after ignition switch turned to OFF. A Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If EVAP pressure is not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM cancels EVAP system monitor. - 10 seconds B First 0.02 inch leak pressure measurement In order to determine 0.02 inch leak pressure standard, vacuum pump creates negative pressure (vacuum) through 0.02 inch orifice and them ECM checks if vacuum pump and vent valve operate normally. 60 seconds C EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) created in EVAP system, and EVAP system pressure then measured. Write down the measured value as it will be used in the leak check. If EVAP pressure does not stabilize within 15 minutes, ECM cancels EVAP system monitor. 15 minutes* D Purge VSV monitor Purge VSV opened and then EVAP system pressure measured by ECM. Large increase indicates normal. 10 seconds E Second 0.02 inch leak pressure measurement Leak check is performed after second 0.02 inch leak pressure standard is measured. If stabilized system pressure higher than second 0.02 inch leak pressure standard, ECM determines that EVAP system leaking. 60 seconds F Final check Atmospheric pressure measured and then monitoring result recorded by ECM. - * If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize. Operation A: Atmospheric Pressure Measurement Operation B, E: 0.02 Inch Leak Pressure Measurement Canister Fuel Tank OFF Vent Valve: OFF (vent) OFF (vent) Purge VSV: OFF 0.02 Inch Orifice Pressure Sensor Vacuum Pump: OFF Air Filter ON Pump Module Operation D: Purge VSV monitor Operation C: EVAP System Pressure Measurement OFF ON ON (closed) ON (closed) Atmospheric Pressure ON Negative Pressure ON A96746 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 402 05-213 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) (a) P0455: EVAP (Evaporative Emission) gross leak In operation C, the vacuum pump creates negative pressure (vacuum) in the EVAP system and the EVAP system pressure is measured. If the stabilized system pressure is higher than [second 0.02 inch leak pressure standard x 0.2] (near atmospheric pressure), the ECM determines that the EVAP system has a large leakage, illuminates the MIL and sets the DTC (2 trip detection logic). (b) P0456: EVAP very small leak In operation C, the vacuum pump creates negative pressure (vacuum) in the EVAP system and the EVAP system pressure is measured. If the stabilized system pressure is higher than second 0.02 inch leak pressure standard, the ECM determines that the EVAP system has a small leakage, illuminates the MIL and sets the DTC (2 trip detection logic). EVAP Pressure when EVAP system Leaks: ON: Open OFF: Closed ON Purge VSV ON Vent Valve ON: Closed OFF: Vent Vacuum Pump ON EVAP Pressure P0455 Positive Negative P0456 Second 0.02 inch Leak Pressure Standard x 0.2 First 0.02 inch Leak Pressure Standard Sequence Time A B 10 sec 60 sec OK C D E Within 15 minutes 10 sec 60 sec G38299 OBD II MONITOR SPECIFICATIONS Monitor Strategy Required Sensors/Components Purge VSV and pump module Frequency of Operation Once per driving cycle Duration Within 15 minutes (varies with amount of fuel in tank) MIL Operation 2 driving cycles Sequence of Operation None Typical Enabling Conditions The monitor will run whenever these DTCs are not present See page 05-16 EVAP key-off monitor runs when all of the following conditions met - Atomspheric pressure 525 to 825 mmHg (70 to 110 kPa) Battery voltage 10.5 V or more Vehicle speed Below 4 km/h (2.5 mph) Ignition switch OFF Engine condition Not running Time after engine stopped 5 hours FTP sensor malfunction (P0450, P0452, P0453) Not detected Purge VSV Not operated by scan tool Vent valve Not operated by scan tool 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 403 05-214 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) Leak detection pump Not operated by scan tool Both of the following conditions are met before IG switch OFF Condition 1 and 2 1. Duration that vehicle is driven 5 min. or more 2. Purge flow Executed ECT 4.4 to 35C (40 to 95F) IAT 4.4 to 35C (40 to 95F) Example of re-start time First time 7 hours Second time 9 hours and 30 min. Key-of f monitor sequence: 1 to 8 1. Atmospheric pressure Next sequence is run if following condition met - Atmospheric pressure change for 10 sec. Within 2.25 mmHg (0.3 kPa) for 1 sec. 2. First reference pressure Next sequence is run if all of following conditions met Condition 1, 2 and 3 1. FTP when 4 sec. after reference pressure measurement -7.5 mmHg (-1 kPa) or less 2. Reference pressure -36.47 to -7.93 mmHg (-4.85 to -1.057 kPa) 3. Reference pressure Saturated 3. Vent valve stuck closed check Next sequence is run if following condition met - FTP change for 10 sec. after vent valve ON (closed) 2.25 mmHg (0.3 kPa) or more 4. Vacuum introduction and leak Next sequence is run if both of following conditions met Condition 1 and 2 1. Vacuum introduction time Within 15 min. 2. FTP FTP was saturated 5. Purge VSV stuck closed check Next sequence is run if following condition met - FTP change for 10 sec. after purge VSV ON (open) 2.25 mmHg (0.3 kPa) or more 6. Second reference pressure measurement Next sequence is run if all of following conditions met Condition 1, 2, 3 and 4 1. FTP when 4 sec. after reference pressure measurement -7.5 mmHg (-1 kPa) or less 2. Reference pressure -36.47 to -7.93 mmHg (-4.85 to -1.057 kPa) 3. Reference pressure Saturated 4. Reference pressure difference between first and second Less than 5.25 mmHg (0.7 kPa) 7. Leak check Next sequence is run if following condition met - FTP when vacuum introduction was complete Lower than second reference pressure 8. Atmospheric pressure Monitor is complete if following - Atmospheric pressure difference between sequence 1 and 8 Within 2.25 mmHg (0.3 kPa) Typical Malfunction Thresholds P0455: EVAP gross leak FTP when vacuum introduction was complete Higher than reference pressure x 0.2 P0456: EVAP small leak FTP when vacuum introduction was complete Between 1 and 2 Condition 1 Higher than second reference pressure Condition 2 Lower than reference pressure x 0.2 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 404 05-215 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) MONITOR RESULT (MODE 06) Refer to page 05-317 for detailed information on Monitor Result. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 405 05-216 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05EVI-05 DTC P0500 VEHICLE SPEED SENSOR ”A” DTC P0503 VEHICLE SPEED SENSOR ”A” INTERMITTENT/ERRATIC/HIGH CIRCUIT DESCRIPTION The speed sensor detects the wheel speed and sends the appropriate signals to the skid control ECU. The skid control ECU converts these wheel speed signals into a 4-pulse signal and outputs it to the ECM via the combination meter. The ECM determines the vehicle speed based on the frequency of these pulse signals. 4-Pulse From Speed Sensor Skid Control ECU 4-Pulse Combination Meter ECM A79413 DTC No. DTC Detection Condition Trouble Area P0500 P0503 The ECM detects the following conditions simultaneously for 2 seconds (1 trip detection logic):
No SPD (speed sensor) signal is output when ECM detects NC (transmission counter gear) signal is more than 300 rpm.
Park/Neutral position switch is OFF (when shift lever is in other than P and N positions)
Open or short in speed sensor circuit
Speed sensor
Combination meter
ECM
Skid control ECU MONITOR DESCRIPTION The ECM assumes that the vehicle is being driven when the transmission counter gear indicates more than 300 rpm and over 30 seconds have passed since the park/neutral position switch was turned OFF. If there is no signal from the vehicle speed sensor with these conditions satisfied, the ECM concludes that the vehicle speed sensor is malfunctioning. The ECM will turn on the MIL and will set a DTC. MONITOR STRATEGY Related DTCs P0500: VSS Circuit Required sensors/ components (Main) Vehicle speed sensor (VSS), Combination meter, ABS ECU Required sensors / components (Related) Transmission counter gear Speed (CS) sensor, PNP switch, ECT sensor Frequency of operation Continuous Duration 2 seconds MIL operation Immediate Sequence of operation None 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 406 05-217 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-16 Transmission counter gear speed 300 rpm or more Engine condition Running Ignition switch ON Battery voltage 8 V or more Starter OFF Either of the following conditions is met: Condition 1 and 2 Condition 1: - Time after PNP switch turns from ON to OFF 2 sec. or more ECT and ECT sensor ECT is 20C (68F) or more and ECT sensor dose not malfunction (P0115 or P0116) Condition 2: - Time after PNP switch turns from ON to OFF 30 sec. or more ECT and ECT sensor ECT is less than 20C (68F) or ECT sensor fail is detected (P0115 or P0116) TYPICAL MALFUNCTION THRESHOLDS Sensor signal No pulse input WIRING DIAGRAM ECM C12 Combination Meter Center J/B 5V W 13 9 3J 1 3B 9 Y Y IL2 J7 J/C 17 SPD E6 1 A BR E9 E1 A BR EE A85370 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 407 05-218 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK OPERATION OF SPEEDOMETER (a) Drive the vehicle and check if operation of the speedometer in the combination meter is normal. HINT: The vehicle speed sensor is operating normally if the speedometer display is normal. NG CHECK SPEEDOMETER CIRCUIT (See page 05-1885 ) OK 2 INSPECT ECM (SPD VOLTAGE) E1 (-) E9 ECM (a) (b) (c) (d) SPD (+) E6 ECM Shift the lever to the neutral position. Jack up the vehicle. Turn the ignition switch ON. Measure the voltage of the ECM connectors as the wheel is turned slowly. Standard: Tester Connection Specified Condition E6-17 (SPD) - E9-1 (E1) Generated intermittently HINT: The output voltage should fluctuate up and down similarly to the diagram on the left when the wheel is turned slowly. 4.5 to 5.5 V 0V Turn Wheel A67446 A62954 A85537 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE ECM (See page 10-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 408 05-219 DIAGNOSTICS DTC P0504 - SFI SYSTEM (2AZ-FE) 05EVK-05 BRAKE SWITCH ”A”/”B” CORRELATION CIRCUIT DESCRIPTION In addition to turning on the stop lamp, the stop lamp switch signals are used for a variety of engine, transmission, and suspension functions as well as being an input for diagnostic checks. It is important that the switch operates properly, therefore this switch is designed with two complementary signal outputs: STP and ST1. The ECM analyzes these signal outputs to detect malfunctions in the stop lamp switch. HINT: Normal condition is as shown in the table. DTC No. P0504 Signal Brake pedal released In transition Brake pedal depressed STP OFF ON ON ST1 ON ON OFF DTC Detection Condition Conditions (a), (b) and (c) continue for 0.5 seconds or more: (a) Ignition switch ON (b) Brake pedal released (c) STP signal is OFF when the ST1 signal is OFF Trouble Area
Short in stop lamp switch signal circuit
STOP fuse
Stop lamp switch
ECM 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 409 05-220 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) WIRING DIAGRAM S15 Stop Lamp Switch Assy Y Instrument Panel J/B Assy 1 12 4M 3 4L B 2 ECM Passenger Side J/B 1 19 BR STP 12 E6 ST1- V 3 E6 4 1E P STOP J6 J/C 1 Passenger Side J/B 1A 1 4E P E E 4 4M W B F7 FL Block Assy 2 1 I15 Ignition Switch ALT AM2 Instrument Panel J/B Assy 1 L-Y 10 IC1 Y AM2 7 GR IG2 6 1 IGN 6 1G 1C 1 W 1 BR E9 E1 FL Main A J7 J/C A BR Battery EE A90301 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 410 05-221 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. Hand-held tester: 1 (a) CHECK STOP LAMP (OPERATION) Check if the stop lamps turn on and off normally when the brake pedal is depressed and released. OK: The stop lamps turn on when you depress the brake pedal. NG REPAIR OR REPLACE STOP LAMP SWITCH CIRCUIT OK 2 INSPECT STOP LAMP SWITCH ASSY (RESISTANCE) (a) Free Pushed in 2 4 1 3 A82517 Measure the resistance of the switch terminals. Standard: Switch Condition Tester Connection Specified Condition Switch pin free 1-2 Below 1.5 V Switch pin free 3-4 10 kΩ or higher Switch pin pushed in 1-2 10 kΩ or higher Switch pin pushed in 3-4 Below 1.5 V NG REPLACE STOP LAMP SWITCH ASSY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 411 05-222 DIAGNOSTICS 3 - SFI SYSTEM (2AZ-FE) READ VALUE OF HAND-HELD TESTER (STP SIGNAL, ST1 VOLTAGE) (a) (b) (c) Brake Pedal Depressed Brake Pedal Released E1 (-) E9 ECM Turn the ignition switch ON. On the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / STOP LIGHT SW. Read the value. Standard: Brake Pedal Condition Specified Condition Depressed STP Signal ON Released STP Signal OFF Measure the voltage of the ECM connectors. Standard: Brake Pedal Condition Specified Condition E6-12 (ST1) - E9-1 (E1) Tester Connection Depressed Below 1.5 V E6-12 (ST1) - E9-1 (E1) Released 7.5 to 14 V ST1 (+) E6 ECM A72880 OK CHECK FOR INTERMITTENT PROBLEMS (See page 05-9 ) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 412 05-223 DIAGNOSTICS 4 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS (STOP LAMP SWITCH - ECM) (a) (b) (c) Wire Harness Side Disconnect the S15 stop lamp switch connector. Disconnect the E6 ECM connector. Measure the resistance of the wire harness side connectors. Standard: S15 Stop Lamp Switch Tester Connection Specified Condition S15-1 - E6-19 (STP) S15-4 - E6-12 (ST1) Below 1 Ω S15-1 or E6-19 (STP) - Body ground S15-4 or E6-12 (ST1) - Body ground 10 kΩ or higher E6 ECM ST1 STP NG Y A56986 A67404 A87771 REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE ECM (See page 10-9 ) OBD II scan tool (excluding hand-held tester): 1 (a) CHECK STOP LAMP (OPERATION) Check if the stop lamps turn on and off normally when the brake pedal is depressed and released. OK: The stop lamps turn on when you depress the brake pedal. NG REPAIR OR REPLACE STOP LAMP SWITCH CIRCUIT OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 413 05-224 DIAGNOSTICS 2 SFI SYSTEM (2AZ-FE) INSPECT STOP LAMP SWITCH ASSY (a) Free - Pushed in 1 2 Measure the resistance of the switch terminals. Standard: Switch Condition Tester Connection Specified Condition Switch pin free 1-2 Below 1 Ω Switch pin free 3-4 10 kΩ or higher Switch pin pushed in 1-2 10 kΩ or higher Switch pin pushed in 3-4 Below 1 Ω 3 4 A82517 NG REPLACE STOP LAMP SWITCH ASSY OK 3 INSPECT ECM (STP, ST1 VOLTAGE) Brake Pedal Depressed (a) (b) Brake Pedal Released Turn the ignition switch ON. Measure the voltage of the ECM connectors. Standard: Tester Connection Brake Pedal Condition Specified Condition Depressed 7.5 to 14 V E6-19 (STP) - E9-1 (E1) Released Below 1.5 V E6-12 (ST1) - E9-1 (E1) Depressed Below 1.5 V E6-12 (ST1) - E9-1 (E1) Released 7.5 to 14 V E6-19 (STP) - E9-1 (E1) E1 (-) E9 ECM ST1 (+) STP (+) E6 ECM OK A72880 CHECK FOR INTERMITTENT PROBLEMS (See page 05-9 ) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 414 05-225 DIAGNOSTICS 4 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS (STOP LAMP SWITCH - ECM) (a) (b) (c) Wire Harness Side Disconnect the S15 stop lamp switch connector. Disconnect the E6 ECM connector. Measure the resistance of the wire harness side connectors. Standard: S15 Stop Lamp Switch Tester Connection Specified Condition S15-1 - E6-19 (STP) S15-4 - E6-12 (ST1) Below 1 Ω S15-1 or E6-19 (STP) - Body ground S15-4 or E6-12 (ST1) - Body ground 10 kΩ or higher E6 ECM ST1 STP Y A56986 A67404 NG A87771 REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE ECM (See page 10-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 415 05-226 DIAGNOSTICS DTC P0505 - SFI SYSTEM (2AZ-FE) 05EVL-05 IDLE AIR CONTROL SYSTEM MONITOR DESCRIPTION The idle speed is controlled by the Electronic Throttle Control System (ETCS). The ETCS is composed of the throttle motor, which operates the throttle valve, and the throttle position sensor, which detects the opening angle of the throttle valve. The ECM controls the throttle motor to provide the proper throttle valve opening angle to obtain the target idle speed. The ECM regulates the idle speed by opening and closing the throttle valve using the ETCS. The ECM concludes that the idle speed control ECM function is malfunctioning if: 1) the actual idle RPM varies more than the specified amount five times or more during a drive cycle, or 2) a learning value of the idle speed control remains at the maximum or minimum five times or more during a drive cycle. The ECM will turn on the MIL and set a DTC. Example: If the actual idle RPM varies from the target idle RPM by more than 200*1 rpm five times during a drive cycle, the ECM will turn on the MIL and will set a DTC. *1: RPM threshold varies with engine load. Large Idle Engine RPM Target RPM Maximum Learning Value of the Idle Speed Control 0 Actual Idle RPM Minimum Small Time Time A82389 DTC No. P0505 DTC Detection Condition Idle speed continues to vary greatly from target speed Trouble Area
Electronic throttle control system
Air induction system
PCV hose connection 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 416 05-227 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) MONITOR STRATEGY Related DTCs IAC Functional Check Required sensors / components (Main) ETCS (Electrical throttle control system) Required sensors / components (Related) CKP sensor, ECT sensor, and VSS Frequency of operation Continuous Duration 10 min. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present See page 05-16 Engine Running TYPICAL MALFUNCTION THRESHOLDS Either of the Conditions is met: Condition 1 or 2 1. Frequency that both of the following conditions (a) and (b) are met: 5 times (a) Engine RPM - Target engine RPM Less than -100 rpm or more than 150 rpm (b) Vehicle condition Stop after vehicle was driven at 10 km/h (6.25 mph) or more 2. Frequency that both of the following conditions (a) and (b) are met: Once (a) IAC flow rate learning value Below 1.3 L/second or above 4.51 L/second (b) Engine RPM - Target engine RPM Less than -100 rpm or more than 150 rpm INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 417 05-228 DIAGNOSTICS 1 (a) - SFI SYSTEM (2AZ-FE) CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0505) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display (DTC Output) Proceed to Only P0505 is output A P0505 and other DTCs are output B HINT: If any other codes besides P0505 are output, perform the troubleshooting for those codes first. B GO TO RELEVANT DTC CHART (See page 05-48 ) A 2 CHECK CONNECTION OF PCV HOSE OK: PCV hose is connected correctly and PCV hose has no damage. NG REPAIR OR REPLACE PCV HOSE OK 3 (a) CHECK AIR INDUCTION SYSTEM Check for vacuum leaks in the air induction system. OK: No leak in air induction system. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK CHECK ELECTRIC THROTTLE CONTROL SYSTEM (See page 10-1 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 418 05-229 DIAGNOSTICS DTC P0560 - SFI SYSTEM (2AZ-FE) 05EVM-05 SYSTEM VOLTAGE MONITOR DESCRIPTION The battery supplies electricity to the ECM even when the ignition switch is OFF. This electricity allows the ECM to store data such as DTC history, freeze frame data, fuel trim values and other data. If the battery voltage falls below a minimum level, the ECM will conclude that there is a fault in the power supply circuit. The next time the engine starts, the ECM will turn on the MIL and a DTC will be set. DTC No. P0560 DTC Detection Condition Trouble Area
Open in back-up power source circuit
ECM Open in ECM back-up power source circuit (1 trip detection logic) HINT: If DTC P0560 is present, the ECM will not store other DTCs. MONITOR STRATEGY Related DTCs P0560: ECM system voltage Required sensors / components (Main) ECM Required sensors / components (Related) - Frequency of operation Continuous Duration 3 sec. MIL operation Immediate (MIL will illuminate after the next engine start) Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present See page 05-16 TYPICAL MALFUNCTION THRESHOLDS ECM power source Less than 3.5 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 419 05-230 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) WIRING DIAGRAM ECM Engine Room J/B 1 EFI NO. 1 7 2I 2B W 3 B-W 11 BR IK2 F7 FL Block Assy BR 3 E5 BATT 1 E9 E1 1 W A J7 J/C FL Main A BR Battery EE A90302 INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 INSPECT FUSE (EFI NO. 1) (a) (b) Engine Room J/B EFI NO. 1 fuse A90343 Remove the EFI NO. 1 fuse from the engine room J/B. Measure the resistance of the EFI NO. 1 fuse. Standard: Below 1 Ω OK REPLACE FUSE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 420 05-231 DIAGNOSTICS 2 - SFI SYSTEM (2AZ-FE) INSPECT ECM (BATT VOLTAGE) (a) E1 (-) E9 ECM BATT (+) Measure the voltage of the ECM connectors. Standard: Tester Connection Specified Condition E5-3 (BATT) - E9-1 (E1) 9 to 14 V E5 ECM A67446 OK REPLACE ECM (See page 10-9 ) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 421 05-232 DIAGNOSTICS 3 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS (ECM - EFI NO. 1 FUSE, EFI NO. 1 FUSE - BATTERY) (a) Wire Harness Side Check the wire harness between the EFI NO. 1 fuse and ECM. (1) Remove the EFI NO. 1 fuse from the engine room J/B. (2) Disconnect the E5 ECM connector. (3) Measure the resistance of the wire harness side connectors. Standard: Engine Room J/B EFI NO. 1 Fuse Tester Connection E5 ECM Specified Condition J/B EFI NO. 1 fuse terminal 2 - E5-3 (BATT) Below 1 Ω J/B EFI NO. 1 fuse terminal 2 or E5-3 (BATT) - Body ground 10 kΩ or higher BATT Y A80025 A67445 A92625 (b) Wire Harness Side Engine Room J/B Check the wire harness between the EFI NO. 1 fuse and battery. (1) Remove the EFI NO. 1 fuse from the engine room J/B. (2) Disconnect the battery positive cable. (3) Measure the resistance of the wire harness side connectors. Standard: EFI NO. 1 Fuse A80025 Tester Connection Specified Condition Battery positive cable - J/B EFI NO. 1 fuse terminal 1 Below 1 Ω Battery positive cable or J/B EFI NO. 1 fuse terminal 1 - Body ground 10 kΩ or higher A92626 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK CHECK AND REPLACE ENGINE ROOM J/B 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 422 05-233 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05EVN-05 DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR DTC P0606 ECM/PCM PROCESSOR DTC P0607 CONTROL MODULE PERFORMANCE DTC P0657 ACTUATOR SUPPLY VOLTAGE CIRCUIT/OPEN MONITOR DESCRIPTION The ECM continuously monitors its internal memory status, internal circuits, and output signals to the throttle actuator. This self-check ensures that the ECM is functioning properly. If any malfunction is detected, the ECM will set the appropriate DTC and illuminate the MIL. The ECM memory status is diagnosed by internal ”mirroring” of the main CPU and the sub CPU to detect random access memory (RAM) errors. The two CPUs also perform continuous mutual monitoring. The ECM sets a DTC if: 1) outputs from the 2 CPUs are different and deviate from the standards, 2) the signals to the throttle actuator deviate from the standards, 3) a malfunction is found in the throttle actuator supply voltage, and 4) any other ECM malfunction is found. DTC No. P0604 P0606 P0607 P0657 DTC Detection Condition Trouble Area ECM internal error (1trip detection logic) ECM MONITOR STRATEGY Related DTCs P0604: RAM errors P0606: CPU malfunction P0607: ECM range check P0657: ETCS (Electrical throttle control) power supply circuit in ECM Required sensors / components (Main) ECM Required sensors / components (Related) - Frequency of operation Continuous Duration Within 1 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-16 TYPICAL MALFUNCTION THRESHOLDS RAM Error P0604: RAM RAM check failure CPU malfunction P0606: Either of the following conditions is met: Condition 1 or 2 1. Difference between TP of main CPU and TP of sub CPU 0.3 V or more 2. Difference between APP of main CPU and APP of sub CPU 0.3 V or more 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 423 05-234 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) ECM range check P0607: Either of the following conditions is met: Condition 1 or 2 1. All of the following conditions are met: Conditions (a), (b) and (c) (a) CPU reset 1 time or more (b) Difference between TP and APP learned 0.4 V or more (c) Electronic throttle actuator OFF 2. CPU reset 2 times or more ETCS power supply circuit in ECM P0657: ETCS power supply when ignition switch turns from OFF to ON 7 V or more INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. REPLACE ECM (See page 10-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 424 05-235 DIAGNOSTICS DTC P0617 - SFI SYSTEM (2AZ-FE) 05EVO-05 STARTER RELAY CIRCUIT HIGH MONITOR DESCRIPTION While the engine is being cranked, the battery positive voltage is applied to terminal STA of the ECM. If the vehicle is being driven and the ECM detects the starter control signal (STA), the ECM concludes that the starter control circuit is malfunctioning. The ECM will turn on the MIL and will set a DTC. DTC No. P0617 DTC Detecting Condition Trouble Area When conditions (a), (b) and (c) are met and the battery (+B) voltage 10.5 V or more is applied for 20 seconds: (1 trip detection logic) (a) Vehicle speed greater than 12 mph (20 km/h) (b) Engine revolution greater than 1,000 rpm (c) STA signal ON
Short in PNP switch assy circuit
PNP switch assy
Ignition switch
ECM MONITOR STRATEGY Related DTCs P0617: Starter signal Required sensors / components (Main) Starter relay and PNP switch Required sensors / components (Related) CKP sensor and vehicle speed sensor Frequency of operation Continuous Duration 20 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present See page 05-16 Battery voltage 10.5 V or more Vehicle speed 20 km/h (12.4 mph) or more Engine RPM 1,000 rpm or more TYPICAL MALFUNCTION THRESHOLDS Starter signal ON 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 425 05-236 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) WIRING DIAGRAM I15 Ignition Switch W 2 AM1 AM2 Instrument Panel J/B Assy ECM 3 IC1 B ST1 1 ST2 7 2 8 Engine Room R/B No. 2 B-W Y 1C 6 2 1 AM1 1 2 IC1 1 STARTER 2 IC1 Engine Room R/B No. 2 1A 1 B-Y 2 L L-W B-W 3 2 EB2 2 B-R 4 P1 PNP Switch 5 L-Y B 5 F7 2 FL Block Assy 1 4 EB2 STARTER Relay 2 3 B ALT AM2 2 B 17 B 2 E7 STA 10 1 W-R W 4 FL Main EB1 B-W B 1 S2 BR W-B A S1 E1 A J2 J/C 1 1 E9 J7 J/C A BR Starter Battery EH EE A90303 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 426 05-237 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand-held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. Hand-held tester: 1 (a) (b) (c) READ VALUE OF HAND-HELD TESTER (STA SIGNAL) Connect the hand-held tester to the DLC3. Turn ON the ignition switch. Push the hand-held tester main switch. On the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / STARTER SIG. Read the values. Result: Ignition Switch Condition ON START STA signal OFF ON OK REPLACE ECM (See page 10-9 ) NG 2 INSPECT PARK/NEUTRAL POSITION SWITCH ASSY (See page 05-922 ) OK: When shift lever is in the N position, the PNP switch is ON. When shift lever is in the P position, the PNP switch is OFF. NG REPLACE PARK/NEUTRAL POSITION SWITCH ASSY (See page 40-3 ) (Go to step 3 AFTER REPLACEMENT) OK 3 (a) (b) (c) READ VALUE OF HAND-HELD TESTER (STA SIGNAL) Connect the hand-held tester to the DLC3. Turn ON the ignition switch. Push the hand-held tester main switch. On the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / STARTER SIG. Read the values. Result: Ignition Switch Condition ON START STA signal OFF ON OK SYSTEM OK NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 427 05-238 DIAGNOSTICS 4 - SFI SYSTEM (2AZ-FE) INSPECT IGNITION OR STARTER SWITCH ASSY (a) AM1 I15 Ignition Switch ST2 4 3 2 1 8 7 6 5 AM2 ST1 Measure the resistance of the ignition switch terminals. Standard: Switch Condition Tester Connection Specified Condition LOCK 1-2 7-8 10 kΩ or higher START 1-2 7-8 Below 1 Ω NG A56879 REPLACE IGNITION OR STARTER SWITCH ASSY (Go to next step 5 AFTER REPLACEMENT) OK 5 (a) (b) (c) READ VALUE OF HAND-HELD TESTER (STA SIGNAL) Connect the hand-held tester to the DLC3. Turn ON the ignition switch. Push the hand-held tester main switch. On the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / STARTER SIG. Read the values. Result: Ignition Switch Condition ON START STA Signal OFF ON OK SYSTEM OK NG REPAIR OR REPLACE HARNESS AND CONNECTOR 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 428 05-239 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) OBD II scan tool (excluding Hand-held Tester): 1 INSPECT ECM STA (+) E7 ECM (a) (b) E1 (-) E9 ECM Turn the ignition switch ON. Measure the voltage of the ECM connectors. Standard: Tester Connection Condition E7-17 (STA) - E9-1 (E1) Ignition switch ON 0V E7-17 (STA) - E9-1 (E1) Engine cranking 6 V or more OK Specified Condition REPLACE ECM (See page 10-9 ) A76903 NG 2 INSPECT PARK/NEUTRAL POSITION SWITCH ASSY (See page 05-922 ) NG REPLACE PARK/NEUTRAL POSITION SWITCH ASSY (See page 40-3 ) (Go to next step 3 AFTER REPLACEMENT) OK 3 INSPECT ECM (a) STA (+) E7 ECM E1 (-) E9 ECM A76903 Measure the voltage of the ECM connectors. Standard: Tester Connection Condition E7-17 (STA) - E9-1 (E1) Ignition switch ON 0V E7-17 (STA) - E9-1 (E1) Engine cranking 6 V or more OK Specified Condition SYSTEM OK NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 429 05-240 DIAGNOSTICS 4 - SFI SYSTEM (2AZ-FE) INSPECT IGNITION OR STARTER SWITCH ASSY (a) AM1 I15 Ignition Switch 4 3 2 1 8 7 6 5 ST2 ST1 Measure the resistance of the ignition switch terminals. Standard: Switch Condition Tester Connection Specified Condition LOCK 1-2 7-8 10 kΩ or higher START 1-2 7-8 Below 1 Ω NG AM2 A56879 REPLACE IGNITION OR STARTER SWITCH ASSY OK 5 INSPECT ECM (a) STA (+) E7 ECM E1 (-) E9 ECM A76903 Measure the voltage of the ECM connectors. Standard: Tester Connection Condition E7-17 (STA) - E9-1 (E1) Ignition switch ON 0V E7-17 (STA) - E9-1 (E1) Engine cranking 6 V or more OK Specified Condition SYSTEM OK NG REPAIR OR REPLACE HARNESS AND CONNECTOR 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 430 05-241 DIAGNOSTICS DTC P0630 - SFI SYSTEM (2AZ-FE) 05MOK-01 VIN NOT PROGRAMMED OR MISMATCH ECM/PCM CIRCUIT DESCRIPTION DTC P0630 is set when the Vehicle Indication Number (VIN) is not stored in the ECM or the input VIN is not accurate. Input the VIN with the hand-held tester (see page 05-12 ). DTC No. DTC Detection Conditions Trouble Areas
VIN is not stored in ECM
Input VIN in ECM is not accurate P0630
ECM MONITOR STRATEGY Related DTCs P0630: VIN not programed Required Sensors/Components (Main) ECM Required Sensors/Components (Related)  Frequency of Operation Continuous Duration 0.5 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-16 Battery voltage 8 V or more Ignition switch ON Stater OFF TYPICAL MALFUNCTION THRESHOLDS VIN code Not programmed COMPONENT OPERATING RANGE VIN code Programmed INSPECTION PROCEDURE 1 READ CURRENT DTC NOTICE: If P0630 is present, the VIN must be input to the ECM using the hand-held tester. However, all DTCs are cleared automatically by the tester when inputting the VIN. If DTCs other than P0630 are present, check them first. NEXT 2 INPUT VIN WITH HAND-HELD TESTER (See page 05-12 ) NEXT END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 431 05-242 DIAGNOSTICS DTC P0705 - SFI SYSTEM (2AZ-FE) 055UU-10 TRANSMISSION RANGE SENSOR CIRCUIT MALFUNCTION (PRNDL INPUT) CIRCUIT DESCRIPTION When the shift lever is in the N or P position: 1) the Park/Neutral Position (PNP) switch turns on, and 2) ECM terminal NSW is grounded to the body ground via the starter relay and voltage becomes 0 V. When the shift lever is in the D, 2, L or R position: 1) the PNP switch turns off, and 2) ECM terminal NSW receives current and becomes the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated control). DTC No. P0705 DTC Detection Condition 2 or more switches are ON simultaneously at R, N, D, 2 and L positions (2 trip detection logic) Trouble Area
Short in PNP switch circuit
PNP switch
ECM HINT: After confirming DTC P0705, use the hand-held tester to confirm the PNP switch signal in the ALL menu (to reach the ALL menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL). WIRING DIAGRAM Refer to DTC P0705 on page 05-922 . INSPECTION PROCEDURE Refer to DTC P0705 on page 05-922 . HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 432 05-243 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05EVQ-05 DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH CIRCUIT DESCRIPTION The throttle actuator is operated by the ECM and it opens and closes the throttle valve. The opening angle of the throttle valve is detected by the throttle position sensor which is mounted on the throttle body. The throttle position sensor provides feedback to the ECM. This feedback allows the ECM to control the throttle actuator and monitor the throttle opening angle in response to driver inputs. HINT: This Electronic Throttle Control System (ETCS) does not use a throttle cable. DTC No. DTC Detection Condition Trouble Area P2102 Conditions (a) and (b) continue for 2.0 seconds: (a) Throttle actuator output duty 80 % or more (b) Throttle actuator current 0.5 A or less (1 trip detection logic)
Open in throttle actuator circuit
Throttle actuator
ECM P2103 Either of following conditions is met:
Throttle actuator current 10 A or more (0.1 seconds)
Throttle actuator current 7 A or more (0.6 seconds) (1 trip detection logic)
Short in throttle actuator circuit
Throttle actuator
Throttle valve
Throttle body assy
ECM MONITOR DESCRIPTION The ECM monitors the flow of electrical current through the electronic throttle actuator, and detects malfunctions or open circuits in the throttle motor based on the value of the electrical current. When the current deviates from the standard, the ECM concludes that there is a fault in the throttle motor. Or, if the throttle valve is not functioning properly (for example, stuck on), the ECM concludes that there is a fault and turns on the MIL and a DTC is set. Example: When the current is more than 10 A, or the current is less than 0.5 A when the actuator driving duty ratio is more than 80 %, the ECM concludes that the current is deviated from the standard, turns on the MIL and a DTC is set. FAIL-SAFE If the ETCS has a malfunction, the ECM cuts off current to the throttle actuator. The throttle control valve returns to a predetermined opening angle (approximately 16) by the force of the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue at a minimal speed. If the accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly. If a ”pass” condition is detected and then the ignition switch is turned OFF, the fail-safe operation will stop and the system will return to normal condition. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 433 05-244 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) MONITOR STRATEGY Related DTCs P2102: Throttle actuator current (low current) P2103: Throttle actuator current (high current) Required sensors / components (Main) Throttle actuator Required sensors / components (Related) - Frequency of operation Continuous Duration 2 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-16 P2102: Throttle actuator duty ratio 80 % or more Throttle actuator power supply 8 V or more P2103: Throttle actuator power supply 8 V or more Battery voltage 8 V or more Starter OFF TYPICAL MALFUNCTION THRESHOLDS P2102: Throttle actuator current Less than 0.5 A P2103: Either of the following conditions is met: Condition 1 or 2 1. Hybrid IC diagnosis signal Fail ( for 0.1 sec.) 2. Hybrid IC current limiter port Fail (for 0.6 sec.) WIRING DIAGRAM T13 Throttle Actuator ECM Shielded M+ 2 B 3 E9 M+ M- W 2 E9 M- 1 17 E9 GE01 A87825 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 434 05-245 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 INSPECT THROTTLE BODY ASSY (THROTTLE ACTUATOR) (a) (b) T13 Throttle Actuator M+ M- Disconnect the T13 throttle actuator connector. Measure the resistance of the throttle actuator terminals. Standard: NG Tester Connection Specified Condition T13-2 (M+) - T13-1 (M-) 0.3 to 100 Ω (20 C (68F)) REPLACE THROTTLE BODY ASSY A59778 OK 2 CHECK WIRE HARNESS (THROTTLE ACTUATOR - ECM) (a) (b) (c) Wire Harness Side T13 Throttle Actuator M- Disconnect the T13 throttle actuator connector. Disconnect the E9 ECM connector. Measure the resistance of the wire harness side connectors. Standard: M+ E9 ECM MM+ Y B53781 A81698 A85540 NG Tester Connection Specified Condition T13-2 (M+) - E9-3 (M+) T13-1 (M-) - E9-2 (M-) Below 1 Ω T13-2 (M+) or E9-3 (M+) - Body ground T13-1 (M-) or E9-2 (M-) - Body ground 10 kΩ or higher REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 435 05-246 DIAGNOSTICS 3 (a) - SFI SYSTEM (2AZ-FE) INSPECT THROTTLE BODY ASSY Visually check for foreign objects between the throttle valve and the housing. Also, check if the valve can open and close smoothly. OK: The throttle valve is not contaminated with foreign objects and can move smoothly. NG REMOVE FOREIGN OBJECT AND CLEAN THROTTLE BODY OK REPLACE ECM (See page 10-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 436 05-247 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05EVS-05 DTC P2111 THROTTLE ACTUATOR CONTROL SYSTEM - STUCK OPEN DTC P2112 THROTTLE ACTUATOR CONTROL SYSTEM - STUCK CLOSED CIRCUIT DESCRIPTION The throttle actuator is operated by the ECM and it opens and closes the throttle valve using gears. The opening angle of the throttle valve is detected by the throttle position sensor, which is mounted on the throttle body. The throttle position sensor provides feedback to the ECM to control the throttle actuator and set the throttle valve angle in response to driver inputs. HINT: This Electronic Throttle Control System (ETCS) does not use a throttle cable. DTC No. DTC Detection Condition Trouble Area P2111 Throttle valve locked during ECM order to close (1 trip detection logic) P2112 Throttle valve locked during ECM order to open (1 trip detection logic)
Throttle actuator circuit
Throttle actuator
Throttle body
Throttle valve
Same as DTC No. P2111 MONITOR DESCRIPTION The ECM concludes that there is a malfunction of the ETCS when the throttle valve remains at a fixed angle despite high drive current from the ECM. The ECM will turn on the MIL and will set a DTC. FAIL-SAFE If the ETCS has a malfunction, the ECM cuts off current to the throttle actuator. The throttle control valve returns to a predetermined opening angle (approximately 16) by the force of the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue at a minimal speed. If the accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly. If a ”pass” condition is detected and then the ignition switch is turned OFF, the fail-safe operation will stop and the system will return to normal condition. MONITOR STRATEGY Related DTCs P2111: Throttle actuator stuck open P2112: Throttle actuator stuck closed Required sensors/ components (Main) Throttle actuator Required sensors/ components (Related) - Frequency of operation Continuous Duration 0.5 sec. MIL operation Immediate Sequence of operation None 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 437 05-248 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present See page 05-16 P2111: Throttle motor current 2 A or more Throttle actuator close duty ratio 80 % or more P2112: Throttle motor current 2 A or more Throttle actuator open duty ratio 80 % or more TYPICAL MALFUNCTION THRESHOLDS TP (throttle position) sensor voltage change for 0.016 second Less than 0.1 V WIRING DIAGRAM Refer to DTC P2102 on page 05-243 . INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK OTHER DTC OUTPUT Display (DTC output) Proceed to P2111 or P2112 A P2111 or P2112 and other DTCs B B GO TO RELEVANT DTC CHART (See page 05-48 ) A 2 CHECK THROTTLE BODY ASSY (VISUALLY CHECK THROTTLE VALVE) Check for contamination between the throttle valve and the housing. If necessary, clean the throttle body. And check that the throttle valve moves smoothly. OK: The throttle valve is not contaminated with foreign objects and can move smoothly. NG REPLACE THROTTLE BODY ASSY (See page 10-6 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 438 05-249 DIAGNOSTICS 3 (a) (b) (c) - SFI SYSTEM (2AZ-FE) CHECK DTC OUTPUT Clear the DTC (See page 05-38 ). Start the engine, and depress and release the accelerator pedal quickly (fully open and fully close). Read the DTC. Result: Display (DTC output) Proceed to No DTC A P2111 and/or P2112 B B REPLACE ECM (See page 10-9 ) A CHECK FOR INTERMITTENT PROBLEMS (See page 05-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 439 05-250 DIAGNOSTICS DTC P2118 - SFI SYSTEM (2AZ-FE) 05EVT-05 THROTTLE ACTUATOR CONTROL MOTOR CURRENT RANGE/PERFORMANCE CIRCUIT DESCRIPTION The Electronic Throttle Control System (ETCS) has a dedicated power supply circuit. The voltage (+BM) is monitored and when the voltage is low (less than 4 V), the ECM concludes that the ETCS has a fault and current to the throttle actuator is cut. When the voltage becomes unstable, the ETCS itself becomes unstable. For this reason, when the voltage is low, the current to the actuator is cut. If repairs are made and the system has returned to normal, turn the ignition switch OFF. The ECM then allows current to flow to the actuator and actuator can be restarted. HINT: This ETCS does not use a throttle cable. ECM From Battery ETCS +BM Actuator Control Circuit Throttle Actuator M+ M- ME01 A85832 DTC No. P2118 DTC Detection Condition Open in ETCS power source circuit (1 trip detection logic) Trouble Area
Open in ETCS power source circuit
ETCS fuse
ECM MONITOR DESCRIPTION The ECM monitors the battery supply voltage applied to the electronic throttle actuator. When the power supply voltage drops below the threshold, the ECM concludes that the power supply circuit has an open circuit. A DTC is set and the MIL is turned on. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 440 05-251 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) FAIL-SAFE If the ETCS has a malfunction, the ECM cuts off current to the throttle actuator. The throttle control valve returns to a predetermined opening angle (approximately 16) by the force of the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue at a minimal speed. If the accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly. If a ”pass” condition is detected and the ignition switch is turned OFF, the fail-safe operation will stop and the system will return to normal. MONITOR STRATEGY Related DTCs P2118: Throttle actuator power supply Required sensors / components (Main) Throttle actuator, ETCS fuse Required sensors / components (Related) - Frequency of operation Continuous Duration 0.8 seconds MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present See page 05-16 Battery voltage More than 8 V TYPICAL MALFUNCTION THRESHOLDS Throttle actuator power supply voltage Less than 4 V COMPONENT OPERATING RANGE Throttle actuator power supply voltage 9 to 14 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 441 05-252 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) WIRING DIAGRAM ECM R 4 W IC1 6 E6 +BM 2 2 ETCS Engine Room R/B No. 2 1 2 T13 Throttle Actuator Shielded M+ 2 B 3 E9 M+ 1 W 2 E9 M- W M3 F7 FL Block Assy 17 E9 GE01 1 W W-B FL Main Battery 4 E9 ME01 EF A90304 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 442 05-253 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK FUSE (ETCS) (a) (b) Engine Room R/B No. 2 ETCS Fuse Remove the ETCS fuse from the engine room R/B No. 2. Measure the resistance of the ETCS fuse. Standard: Below 1 Ω NG A92628 REPLACE FUSE OK 2 INSPECT ECM (+BM VOLTAGE) (a) ME01 (-) E9 ECM +BM (+) Measure the voltage of the ECM connectors. Standard: Tester Connection Specified Condition E6-6 (+BM) - E9-4 (ME01) 9 to 14 V E6 ECM A67446 OK REPLACE ECM (See page 10-9 ) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 443 05-254 DIAGNOSTICS 3 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS (ECM - ETCS FUSE, ETCS FUSE - BATTERY) (a) Wire Harness Side Engine Room R/B No. 2 Check the wire harness between the ETCS fuse and ECM. (1) Remove the ETCS fuse from the engine room R/B No. 2. (2) Disconnect the E6 ECM connector. (3) Measure the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition R/B No. 2 ETCS fuse terminal 2 - E6-6 (+BM) Below 1 Ω R/B No. 2 ETCS fuse terminal 2 or E6-6 (+BM) - Body ground 10 kΩ or higher ETCS Fuse E6 ECM +BM A80017 A67404 A92627 (b) Wire Harness Side Engine Room R/B No. 2 ETCS Fuse Check the wire harness between the ETCS fuse and battery. (1) Remove the ETCS fuse from the engine room R/B No. 2. (2) Disconnect the battery positive cable. (3) Measure the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition Battery positive cable - R/B No. 2 ETCS fuse terminal 1 Below 1 Ω Battery positive cable or R/B No. 2 ETCS fuse terminal 1 - Body ground 10 kΩ or higher A92628 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK CHECK ENGINE ROOM RELAY BLOCK NO.2 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 444 05-255 DIAGNOSTICS DTC P2119 - SFI SYSTEM (2AZ-FE) 05EVU-05 THROTTLE ACTUATOR CONTROL THROTTLE BODY RANGE/PERFORMANCE CIRCUIT DESCRIPTION The Electronic Throttle Control System (ETCS) is composed of a throttle actuator that operates the throttle valve, a throttle position sensor that detects the opening angle of the throttle valve, an accelerator pedal position sensor that detects the accelerator pedal position, and the ECM that controls the ETCS system. The ECM operates the throttle actuator to position the throttle valve for proper response to driver inputs. The throttle position sensor, which is mounted on the throttle body, detects the opening angle of the throttle valve and provides this signal to the ECM so that the ECM can regulate the throttle actuator. DTC No. P2119 DTC Detection Condition Trouble Area Throttle opening angle continues to vary greatly from target throttle opening angle (1 trip detection logic)
Electronic throttle control system
ECM MONITOR DESCRIPTION The ECM determines the ”actual” throttle angle based on the throttle position sensor signal. The ”actual” throttle position is compared to the ”target” throttle position commanded by the ECM. If the difference between these two values exceeds a specified limit, the ECM interprets this as a fault in the ETCS system. The ECM turns on the MIL and a DTC is set. FAIL-SAFE If the ETCS has a malfunction, the ECM cuts off current to the throttle actuator. The throttle control valve returns to a predetermined opening angle (approximately 16) by the force of the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue at a minimal speed. If the accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly. If a ”pass” condition is detected and then the ignition switch is turned OFF, the fail-safe operation will stop and the system will return to normal condition. MONITOR STRATEGY Related DTCs P2119: ETCS malfunction Required sensors / components (Main) Throttle actuator Required sensors / components (Related) - Frequency of operation Continuous Duration 1 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present See page 05-16 TYPICAL MALFUNCTION THRESHOLDS Difference between ”target TP (Throttle position)” and ”actual TP” 0.3 V or more WIRING DIAGRAM Refer to DTC P2102 on page 05-243 . 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 445 05-256 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P2119) Display (DTC output) Proceed to Only P2119 is output A P2119 and other codes are output B B GO TO RELEVANT DTC CHART (See page 05-48 ) A 2 CHECK IF DTC OUTPUT REOCCURS (a) Clear the DTC (see page 05-38 ). (b) Allow the engine to idle for 15 seconds. (c) Pull the hand brake and shift the gear to D. (d) Depress the brake pedal securely and the accelerator pedal fully for 5 seconds. (e) Read the DTC. HINT: Actual throttle position (TP) sensor voltage can be confirmed using the hand-held tester [DATA LIST / ALL / THROTTLE POS #1]. OK: No DTC is output. OK NORMAL NG REPLACE THROTTLE BODY ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 446 05-257 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05ITG-02 DTC P2120 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”D” CIRCUIT DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”D” CIRCUIT LOW INPUT DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”D” CIRCUIT HIGH INPUT DTC P2125 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”E” CIRCUIT DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”E” CIRCUIT LOW INPUT DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”E” CIRCUIT HIGH INPUT DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”D”/”E” VOLTAGE CORRELATION HINT: This is the repair procedure for the ”accelerator pedal position sensor”. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 447 05-258 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) CIRCUIT DESCRIPTION HINT:

Accelerator Pedal Position Sensor Magnet IC No. 1 ECM VPA EPA VCPA VPA2 EPA2 IC No. 2 VCP2 Accelerator Pedal Position Sensor Output Voltage (V) This Electronic Throttle Control System (ETCS) does not use a throttle cable. This description is for the accelerator pedal position sensor. The Accelerator Pedal Position (APP) sensor is mounted on the accelerator pedal to detect the angle of the accelerator pedal. This sensor is electronically controlled and uses Hall-effect elements. In the accelerator pedal position sensor, the voltage applied to terminals VPA and VPA2 of the ECM changes between 0 V and 5 V in proportion to the angle of the accelerator pedal. The VPA is a signal to indicate the actual accelerator pedal angle and is used for the engine control. VPA2 is used to detect malfunctions of the sensor itself. The ECM monitors the accelerator pedal angle from VPA and VPA2 signal outputs, and controls the throttle motor based on these signals. *1 *2 5 3.4 to 5.3 2.6 to 4.5 1.6 0.8 0 Usable Range 25 Accelerator Pedal Turning Angle (deg) Magnet *1: Accelerator Pedal Released *2: Accelerator Pedal Fully Depressed A19694 A19803 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 448 05-259 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) DTC Detection Condition (All of the following are 1 trip detection logic) DTC No. Trouble Area P2120 Condition (a) continues for 0.5 sec. or more: (a) VPA is 0.2 V or less or VPA is 4.8 V or more
Accelerator pedal position sensor
ECM P2122 VPA is 0.2 V or less for 0.5 sec. or more when VPA2 output indicates accelerator pedal is opened
Accelerator pedal position sensor
Open in VCP1 circuit
VPA circuit open or ground short
ECM P2123 Condition (a) continues for 2.0 sec. or more: (a) VPA is 4.8 V or more
Accelerator pedal position sensor
Open in EPA circuit
ECM P2125 Condition (a) continues for 0.5 sec. or more: (a) (VPA2 is 0.5 V or less) or (VPA2 is 4.8 V or more)
Accelerator pedal position sensor
ECM P2127 VPA2 is 0.5 V or less for 0.5 sec. or more when VPA output indicates accelerator pedal is opened
Accelerator pedal position sensor
Open in VCP2 circuit
VPA2 circuit open or ground short
ECM P2128 Conditions (a) and (b) continue for 2.0 sec. or more: (a) VPA2 is 4.8 V or more (b) VPA is 0.2 V or more and VPA is 3.45 V or less
Accelerator pedal position sensor
Open in EPA2 circuit
ECM P2138 Condition (a) or (b) continues for 2.0 sec. or more: (a) Difference between VPA and VPA2 is 0.02 V or less (b) VPA is 0.2 V or less and VPA2 is 0.5 V or less
VPA and VPA2 circuit are short circuited
Accelerator pedal position sensor
ECM HINT: After confirming DTC P2120, P2122, P2123, P2125, P2127, P2128 and P2138, use the hand-held tester or the OBD II scan tool to confirm the accelerator pedal position sensor output voltage. Accelerator pedal position expressed as voltage output Accelerator pedal released Trouble Area Accelerator pedal depressed ACCEL POS #1 ACCEL POS #2 ACCEL POS #1 VCP circuit open 0 to 0.2 V 0 to 0.2 V 0 to 0.2 V ACCEL POS #2 0 to 0.2 V VPA circuit open or ground short 0 to 0.2 V 1.2 to 2.0 V 0 to 0.2 V 3.4 to 5.3 V VPA2 circuit open or ground short 0.5 to 1.1 V 0 to 0.2 V 2.6 to 4.5 V 0 to 0.2 V EPA circuit open 4.5 to 5.5 V 4.5 to 5.5 V 4.5 to 5.5 V 4.5 to 5.5 V MONITOR DESCRIPTION When VPA or VPA2 deviates from the standard, or the difference between the voltage outputs of the two sensors is less than the threshold, the ECM concludes that there is a defect in the accelerator pedal position sensor. The ECM turns on the MIL and a DTC is set. Example: The voltage output of the VPA is below 0.2 V or exceeds 4.8 V. FAIL-SAFE The accelerator pedal position sensor has 2 (main and sub) sensor circuits. If a malfunction occurs in either of the sensor circuits, the ECM detects the abnormal signal voltage difference between the 2 sensor circuits and switches to fail-safe mode. In fail-safe mode, the remaining circuit is used to calculate the accelerator pedal opening angle to allow the vehicle to continue driving. If both circuits malfunction, the ECM regards the opening angle of the accelerator pedal to be fully closed. In this case, the throttle valve will remain closed as if the engine is idling. If a ”pass” condition is detected and then the ignition switch is turned OFF, the fail-safe operation will stop and the system will return to normal condition. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 449 05-260 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) MONITOR STRATEGY Related DTCs P2120: APP (Accelerator pedal position) Sensor 1 range check (chattering) P2122: APP sensor 1 range check (low voltage) P2123: APP sensor 1 range check (high voltage) P2125: APP sensor 2 range check (chattering) P2127: APP sensor 2 range check (low voltage) P2128: APP sensor 2 range check (high voltage) P2138: APP sensor range check (correlation) Required sensors / components (Main) APP sensor Required sensors / components (Related) - Frequency of operation Continuous Duration 0.5 sec.: P2120, P2122, P2125 and P2127 2 sec.: P2123, P2128 and P2138 MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-16 TYPICAL MALFUNCTION THRESHOLDS P2120: Either of the following conditions is met: Condition 1 or 2 1. VPA1 voltage when VPA2 is 0.97 or more 0.2 V or less 2. VPA1 voltage 4.8 V or more P2122: VPA1 voltage when VPA2 is 0.97 or more 0.2 V or less P2123: VPA1 voltage 4.8 V or more P2125: Either of the following conditions is met: Condition 1 or 2 1. VPA2 voltage when VPA1 is 0.97 or more 0.5 V or less 2. VPA2 voltage when VPA1 is 0.2 to 3.45 V 4.8 V or more P2127: VPA2 voltage when VPA1 is 0.97 or more 0.5 V or less P2128: VPA2 voltage when VPA1 is 0.2 to 3.45 V 4.8 V or more P2138: Either of the following conditions is met: Condition 1 or 2 1. Difference betrween VPA 1 and VPA2 voltage 0.02 V or less Condition 2 - VPA1 voltage 0.2 V or less VPA2 voltage 0.5 V or less COMPONENT OPERATING RANGE VPA voltage 0.5 to 4.5 V VPA2 voltage 1.2 to 4.8 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 450 05-261 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) WIRING DIAGRAM A27 Accelerator Pedal Position Sensor VPA EPA VCPA VPA2 EPA2 VCP2 ECM 6 B 22 VPA E5 5 R 28 E5 4 G EPA 26 VCPA E5 3 W 23 VPA2 E5 2 BR 29 E5 EPA2 27 VCP2 E5 L 1 A80021 INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. Hand-held tester: 1 READ VALUE OF HAND-HELD TESTER (ACCEL POS #1 AND ACCEL POS #2) (a) (b) (c) Depressed Released Connect the hand-held tester to the DLC3. Turn the ignition switch ON. On the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ETCS / ACCEL POS #1 and ACCEL POS #2” and read its value displayed on the hand-held tester. Standard: Accelerator Pedal ACCEL POS #1 ACCEL POS #2 Released 0.5 to 1.1 V 1.2 to 2.0 V Depressed 2.6 to 4.5 V 3.4 to 5.3 V FI7052 OK Go to step 5 NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 451 05-262 DIAGNOSTICS 2 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS (ACCELERATOR PEDAL POSITION SENSOR - ECM) (a) (b) (c) Wire Harness Side A27 Accelerator Pedal Position Sensor Disconnect the A27 sensor connector. Disconnect the E5 ECM connector. Measure the resistance of the wire harness side connectors. Standard: Tester Connection VCP2 EPA2 VPA2 VCPA EPA VPA VCP2 VPA EPA VCPA VPA2 EPA2 VCP2 VPA E5 VCPA ECM (A27-6) (A27-5) (A27-4) (A27-3) (A27-2) (A27-1) - Specified Condition VPA (E5-22) EPA (E5-28) VCPA (E5-26) VPA2 (E5-23) EPA2 (E5-29) VCP2 (E5-27) Below 1 Ω VPA (A27-6) or VPA (E5-22) - Body ground EPA (A27-5) or EPA (E5-28) - Body ground VCPA (A27-4) or VCPA (E5-26) - Body ground VPA2 (A27-3) or VPA2 (E5-23) - Body ground EPA2 (A27-2) or EPA2 (E5-29) - Body ground VCP2 (A27-1) or VCP2 (E5-27) - Body ground VPA2 EPA2 10 kΩ or higher EPA B53781 A67445 A92629 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 3 INSPECT ECM (VCPA AND VCP2 VOLTAGE) (a) (b) (c) A27 Accelerator Pedal Position Sensor EPA2 (-) A19521 A53765 EPA (-) VCP2 (+) VCPA (+) Disconnect the A27 sensor connector. Turn the ignition switch ON. Measure the voltage of the ECM connector. Standard: Tester Connection Specified Condition VCPA (E5-26) - EPA (E5-28) VCP2 (E5-27) - EPA2 (E5-29) 4.5 to 5.5 V E5 ECM A92544 NG REPLACE ECM (See page 10-9 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 452 05-263 DIAGNOSTICS 4 - SFI SYSTEM (2AZ-FE) REPLACE ACCELERATOR PEDAL ROD ASSY (See page 10-1 1) GO 5 (a) (b) (c) (d) READ OUTPUT DTC (ACCELERATOR PEDAL POSITION SENSOR DTCS ARE OUTPUT AGAIN) Clear the DTC (see page 05-38 ). Start the engine. Run the engine at idle for 15 seconds or more. Read the DTC. Result: Display (DTC Output) Proceed to P2120, P2122, P2123, P2125, P2127, P2128 and/or P2138 are output again A No DTC output B B SYSTEM OK A REPLACE ECM (See page 10-9 ) OBD II scan tool (excluding hand-held tester): 1 CHECK WIRE HARNESS (ACCELERATOR PEDAL POSITION SENSOR - ECM) (a) (b) (c) Wire Harness Side A27 Accelerator Pedal Position Sensor Disconnect the A27 sensor connector. Disconnect the E5 ECM connector. Measure the resistance of the wire harness side connectors. Standard: Tester Connection VCP2 EPA2 VPA2 VCPA EPA VPA VCP2 VPA EPA VCPA VPA2 EPA2 VCP2 VPA E5 VCPA ECM VPA2 EPA2 (A27-6) (A27-5) (A27-4) (A27-3) (A27-2) (A27-1) - Specified Condition VPA (E5-22) EPA (E5-28) VCPA (E5-26) VPA2 (E5-23) EPA2 (E5-29) VCP2 (E5-27) Below 1 Ω VPA (A27-6) or VPA (E5-22) - Body ground EPA (A27-5) or EPA (E5-28) - Body ground VCPA (A27-4) or VCPA (E5-26) - Body ground VPA2 (A27-3) or VPA2 (E5-23) - Body ground EPA2 (A27-2) or EPA2 (E5-29) - Body ground VCP2 (A27-1) or VCP2 (E5-27) - Body ground 10 kΩ or higher EPA B53781 A67445 A92629 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 453 05-264 DIAGNOSTICS 2 - SFI SYSTEM (2AZ-FE) INSPECT ECM (VCPA AND VCP2 VOLTAGE) (a) (b) (c) A27 Accelerator Pedal Position Sensor EPA2 (-) EPA (-) VCP2 (+) A19521 A53765 Disconnect the A27 sensor connector. Turn the ignition switch ON. Measure the voltage of the ECM connector. Standard: Tester Connection Specified Condition VCPA (E5-26) - EPA (E5-28) VCP2 (E5-27) - EPA2 (E5-29) 4.5 to 5.5 V E5 ECM VCPA (+) A92544 NG REPLACE ECM (See page 10-9 ) OK 3 REPLACE ACCELERATOR PEDAL ROD ASSY (See page 10-1 1) GO 4 (a) (b) (c) (d) READ OUTPUT DTC (ACCELERATOR PEDAL POSITION SENSOR DTCS ARE OUTPUT AGAIN) Clear the DTC (see page 05-38 ). Start the engine. Run the engine at idle for 15 seconds or more. Read the DTC. Result: Display (DTC Output) Proceed to P2120, P2122, P2123, P2125, P2127, P2128 and/or P2138 are output again A No DTC output B B SYSTEM OK A REPLACE ECM (See page 10-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 454 05-265 DIAGNOSTICS DTC P2121 - SFI SYSTEM (2AZ-FE) 05ITH-02 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”D” CIRCUIT RANGE/PERFORMANCE HINT: This is repair procedure for the ”accelerator pedal position sensor”. CIRCUIT DESCRIPTION Refer to DTC P2120 on page 05-257 . DTC No. P2121 DTC Detection Condition Trouble Area Conditions (a) continue for 0.5 seconds: (a) Difference between VPA and VPA2 exceeds the threshold (1 trip detection logic)
Open or short in Accelerator pedal position sensor circuit
Accelerator pedal position sensor
ECM MONITOR DESCRIPTION The accelerator pedal position sensor is mounted on the accelerator pedal bracket. The accelerator pedal position sensor has two sensor elements/signal outputs: VPA and VPA2. VPA is used to detect the actual accelerator pedal angle (used for engine control) and VPA2 is used to detect malfunctions in VPA. When the difference between the voltage outputs of VPA and VPA2 deviate from the standard, the ECM concludes the accelerator pedal position sensor has a malfunction. The ECM turns on the MIL and a DTC is set. FAIL-SAFE The accelerator pedal position sensor has 2 (main and sub) sensor circuits. If a malfunction occurs in either of the sensor circuits, the ECM detects the abnormal signal voltage difference between the 2 sensor circuits and switches to fail-safe mode. In fail-safe mode, the remaining circuit is used to calculate the accelerator pedal opening to allow the vehicle to continue driving. If both circuits malfunction, the ECM regards the opening angle of the accelerator pedal to be fully closed. In this case, the throttle valve will remain closed as if the engine is idling. If a ”pass” condition is detected and then the ignition switch is turned OFF, the fail-safe operation will stop and the system will return to normal condition. MONITOR STRATEGY Related DTCs P2121: TP sensor malfunction Required sensors / components (Main) Accelerator position sensor Required sensors / components (Related) - Frequency of operation Continuous Duration 0.5 sec. MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present See page 05-16 Either of the following conditions is met: Condition 1 or 2 1. Electronic throttle actuator power ON 2. Ignition switch ON TYPICAL MALFUNCTION THRESHOLDS Learned voltage value of (VTA1 - VTA2) Less than 0.4 V, or more than 1.2 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 455 05-266 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) WIRING DIAGRAM Refer to DTC P2120 on page 05-257 . INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. Hand-held tester: 1 READ VALUE OF HAND-HELD TESTER (ACCEL POS #1, ACCEL POS #2) (a) (b) (c) Depressed Released Connect the hand-held tester to the DLC3. Turn the ignition switch ON. On the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ETCS / ACCEL POS #1 and ACCEL POS #2” and read its value displayed on the hand-held tester. Standard: Accelerator Pedal ACCEL POS #1 ACCEL POS #2 Released 0.5 to 1.1 V 1.2 to 2.0 V Depressed 2.6 to 4.5 V 3.4 to 5.3 V FI7052 OK REPLACE ECM (See page 10-9 ) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 456 05-267 DIAGNOSTICS 2 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS (ACCELERATOR PEDAL POSITION SENSOR - ECM) (a) (b) (c) Wire Harness Side A27 Accelerator Pedal Position Sensor Disconnect the A27 sensor connector. Disconnect the E5 ECM connector. Measure the resistance of the wire harness side connectors. Standard: Tester Connection VCP2 EPA2 VPA2 VCPA EPA VPA VCP2 VPA EPA VCPA VPA2 EPA2 VCP2 VPA E5 VCPA ECM (A27-6) (A27-5) (A27-4) (A27-3) (A27-2) (A27-1) - Specified Condition VPA (E5-22) EPA (E5-28) VCPA (E5-26) VPA2 (E5-23) EPA2 (E5-29) VCP2 (E5-27) Below 1 Ω VPA (A27-6) or VPA (E5-22) - Body ground EPA (A27-5) or EPA (E5-28) - Body ground VCPA (A27-4) or VCPA (E5-26) - Body ground VPA2 (A27-3) or VPA2 (E5-23) - Body ground EPA2 (A27-2) or EPA2 (E5-29) - Body ground VCP2 (A27-1) or VCP2 (E5-27) - Body ground VPA2 EPA2 10 kΩ or higher EPA B53781 A67445 A92629 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE ACCELERATOR PEDAL ROD ASSY (See page 10-1 1) OBD II scan tool (excluding hand-held tester): 1 INSPECT ECM (VPA AND VPA2 VOLTAGE) VPA2 (+) VPA (+) (a) (b) Turn the ignition switch ON. Measure the voltage between the specified terminals of the E5 ECM connector. Standard: Tester Connection Tester Connection Accelerator Pedal Position VPA (E5-22) - EPA (E5-28) VPA2 (E5-23) - EPA2 (E5-29) Released 0.5 to 1.1 V 1.2 to 2.0 V Depressed 2.6 to 4.5 V 3.4 to 5.3 V EPA2 (-) E5 EPA (-) ECM A53765 OK REPLACE ECM (See page 10-9 ) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 457 05-268 DIAGNOSTICS 2 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS (ACCELERATOR PEDAL POSITION SENSOR - ECM) (a) (b) (c) Wire Harness Side A27 Accelerator Pedal Position Sensor Disconnect the A27 sensor connector. Disconnect the E5 ECM connector. Measure the resistance of the wire harness side connectors. Standard: Tester Connection VCP2 EPA2 VPA2 VCPA EPA VPA VCP2 VPA EPA VCPA VPA2 EPA2 VCP2 VPA E5 VCPA ECM VPA2 EPA2 (A27-6) (A27-5) (A27-4) (A17-3) (A27-2) (A27-1) - Specified Condition VPA (E5-22) EPA (E5-28) VCPA (E5-26) VPA2 (E5-23) EPA2 (E5-29) VCP2 (E5-27) Below 1 Ω VPA (A27-6) or VPA (E5-22) - Body ground EPA (A27-5) or EPA (E5-28) - Body ground VCPA (A27-4) or VCPA (E5-26) - Body ground VPA2 (A27-3) or VPA2 (E5-23) - Body ground EPA2 (A27-2) or EPA2 (E5-29) - Body ground VCP2 (A27-1) or VCP2 (E5-27) - Body ground 10 kΩ or higher EPA B53781 A67445 A92629 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE ACCELERATOR PEDAL ROD ASSY (See page 10-1 1) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 458 05-269 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05EVX-06 DTC P2195 OXYGEN (A/F) SENSOR SIGNAL STUCK LEAN (BANK 1 SENSOR 1) DTC P2196 OXYGEN (A/F) SENSOR SIGNAL STUCK RICH (BANK 1 SENSOR 1) HINT: Although the title (DTC description) says ”oxygen sensor”, this DTC is related to the ”A/F sensor”. CIRCUIT DESCRIPTION The Air-Fuel ratio (A/F) sensor provides output voltage* approximately equal to the existing air-fuel ratio. The A/F sensor output voltage is used to provide feedback for the ECM to control the air-fuel ratio. With the A/F sensor output, the ECM can determine deviation from the stoichiometric air-fuel ratio and control proper injection time. If the A/F sensor is malfunctioning, the ECM is unable to accurately control air-fuel ratio. The A/F sensor is equipped with a heater which heats the zirconia element. The heater is also controlled by the ECM. When the intake air volume is low (the temperature of the exhaust gas is low), current flows to the heater which heats the sensor to facilitate detection of accurate oxygen concentration. The A/F sensor is a planar type. Compared to a conventional type, the sensor and heater portions are narrower. Because the heat of the heater is conducted through the alumina to zirconia (of the sensor portion), sensor activation is accelerated. To obtain a high purification rate of the CO, HC and NOx components of the exhaust gas, a three-way catalytic converter is used. The converter is most efficient when the air-fuel ratio is maintained near the stoichiometric air-fuel ratio. HINT: *: The voltage value changes on the inside of the ECM only. Alumina Heater Platinum Electrode Element Exhaust Gas A ECM Monitored A/F Sensor Voltage Solid Electrolyte (Zirconia Element) Cover A Atomosphere Air-Fuel Ratio A - A Section A73819 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 459 05-270 DIAGNOSTICS DTC No. - SFI SYSTEM (2AZ-FE) DTC Detection Condition Trouble Area P2195 Conditions (a) and (b) continue for 2 seconds or more: (a) A/F sensor voltage is more than 3.8 V (b) Rear oxygen sensor voltage is 0.15 V or more (2 trip detection logic)
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 Conditions (a) and (b) continue for 2 seconds or more: (a) A/F sensor voltage is less than 2.8 V (b) Rear oxygen sensor voltage is less than 0.85 V (2 trip detection logic)
Same as DTC No. P2195 HINT:





DTCs P2195 and P2196 indicate a malfunction related to bank 1 of the A/F sensor circuit. Sensor 1 is the sensor closest to the engine assembly. After confirming DTC P2195 and P2196, use the hand−held tester or the OBD II scan tool to confirm A/F sensor output voltage (AFS B1S1) from the ALL menu (to reach the ALL menu: DIAGNOSIS / EN− HANCED OBD II / DATA LIST / ALL). The A/F sensor’s output voltage and the short−term fuel trim value can be read using the OBD II scan tool or the hand−held tester. The ECM controls the voltage of the A1A+ and A1A− terminals of the ECM to a fixed voltage. Therefore, it is impossible to confirm the A/F sensor output voltage without the OBD II scan tool or the handheld tester. The OBD II scan tool (excluding hand−held tester) displays one fifth of the A/F sensor output voltage which is displayed on the hand−held tester. MONITOR DESCRIPTION Under the air-fuel ratio feedback control, if the voltage output of the A/F sensor indicates RICH or LEAN for more than a certain period of time, the ECM concludes that there is a fault in the A/F sensor system. The ECM will turn on the MIL and will set a DTC. Example: If the A/F sensor voltage output is less than 2.8 V (very RICH) for 10 seconds even though voltage output of the heated oxygen sensor output voltage is less than 0.85 V, the ECM sets DTC P2196 or DTC P2198. If the heated oxygen sensor output voltage is 0.15 V or more but the A/F sensor voltage output is more than 3.8 V (very LEAN) for 10 seconds, DTC P2195 is set. MONITOR STRATEGY Related DTCs P2195: A/F Sensor Signal (Bank 1) Stuck Lean P2196: A/F Sensor Signal (Bank 1) Stuck Rich Required sensors / components (Main) A/F sensor Required sensors / components (Related) Rear HO2S Frequency of operation Continuous Duration 10 sec. MIL operation 2 driving cycles Sequence of operation None 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 460 05-271 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-16 Time after engine start 30 sec. or more A/F sensor status Activated Fuel system status Closed Loop Engine condition Running TYPICAL MALFUNCTION THRESHOLDS P2195: Both of the following conditions are met: - A/F sensor voltage More than 3.8 V Rear HO2S voltage 0.15 V or more P2196: Both of the following conditions are met: - A/F sensor voltage Less than 2.8 V Rear HO2S voltage Less than 0.85 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 461 05-272 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) WIRING DIAGRAM ECM A6 A/F Sensor 3 EB1 B-W B-R 2 +B 4 AF- B-W HT 1 Shielded BR AF+ 3 2 2 EFI NO. 2 1 Engine Room R/B No. 2 2 13 IK3 HA1A 23 E8 A1A+ 31 Y P-L 5 E8 E8 8 E5 B A1A- MREL Y 3 2D 5 2B 3 1 5 2 EFI Relay Engine Room J/B EFI NO. 1 1 4 2I 2F A J7 J/C A BR W 3 1 E9 E1 A W-B F7 FL Block Assy A 1 BR J2 J/C W FL Main Battery EH EE A90305 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 462 05-273 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) CONFIRMATION DRIVING PATTERN Vehicle Speed (d) 38 to 75 mph (60 to 120 km/h) Idling Ignition Switch OFF (c) 2 minutes (a), (b) 3 to 5 minutes Time A79199 (a) (b) (c) (d) Connect the hand-held tester to the DLC3. Switch the hand-held tester from normal mode to check mode (see page 05-40 ). Start the engine and warm it up with all the accessory switched OFF. Drive the vehicle at 38 to 75 mph (60 to 120 km/h) and engine speed at 1,400 to 3,200 rpm for 3 to 5 minutes. HINT: If a malfunction exists, the MIL will be illuminated during step (d). NOTICE: If the conditions in this test are not strictly followed, detection of a malfunction will not occur. If you do not have a hand-held tester, turn the ignition switch OFF after performing steps (c) and (d), then perform steps (c) and (d) again. INSPECTION PROCEDURE HINT: Hand-held tester only: It is possible the malfunctioning area can be found using the ACTIVE TEST A/F CONTROL operation. The A/F CONTROL operation can determine if the A/F sensor, heated oxygen sensor or other potential trouble areas are malfunctioning or not. (a) Perform the ACTIVE TEST A/F CONTROL operation. HINT: The A/F CONTROL operation lowers the injection volume 12.5 % or increases the injection volume 25 %. (1) Connect the hand-held tester to the DLC3 on the vehicle. (2) Turn the ignition switch ON. (3) Warm up the engine by running the engine at 2,500 rpm for approximately 90 seconds. (4) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (5) Perform the A/F CONTROL operation with the engine idle (press the right or left button). Result: A/F sensor reacts in accordance with increase and decrease of injection volume: +25 % → RICH output: Less than 3.0 V -12.5 % → LEAN output: More than 3.35 V Heated oxygen sensor reacts in accordance with increase and decrease of injection volume: +25 % → RICH output: More than 0.55 V -12.5 % → LEAN output: Less than 0.4 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 463 05-274 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) NOTICE: The A/F sensor output has a few seconds of delay and the heated oxygen sensor output has about 20 seconds of delay. Output voltage of A/F sensor (sensor 1) Output voltage of heated oxygen sensor (sensor 2) Injection volume Injection volume +25 % +25 % -12.5 % -12.5 % Case 1 Output voltage More than 3.35 V Less than 3.0 V OK More than 0.55 V Injection volume +25 % -12.5 % -12.5 % Case 2 Output voltage A/F sensor (A/F sensor, heater, A/F sensor circuit) Output voltage NG Injection volume More than 0.55 V OK Less than 0.4V Injection volume +25 % +25 % -12.5 % -12.5 % Case 3 Output voltage Output voltage More than 3.35 V OK Injection volume Almost No reaction NG Injection volume +25 % +25 % -12.5 % -12.5 % Case 4 Output voltage Almost No reaction OK Less than 0.4V +25 % Less than 3.0V  Output voltage Injection volume Almost No reaction Main suspect trouble area Output voltage NG Almost No reaction NG Heated oxygen sensor (heated oxygen sensor, heater, heated oxygen sensor circuit) Extremely rich or lean actual air-fuel ratio (Injector, fuel pressure, gas leakage in exhaust system, etc.) The following A/F CONTROL procedure enables a technician to check and graph the voltage outputs of both the A/F sensor and the heated oxygen sensor. For displaying the graph, enter ”ACTIVE TEST / A/F CONTROL / USER DATA”, select ”AFS B1S1 and O2S B1S2” by pressing ”YES” and push ”ENTER”. Then press ”F4”. HINT:
If DTC P2195 or P2196 is displayed, check bank 1 sensor 1 circuit.
A low A/F sensor voltage could be caused by a RICH air-fuel mixture. Check for conditions that would cause the engine to run with a RICH air-fuel mixture.
A high A/F sensor voltage could be caused by a LEAN air-fuel mixture. Check for conditions that would cause the engine to run with a LEAN air-fuel mixture.
Read freeze frame data using the hand-held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 464 05-275 DIAGNOSTICS 1 (a) - SFI SYSTEM (2AZ-FE) CHECK OTHER DTC OUTPUT (IN ADDITION TO A/F SENSOR DTC) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display Proceed to A/F sensor circuit DTC are output A A/F sensor circuit DTC and other codes are output B HINT: If any other codes besides A/F sensor DTC are output, perform the troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART (See page 05-48 ) A 2 (a) (b) (c) (d) (e) (f) (g) READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (OUTPUT VOLTAGE OF A/F SENSOR) Connect the hand-held tester or the OBD II scan tool to the DLC3. Warm up the A/F sensor (bank 1 sensor 1) by running the engine at 2,500 rpm for approximately 90 seconds. Read A/F sensor voltage output on the hand-held tester or the OBD II scan tool. Hand-held tester only: On the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / SNAPSHOT / MANUAL SNAPSHOT / USER DATA. Read the values. Select ”AFS B1S1 / ENGINE SPD” and press YES. Monitor the A/F sensor voltage carefully. Check the A/F sensor voltage output under the following conditions: (1) Allow the engine to idle for 30 seconds. (2) Run the engine at approximately 2,500 rpm. Do not suddenly change the rpm. (3) Raise the engine to 4,000 rpm and quickly release the accelerator pedal so that the throttle is fully closed. Standard: Condition (1) and (2) Voltage change of 3.3 V (0.66 V)* (between approximately 3.1 to 3.5 V) as shown in the illustration. Condition (3) A/F sensor voltage increases to 3.8 V (0.76 V)* or more during engine deceleration when fuel is cut as shown in the illustration. *: Voltage when using the OBD II scan tool. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 465 05-276 DIAGNOSTICS Normal Condition - SFI SYSTEM (2AZ-FE) Malfunction Condition (3) Approximately 4,000 rpm (3) Approximately 4,000 rpm (2) Approximately 2,500 rpm (2) Approximately 2,500 rpm (1) Idle A/F Sensor Voltage (1) Idle (1) Idle (1) Idle Engine RPM Engine RPM ”Condition (3)” 3.8 V or More A/F Sensor Voltage Fuel Cut Fuel Cut ”Condition (1), (2)” Change of approximately 3.3 V When A/F sensor circuit is malfunctioning, voltage output does not change A72304 HINT:
Whenever the A/F sensor output voltage remains at approximately 3.3 V (0.660 V)* (see ”Malfunction Condition” graphic) under any condition as well as the above conditions, the A/F sensor may have an open circuit. This will happen also when the A/F sensor heater has an open circuit.
Whenever the A/F sensor output voltage remains at a certain value of approximately 3.8 V (0.76 V)* or more, or 2.8 V (0.56 V)* or less (see ”Malfunction Condition” graphic) under any condition as well as the above conditions, the A/F sensor may have a short circuit.
The ECM will stop fuel injection (fuel is cut) during engine deceleration. This will cause a LEAN condition and should result in a momentary increase in the A/F sensor output voltage.
The ECM must establish a closed throttle position learned value to perform fuel cut. If the battery terminal has been disconnected, the vehicle must be driven over 10 mph (16 km/h) to allow the ECM to learn the closed throttle position.
When the vehicle is driven: The output voltage of the A/F sensor may be below 2.8 V (0.76 V)* during fuel enrichment. For the vehicle, this translates to a sudden increase in speed with the accelerator pedal fully depressed when trying to overtake another vehicle. The A/F sensor is functioning normally.
The A/F sensor is a current output element, and therefore the current is converted into voltage inside the ECM. If measuring voltage at connectors of A/F sensor or ECM, you will observe a constant voltage. *: Voltage when using the OBD II scan tool. OK Go to step 13 NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 466 05-277 DIAGNOSTICS 3 - SFI SYSTEM (2AZ-FE) INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) (b) A6 A/F sensor Disconnect the A6 A/F sensor connector. Measure the resistance of the A/F sensor terminals. Standard: Tester Connection Condition Specified Condition 1 (HT) - 2 (+B) 20C (68F) 1.8 to 3.4 Ω 1 (HT) - 4 (AF-) - 10 kΩ or higher AF+ AF- A52607 NG REPLACE AIR FUEL RATIO SENSOR OK 4 INSPECT RELAY (EFI) 1 3 1 5 2 2 5 (a) (b) Remove the EFI relay from the engine room J/B. Measure the resistance of the EFI relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 3 B60778 NG REPLACE RELAY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 467 05-278 DIAGNOSTICS 5 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS (A/F SENSOR - ECM) (a) Wire Harness Side A6 A/F Sensor HT AF+ +B 1 3 2 4 AF- Check the wire harness between the ECM and A/F sensor. (1) Disconnect the A6 A/F sensor connector. (2) Disconnect the E8 ECM connector. (3) Measure the resistance of the wire harness side connectors. Standard: E8 ECM Tester Connection Specified Condition A6-3 (AF+) - E8-23 (A1A+) A6-4 (AF-) - E8-31 (A1A-) A6-1 (HT) - E8-5 (HA1A) Below 1 Ω A6-3 (AF+) or A1A+ (E8-23) - Body ground A6-4 (AF-) or A1A- (E8-31) - Body ground A6-1 (HT) or HA1A (E8-5) - Body ground 10 kΩ or higher A1A+ A1A- HA1A A76787 A81695 A86849 Reference A/F Sensor EFI Relay From Battery EFI NO. 1 Fuse ECM +B Heater HT EFI NO. 2 Fuse AF- Sensor AF+ HA1A A1A+ Duty Control A1AMREL A90346 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 468 05-279 DIAGNOSTICS 6 (a) - SFI SYSTEM (2AZ-FE) CHECK AIR INDUCTION SYSTEM Check for vacuum leaks in the air induction system. OK: No leak in the air induction system. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK 7 (a) CHECK FUEL PRESSURE (See page 11-4 ) Check fuel pressure (high or low fuel pressure). Standard: Item Specified Condition Fuel pressure 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 55 psi) NG REPAIR OR REPLACE FUEL SYSTEM OK 8 (a) INSPECT FUEL INJECTOR ASSY (See page 11-7 ) Check injector injection (high or low fuel injection quantity or poor injection pattern). Standard: Injection Volume Difference Between Each Injector 76 to 91 cm3 (4.6 to 5.5 cu in.)/15 seconds 15 cm3 (0.9 cu in.) or less NG REPLACE FUEL INJECTOR ASSY (See page 11-10 ) OK 9 REPLACE AIR FUEL RATIO SENSOR GO 10 PERFORM CONFIRMATION DRIVING PATTERN HINT: Clear all DTCs prior to performing the confirmation driving pattern. GO 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 469 05-280 DIAGNOSTICS 11 (a) - SFI SYSTEM (2AZ-FE) READ OUTPUT DTC Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display Proceed to A/F sensor circuit DTC are not output A A/F sensor circuit DTC are output B B REPLACE ECM (See page 10-9 ) AND PERFORM CONFIRMATION DRIVING PATTERN A 12 CONFIRM IF VEHICLE HAS RUN OUT OF FUEL IN PAST OK: Vehicle has run out of fuel in past. NO CHECK FOR INTERMITTENT PROBLEMS (See page 05-9 ) YES DTC IS CAUSED BY RUNNING OUT OF FUEL 13 PERFORM CONFIRMATION DRIVING PATTERN HINT: Clear all DTCs prior to performing the confirmation driving pattern. GO 14 (a) GO TO RELEVANT DTC CHART (A/F SENSOR DTC OUTPUT AGAIN) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display Proceed to A/F sensor circuit DTC are output A A/F sensor circuit DTC are not output B B Go to step 18 A 15 REPLACE AIR FUEL RATIO SENSOR GO 16 PERFORM CONFIRMATION DRIVING PATTERN HINT: Clear all DTCs prior to performing the confirmation driving pattern. GO 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 470 05-281 DIAGNOSTICS 17 (a) - SFI SYSTEM (2AZ-FE) READ OUTPUT DTC (A/F SENSOR DTC OUTPUT AGAIN) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display Proceed to A/F sensor circuit DTC are not output A A/F sensor circuit DTC are output B B REPLACE ECM (See page 10-9 ) AND PERFORM CONFIRMATION DRIVING PATTERN A 18 CONFIRM IF VEHICLE HAS RUN OUT OF FUEL IN PAST OK: Vehicle has run out of fuel in past. NO CHECK FOR INTERMITTENT PROBLEMS (See page 05-9 ) YES DTC IS CAUSED BY RUNNING OUT OF FUEL 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 471 05-282 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05EVY-06 DTC P2238 OXYGEN SENSOR PUMPING CURRENT CIRCUIT LOW (FOR A/F SENSOR)(BANK 1 SENSOR 1) DTC P2239 OXYGEN SENSOR PUMPING CURRENT CIRCUIT HIGH (FOR A/F SENSOR)(BANK 1 SENSOR 1) DTC P2252 OXYGEN SENSOR REFERENCE GROUND CIRCUIT LOW (FOR A/F SENSOR)(BANK 1 SENSOR 1) DTC P2253 OXYGEN SENSOR REFERENCE GROUND CIRCUIT HIGH (FOR A/F SENSOR)(BANK 1 SENSOR 1) HINT: Although the title (DTC description) says ”oxygen sensor”, this DTC is related to the ”A/F sensor”. CIRCUIT DESCRIPTION Refer to DTC P2195 on page 05-269 . DTC No. DTC Detection Condition Trouble Area P2238 A/F sensor (bank 1 sensor 1) circuit low A/F sensor admittance is less than 0.022 1/Ω (1 trip detection logic) HINT: Main trouble area
Open in A/F sensor circuit P2238
Condition (a) continues for 5.0 seconds or more : (a) AF+ is 0.5 V or less
Condition (a) continues for 5.0 seconds or more : (a) (AF+) - (AF-) is 0.1 V or less (1 trip detection logic)
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 A/F sensor (bank 1 sensor 1) circuit high (1 trip detection logic) HINT: Main trouble area
Short in A/F sensor circuit P2239
Condition (a) continues for 5.0 seconds or more : (a) AF+ is more than 4.5 V
Condition (a) continues for 5.0 seconds or more : (a) (AF+) - (AF-) is more than 0.8 V (1 trip detection logic)
Same as DTC No. P2238 P2252 Condition (a) continues for 5.0 seconds or more : (a) AF- is 0.5 V or less (1 trip detection logic)
Same as DTC No. P2238 P2253 Condition (a) continues for 5.0 seconds or more : (a) AF- is more than 4.5 V (1 trip detection logic)
Same as DTC No. P2238 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 472 05-283 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) MONITOR DESCRIPTION The air-fuel ratio (A/F) sensor varies its voltage output in proportion to the air-fuel ratio. If impedance (alternating current resistance) or voltage output of the sensor deviates greatly from the standard, the ECM determines that an open or short is in the A/F sensor circuit. MONITOR STRATEGY Related DTCs P2238: A/F sensor (Bank1) open circuit between AF+ and AFP2238: A/F sensor (Bank1) short circuit between AF+ and AFP2238: A/F sensor (Bank 1) short circuit between AF+ and GND P2239: A/F sensor (Bank 1) short circuit between AF+ and +B P2252: A/F sensor (Bank 1) short circuit between AF- and GND P2253: A/F sensor (Bank 1) short circuit between AF- and +B Required sensors/ components (Main) A/F sensor Required sensors/ components (Related) ECT sensor, CKP sensor Frequency of operation Once per driving cycle Duration 10 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present See page 05-16 P2238 (open circuit between AF+ and AF-): Duration while all of the following conditions are met: 20 seconds or more AF+ terminal voltage 0.5 to 4.5 V AF- terminal voltage 0.5 to 4.5 V Difference between AF+ terminal and AF- terminal voltages 0.1 to 0.8 V ECT 20C (68F) or more Engine condition Running Time after engine start 20 seconds or more Fuel-cut OFF A/F sensor heater duty cycle 0.5% or more Time after A/F sensor heating 20 seconds or more Battery voltage 10.5 V or more Ignition switch ON Others: Battery voltage 10.5 V or more Ignition switch ON 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 473 05-284 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) TYPICAL MALFUNCTION THRESHOLDS P2238 (Open circuit between AF+ and AF-): A/F sensor admittance Below 0.022 1/ohm P2238 (Short circuit between AF+ and GND): AF+ terminal voltage 0.5 V or less P2238 (Short circuit between AF+ and AF-): Difference between AF+ terminal and AF- terminal voltages 0.1 V or less P2239 (Short circuit between AF+ and +B): AF+ terminal voltage More than 4.5 V P2252 (Short circuit between AF- and GND): AF- terminal voltage 0.5 V or less P2253 (Short circuit between AF- and +B): AF- terminal voltage More than 4.5 V WIRING DIAGRAM Refer to DTC P2195 on page 05-269 . INSPECTION PROCEDURE HINT: Hand-held tester only: The malfunctioning area can be found by the ACTIVE TEST A/F CONTROL operation. The A/F CONTROL operation can determine if the A/F sensor, heated oxygen sensor or other suspected trouble areas are malfunctioning or not. (a) Perform the ACTIVE TEST A/F CONTROL operation. HINT: The A/F CONTROL operation lowers the injection volume by 12.5 % or increases the injection volume by 25 %. (1) Connect the hand-held tester to the DLC3 on the vehicle. (2) Turn the ignition switch ON. (3) Warm up the engine by running the engine at 2,500 rpm for approximately 90 seconds. (4) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (5) Perform the A/F CONTROL operation with the engine idling (press the right or left button). Result: A/F sensor reacts in accordance with increase and decrease of injection volume: +25 % → RICH output: Less than 3.0 V -12.5 % → LEAN output: More than 3.35 V Heated oxygen sensor reacts in accordance with increase and decrease of injection volume: +25 % → RICH output: More than 0.55 V -12.5 % → LEAN output: Less than 0.4 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 474 05-285 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) NOTICE: The A/F sensor output has a few seconds of delay and the heated oxygen sensor output has about 20 seconds of delay at maximum. Output voltage of A/F sensor (sensor 1) Output voltage of heated oxygen sensor (sensor 2) Injection volume Injection volume +25 % +25 % -12.5 % -12.5 % Case 1 Output voltage More than 3.35 V Less than 3.0 V OK More than 0.55 V Injection volume +25 % -12.5 % -12.5 % Case 2 Output voltage A/F sensor (A/F sensor, heater, A/F sensor circuit) Output voltage NG Injection volume More than 0.55 V OK Less than 0.4V Injection volume +25 % +25 % -12.5 % -12.5 % Case 3 Output voltage Output voltage More than 3.35 V OK Injection volume Almost No reaction NG Injection volume +25 % +25 % -12.5 % -12.5 % Case 4 Output voltage Almost No reaction OK Less than 0.4V +25 % Less than 3.0V  Output voltage Injection volume Almost No reaction Main suspect trouble area Output voltage NG Almost No reaction NG Heated oxygen sensor (heated oxygen sensor, heater, heated oxygen sensor circuit) Extremely rich or lean actual air-fuel ratio (Injector, fuel pressure, gas leakage in exhaust system, etc.) The following A/F CONTROL procedure enables a technician to check and graph the voltage outputs of both the A/F sensor and the heated oxygen sensor. For displaying the graph, enter ”ACTIVE TEST / A/F CONTROL / USER DATA”, select ”AFS B1S1 and O2S B1S2” by pressing ”YES” and push ”ENTER”. Then press ”F4”. HINT:
If DTC P2237, P2238, P2239, P2251, P2252 or P2253 is displayed, check the bank 1 sensor 1 circuit.
Read freeze frame data using the hand-held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 475 05-286 DIAGNOSTICS 1 - SFI SYSTEM (2AZ-FE) INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) (b) A6 A/F sensor Disconnect the A6 A/F sensor connector. Measure the resistance of the A/F sensor terminals. Standard: Tester Connection Condition Specified Condition 1 (HT) - 2 (+B) 20C (68F) 1.8 to 3.4 Ω 1 (HT) - 4 (AF-) - 10 kΩ or higher AF+ AF- A52607 NG REPLACE AIR FUEL RATIO SENSOR OK 2 INSPECT RELAY (EFI) 1 3 1 5 2 2 5 (a) (b) Remove the EFI relay from the engine room J/B. Measure the resistance of the EFI relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 3 B60778 NG REPLACE RELAY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 476 05-287 DIAGNOSTICS 3 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS (A/F SENSOR - ECM) (a) Wire Harness Side A6 A/F Sensor HT AF+ +B 1 3 2 4 AF- Check the wire harness between the ECM and A/F sensor. (1) Disconnect the A6 A/F sensor connector. (2) Disconnect the E8 ECM connector. (3) Measure the resistance of the wire harness side connectors. Standard: E8 ECM Tester Connection Specified Condition A6-3 (AF+) - E8-23 (A1A+) A6-4 (AF-) - E8-31 (A1A-) A6-1 (HT) - E8-5 (HA1A) Below 1 Ω A6-3 (AF+) or A1A+ (E8-23) - Body ground A6-4 (AF-) or A1A- (E8-31) - Body ground A6-1 (HT) or HA1A (E8-5) - Body ground 10 kΩ or higher A1A+ A1A- HA1A A76787 A81695 A86849 Reference A/F Sensor EFI Relay From Battery EFI NO. 1 Fuse ECM +B Heater HT EFI NO. 2 Fuse AF- Sensor AF+ HA1A A1A+ Duty Control A1AMREL A90346 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE ECM (See page 10-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 477 05-288 DIAGNOSTICS - SFI SYSTEM (2AZ-FE)(From August, 2004) 05PGP-01 DTC P2401 EVAPORATIVE EMISSION SYSTEM LEAK DETECTION PUMP CONTROL CIRCUIT LOW DTC P2402 EVAPORATIVE EMISSION SYSTEM LEAK DETECTION PUMP CONTROL CIRCUIT HIGH CIRCUIT DESCRIPTION Refer to EVAP Inspection Procedure (see page 05-317). DTCs P2401 P2402 Monitoring Item Vacuum pump stuck OFF (built-in pump module) Vacuum pump stuck ON (built-in pump module) Detection Condition Trouble Area To determine leak criterion (Reference pressure), vacuum pump creates negative pressure in canister pump module through 0.02 inch orifice and pressure is measured.
Pump module If one of following conditions is met, ECM
Connector / wire harness sets pump module related DTCs: P043E, P043E (Pump module - ECM) P043F, P2401, P2402 and P2419:
ECM
Reference pressure is -1 kPa or higher
Reference pressure is -4.85 kPa or lower
Reference pressure is not saturated within 60 seconds Detection Timing Detection Period Ignition OFF 2 trips WIRING DIAGRAM Refer to EVAP Inspection Procedure (see page 05-317). INSPECTION PROCEDURE Refer to EVAP Inspection Procedure (see page 05-317). Author
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: 478 05-289 DIAGNOSTICS - SFI SYSTEM (2AZ-FE)(From August, 2004) MONITOR DESCRIPTION 5 hours* after the ignition switch is turned OFF, the electric vacuum pump creates negative pressure (vacuum) in the EVAP (Evaporative Emission) system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35C (95F) 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later. If it is still not below 35C (95F) 7 hours after the ignition switch is turned off, the monitor check starts 2.5 hours later. Sequence - Operations Descriptions Duration ECM activation Activated by soak timer, 5 hours (7 or 9.5 hours) after ignition switch turned to OFF. A Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If EVAP pressure is not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM cancels EVAP system monitor. - 10 seconds B First 0.02 inch leak pressure measurement In order to determine 0.02 inch leak pressure standard, vacuum pump creates negative pressure (vacuum) through 0.02 inch orifice and them ECM checks if vacuum pump and vent valve operate normally. 60 seconds C EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) created in EVAP system, and EVAP system pressure then measured. Write down the measured value as it will be used in the leak check. If EVAP pressure does not stabilize within 15 minutes, ECM cancels EVAP system monitor. 15 minutes* D Purge VSV monitor Purge VSV opened and then EVAP system pressure measured by ECM. Large increase indicates normal. 10 seconds E Second 0.02 inch leak pressure measurement Leak check is performed after second 0.02 inch leak pressure standard is measured. If stabilized system pressure higher than second 0.02 inch leak pressure standard, ECM determines that EVAP system leaking. 60 seconds F Final check Atmospheric pressure measured and then monitoring result recorded by ECM. - * If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize. Operation A: Atmospheric Pressure Measurement Operation B, E: 0.02 Inch Leak Pressure Measurement Canister Fuel Tank OFF Vent Valve: OFF (vent) OFF (vent) Purge VSV: OFF 0.02 Inch Orifice Pressure Sensor Vacuum Pump: OFF Air Filter ON Pump Module Operation D: Purge VSV monitor Operation C: EVAP System Pressure Measurement OFF ON ON (closed) ON (closed) Atmospheric Pressure ON Negative Pressure ON A96746 Author
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: 479 05-290 DIAGNOSTICS - SFI SYSTEM (2AZ-FE)(From August, 2004) In sequence B and E, to determine the leak criterion, the vacuum pump creates negative pressure in the canister pump module through the 0.02 inch orifice. If the pressure is out of specified range or is not saturated, the ECM illuminates the MIL and sets DTCs P043E, P043F, P2401, P2402 and P2419 (2-trip detection logic). EVAP Pressure during EVAP Monitor Purge VSV OFF OFF ON: Open OFF: Closed Vent Valve OFF OFF ON: Closed OFF: Vent ON ON Vacuum Pump Malfunction Malfunction EVAP Pressure -1 kPa Specified OK OK Malfunction Malfunction Range -4.85 kPa Sequence Time A B 10 sec 60 sec C D E Within 15 minutes 10 sec 60 sec A85217 Author
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: 480 05-291 DIAGNOSTICS - SFI SYSTEM (2AZ-FE)(From August, 2004) OBD II MONITOR SPECIFICATIONS Monitor Strategy Required Sensors/Components Purge VSV and pump module Frequency of Operation Once per driving cycle Duration Within 15 minutes (varies with amount of fuel in tank) MIL Operation 2 driving cycles Sequence of Operation None Typical Enabling Conditions The monitor will run whenever these DTCs are not present See page 05-16 EVAP key-off monitor runs when all of the following conditions are met: - Atomspheric pressure 525 to 825 mmHg (70 to 110 kPa) Battery voltage 10.5 V or more Vehicle speed Below 4 km/h (2.5 mph) Ignition switch OFF Engine condition Not running Time after engine is stopped 5 hours FTP sensor malfunction (P0450, P0452, P0453) Not detected Purge VSV Not operated by scan tool Vent valve Not operated by scan tool Leak detection pump Not operated by scan tool Both of the following conditions are met before IG switch OFF: Condition 1 and 2 1. Duration that vehicle is driven 5 min. or more 2. Purge flow Executed ECT 4.4 to 35C (40 to 95F) IAT 4.4 to 35C (40 to 95F) Example of re-start time First time 7 hours Second time 9 hours and 30 min. Key-of f monitor sequence: 1 to 8 1. Atmospheric pressure Next sequence is run if following condition met - Atmospheric pressure change for 10 sec. Within 2.25 mmHg (0.3 kPa) for 1 sec. 2. First reference pressure Next sequence is run if all of following conditions met Condition 1, 2 and 3 1. FTP when 4 sec. after reference pressure measurement -7.5 mmHg (-1 kPa) or less 2. Reference pressure -36.47 to -7.93 mmHg (-4.85 to -1.057 kPa) 3. Reference pressure Saturated 3. Vent valve stuck closed check Next sequence is run if following condition met - FTP change for 10 sec. after vent valve ON (closed) 2.25 mmHg (0.3 kPa) or more 4. Vacuum introduction and leak Next sequence is run if both of following conditions met Condition 1 and 2 1. Vacuum introduction time Within 15 min. 2. FTP FTP was saturated 5. Purge VSV stuck closed check Next sequence is run if following condition met - FTP change for 10 sec. after purge VSV ON (open) 2.25 mmHg (0.3 kPa) or more Author
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: 481 05-292 DIAGNOSTICS - SFI SYSTEM (2AZ-FE)(From August, 2004) 6. Second reference pressure measurement Next sequence is run if all of following conditions met Condition 1, 2, 3 and 4 1. FTP when 4 sec. after reference pressure measurement -7.5 mmHg (-1 kPa) or less 2. Reference pressure -36.47 to -7.93 mmHg (-4.85 to -1.057 kPa) 3. Reference pressure Saturated 4. Reference pressure difference between first and second Less than 5.25 mmHg (0.7 kPa) 7. Leak check Next sequence is run if following condition met - FTP when vacuum introduction was complete Lower than second reference pressure 8. Atmospheric pressure Monitor is complete if following - Atmospheric pressure difference between sequence 1 and 8 Within 2.25 mmHg (0.3 kPa) Typical Malfunction Thresholds One of the following conditions is met: Condition 1, 2, 3, 4 or 5 1. FTP when 4 seconds after reference pressure measurement began More than -7.5 mmHg (-1 kPa) 2. Reference pressure Less than -36.4 mmHg (-4.85 kPa) 3. Reference pressure -7.9 mmHg (-1.057 kPa) or more 4. Reference pressure Not saturated 5. Reference pressure difference between first and second 5.2 mmHg (0.7 kPa) or more MONITOR RESULT (MODE 06) Refer to page 05-317 for detailed information on Monitor Result. Author
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: 482 05-293 DIAGNOSTICS - SFI SYSTEM (2AZ-FE)(From August, 2004) -MEMO- Author
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: 483 05-294 DIAGNOSTICS - SFI SYSTEM (2AZ-FE)(From August, 2004) 05IRD-03 DTC P2419 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE CONTROL CIRCUIT LOW DTC P2420 EVAPORATIVE EMISSION SYSTEM SWITCHING VALVE CONTROL CIRCUIT HIGH CIRCUIT DESCRIPTION Refer to the EVAP Inspection Procedure (see page 05-317). DTCs P2419 P2420 Monitoring Items Vent valve stuck ON / Closed (built-in pump module) Vent valve stuck OFF / Vent (built-in pump module) Detection Conditions Trouble Areas To determine leak criterion (Reference pressure), vacuum pump creates negative pressure in canister pump module through 0.02 inch orifice and pressure is measured. If one of following conditions is met, ECM sets pump module related DTCs: P043E, P043F, P2401, P2402 and P2419:
Pump module
Reference pressure is -1 kPa or higher
Connector/Wire harness
Reference pressure is -4.85 kPa or lower (Pump module - ECM)
Reference pressure is not saturated within
ECM 60 seconds Detection Timings Detection Logic Ignition OFF 2 trips To determine leak criterion, vacuum pump creates negative pressure in canister pump module through 0.02 inch orifice. After that, ECM turns vent valve ON (Vent) and measures pressure. If it does not change, ECM sets DTC P2420. WIRING DIAGRAM Refer to the EVAP Inspection Procedure (see page 05-317). INSPECTION PROCEDURE Refer to the EVAP Inspection Procedure (see page 05-317). Author
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: 484 05-295 DIAGNOSTICS - SFI SYSTEM (2AZ-FE)(From August, 2004) MONITOR DESCRIPTION 5 hours* after the ignition switch is turned OFF, the electric vacuum pump creates negative pressure (vacuum) in the EVAP (Evaporative Emission) system. The ECM monitors for leaks and actuator malfunctions based on the EVAP pressure. HINT: *: If the engine coolant temperature is not below 35C (95F) 5 hours after the ignition switch is turned off, the monitor check starts 2 hours later. If it is still not below 35C (95F) 7 hours after the ignition switch is turned off, the monitor check starts 2.5 hours later. Sequence - Operations Descriptions Duration ECM activation Activated by soak timer, 5 hours (7 or 9.5 hours) after ignition switch turned to OFF. A Atmospheric pressure measurement Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to register atmospheric pressure. If EVAP pressure is not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM cancels EVAP system monitor. - 10 seconds B First 0.02 inch leak pressure measurement In order to determine 0.02 inch leak pressure standard, vacuum pump creates negative pressure (vacuum) through 0.02 inch orifice and them ECM checks if vacuum pump and vent valve operate normally. 60 seconds C EVAP system pressure measurement Vent valve turned ON (closed) to shut EVAP system. Negative pressure (vacuum) created in EVAP system, and EVAP system pressure then measured. Write down the measured value as it will be used in the leak check. If EVAP pressure does not stabilize within 15 minutes, ECM cancels EVAP system monitor. 15 minutes* D Purge VSV monitor Purge VSV opened and then EVAP system pressure measured by ECM. Large increase indicates normal. 10 seconds E Second 0.02 inch leak pressure measurement Leak check is performed after second 0.02 inch leak pressure standard is measured. If stabilized system pressure higher than second 0.02 inch leak pressure standard, ECM determines that EVAP system leaking. 60 seconds F Final check Atmospheric pressure measured and then monitoring result recorded by ECM. - * If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize. Operation A: Atmospheric Pressure Measurement Operation B, E: 0.02 Inch Leak Pressure Measurement Canister Fuel Tank OFF Vent Valve: OFF (vent) OFF (vent) Purge VSV: OFF 0.02 Inch Orifice Pressure Sensor Vacuum Pump: OFF Air Filter ON Pump Module Operation D: Purge VSV monitor Operation C: EVAP System Pressure Measurement OFF ON ON (closed) ON (closed) Atmospheric Pressure ON Negative Pressure ON A96746 Author
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: 485 05-296 DIAGNOSTICS (a) - SFI SYSTEM (2AZ-FE)(From August, 2004) P2419: Vent valve stuck ON (Closed) In sequence B and E, to determine the leak criterion, the vacuum pump creates negative pressure in the canister pump module through the 0.02 inch orifice. If the pressure is out of specified range or is not saturated, the ECM illuminates the MIL and sets DTCs P043E, P043F, P2401, P2402 and P2419 (2-trip detection logic). EVAP Pressure during EVAP Monitor Purge VSV OFF OFF ON: Open OFF: Closed Vent Valve OFF OFF ON: Closed OFF: Vent ON ON Vacuum Pump Malfunction Malfunction EVAP Pressure -1 kPa Specified OK OK Malfunction Malfunction Range -4.85 kPa Sequence Time A B C D E 10 sec 60 sec Within 15 minutes 10 sec 60 sec A85217 Author
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: 486 05-297 DIAGNOSTICS (b) - SFI SYSTEM (2AZ-FE)(From August, 2004) P2420: Vent valve stuck OFF (Vent) After sequence B, the ECM changes the vent valve from OFF (Vent) to ON (Closed) and measures the EVAP pressure. If the pressure does not change, the ECM illuminates the MIL and sets DTC P2420 (2-trip detection logic). EVAP Pressure when Vent Valve Stuck OFF (vent): Purge VSV OFF Vent Valve Vacuum Pump OFF ON: Open OFF: Closed ON ON: Closed OFF: Vent ON EVAP Pressure Positive Negative OK First 0.02 inch Leak Pressure Standard Malfunction Sequence Time A B 10 sec 60 sec C D E Within 15 minutes 10 60 sec G36780 Author
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: 487 05-298 DIAGNOSTICS - SFI SYSTEM (2AZ-FE)(From August, 2004) OBD II MONITOR SPECIFICATIONS Monitor Strategy Required Sensors/Components Purge VSV and pump module Frequency of Operation Once per driving cycle Duration Within 15 minutes (varies with amount of fuel in tank) MIL Operation 2 driving cycles Sequence of Operation None Typical Enabling Conditions The monitor will run whenever these DTCs are not present See page 05-16 EVAP key-off monitor runs when all of the following conditions met: - Atmospheric pressure 525 to 825 mmHg (70 to 110 kPa) Battery voltage 10.5 V or more Vehicle speed Below 4 km/h (2.5 mph) Ignition switch OFF Engine condition Not running Time after engine stopped 5 hours FTP sensor malfunction (P0450, P0452, P0453) Not detected Purge VSV Not operated by scan tool Vent valve Not operated by scan tool Leak detection pump Not operated by scan tool Both of the following conditions are met before IG switch OFF: Condition 1 and 2 1. Duration that vehicle is driven 5 min. or more 2. Purge flow Executed ECT 4.4 to 35C (40 to 95F) IAT 4.4 to 35C (40 to 95F) Accumulated purge volume 100 g or more (varies with engine coolant temperature) Example of re-start time First time 7 hours Second time 9 hours and 30 min. Key-of f monitor sequence: 1 to 8 1. Atmospheric pressure Next sequence is run if following condition met - Atmospheric pressure change for 10 sec. Within 2.25 mmHg (0.3 kPa) for 1 sec. 2. First reference pressure Next sequence is run if all of following conditions met Condition 1, 2 and 3 1. FTP when 4 sec. after reference pressure measurement -7.5 mmHg (-1 kPa) or less 2. Reference pressure -36.47 to -7.93 mmHg (-4.85 to -1.057 kPa) 3. Reference pressure Saturated 3. Vent valve stuck closed check Next sequence is run if following condition met - FTP change for 10 sec. after vent valve ON (closed) 2.25 mmHg (0.3 kPa) or more 4. Vacuum introduction and leak Next sequence is run if both of following conditions met Condition 1 and 2 1. Vacuum introduction time Within 15 min. 2. FTP FTP was saturated 5. Purge VSV stuck closed check Next sequence is run if following condition met - FTP change for 10 sec. after purge VSV ON (open) 2.25 mmHg (0.3 kPa) or more Author
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: 488 05-299 DIAGNOSTICS - SFI SYSTEM (2AZ-FE)(From August, 2004) 6. Second reference pressure measurement Next sequence is run if all of following conditions met Condition 1, 2, 3 and 4 1. FTP when 4 sec. after reference pressure measurement -7.5 mmHg (-1 kPa) or less 2. Reference pressure -36.47 to -7.93 mmHg (-4.85 to -1.057 kPa) 3. Reference pressure Saturated 4. Reference pressure difference between first and second Less than 5.25 mmHg (0.7 kPa) 7. Leak check Next sequence is run if following condition met - FTP when vacuum introduction was complete Lower than second reference pressure 8. Atmospheric pressure Monitor is complete if following - Atmospheric pressure difference between sequence 1 and 8 Within 2.25 mmHg (0.3 kPa) Typical Malfunction Thresholds P2419: Vent valve stuck open Following values are when atmospheric pressure is 760 mmHg (100 kPa) - One of the following conditions is met: Condition 1, 2, 3, 4 or 5 1. FTP when 4 seconds after reference pressure measurement began More than -7.5 mmHg (-1 kPa) 2. Reference pressure Less than -36.4 mmHg (-4.85 kPa) 3. Reference pressure -7.9 mmHg (-1.057 kPa) or more 4. Reference pressure Not saturated 5. Reference pressure difference between first and second 5.2 mmHg (0.7 kPa) or more P2420: Vent valve stuck closed FTP change for 10 sec. after vent valve opened Less than 0.3 kPa (2.25 mmHg) MONITOR RESULT (MODE 06) Refer to page 05-317 for detailed information on Monitor Result. Author
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: 489 05-300 DIAGNOSTICS DTC P2610 - SFI SYSTEM (2AZ-FE) 05IRF-02 ECM/PCM INTERNAL ENGINE OFF TIMER PERFORMANCE DTC SUMMARY DTC P2610 Monitoring Items Malfunction Detection Conditions Soak timer (built into ECM) ECM internal malfunction Trouble Areas ECM Detection Timings Detection Logic Engine running 2 trip CIRCUIT DESCRIPTION To ensure the accuracy of the EVAP (Evaporative Emission) monitor values, the soak timer, which is built into the ECM, measures 5 hours (
15 minutes) from when the ignition switch is turned OFF, before the monitor is run. This allows the fuel to cool down, which stabilizes the Fuel Tank Pressure (FTP). When 5 hours have elapsed, the ECM turns on. Soak Timer Circuit Ignition Switch ECM IGSW 15 A EFI MAIN +B MREL Battery Power Source IC Main Relay Control IC Soak Timer IC A85251 MONITOR DESCRIPTION 5 hours after the ignition switch is turned OFF, the soak timer activates the ECM to begin the EVAP system monitor. While the engine is running, the ECM monitors the synchronization of the soak timer and the CPU clock. If these two are not synchronized, the ECM interprets this as a malfunction, illuminates the MIL and sets the DTC (2 trip detection logic). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 490 05-301 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) OBD II MONITOR SPECIFICATIONS Monitor Strategy Required Sensors/Components ECM Frequency of Operation Once per driving cycle Duration 10 minutes MIL Operation 2 driving cycles Sequence of Operation None Typical Enabling Conditions The monitor will run whenever this DTC is not present See page 05-16 Ignition switch ON Engine Running Battery voltage 8 V or more Starter OFF Typical Malfunction Thresholds Soak timer measurement when ECM CPU clock counts 10 minutes Less than 7 minutes, or more than 13 minutes INSPECTION PROCEDURE HINT:
DTC P2610 is set if an internal ECM problem is detected. Diagnostic procedures are not required. ECM replacement is required. Read freeze frame data using a hand-held tester or OBD II scan tool. Freeze frame data record the engine condition when malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data, from the time the malfunction occurred.
1 REPLACE ECM (see page 10-9 ) NEXT CHECK WHETHER DTC OUTPUT RECURS (a) (b) (c) (d) (e) (f) Connect a hand-held tester to the DLC3. Turn the ignition switch to ON. Clear DTCs (see page 05-38 ). Start the engine and wait for 10 minutes or more. On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES. If no pending DTC is displayed, the repair has been successfully completed. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 491 05-302 DIAGNOSTICS DTC P2A00 - SFI SYSTEM (2AZ-FE) 05EW5-06 A/F SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1) CIRCUIT DESCRIPTION Refer to DTC P2195 on page 05-269 . DTC No. P2A00 DTC Detection Condition Trouble Area In conditions (a), (b) and (c), when A/F sensor output voltage change value is below regular value against fuel trim change value, ECM judges that A/F sensor circuit has slow response: (2 trip detection logic) (a) Engine is warmed up (b) Engine speed 1,400 rpm or more (c) Vehicle speed 60 to 120 km/h (37 to 74 mph)
Open or short in A/F sensor circuit
A/F sensor
A/F sensor heater
EFI relay
Open or short in A/F sensor and EFI relay circuits
Air induction system
Fuel pressure
Injector
PCV hose connection
ECM MONITOR DESCRIPTION Locus Length A/F Output (V) Fuel Trim Fast Sensor Slow Sensor A82390 The Air-Fuel ratio (A/F) sensor varies its output voltage in proportion to the air-fuel ratio. Based on the output voltage, the ECM determines if the air-fuel ratio is RICH or LEAN and adjusts the stoichiometric air-fuel ratio. The ECM also checks the fuel injection volume compensation value to check if the A/F sensor is deteriorating or not. A/F sensor response deterioration is determined by the ratio of the A/F sensor output voltage variation and fuel trim variation. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 492 05-303 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) MONITOR STRATEGY Related DTCs P2A00: A/F sensor slow response Required sensors / components (Main) A/F sensor Required sensors / components (Related) Vehicle speed sensor (VSS) and crankshaft position (CKP) sensor Frequency of operation Once per driving cycle Duration 60 sec. MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-16 Engine condition Running Time after engine start 120 sec. or more Fuel system status Closed Loop A/F sensor status Activated Idle OFF Time after idle OFF 2 sec. or more Engine RPM 1,400 to 3,200 rpm Vehicle speed 60 to 120 km/h (37.5 to 75 mph) Fuel cut OFF Time after fuel cut is OFF 2 sec. or more Driving for 20 sec. or more 40 km/h (25 mph) or more and 900 rpm or more TYPICAL MALFUNCTION THRESHOLDS Response rate deterioration level 8 or more MONITOR RESULT Refer to page 05-24 for detailed information. The test value and test limit information are described as shown in the following table. Check the monitor result and test values after performing the monitor drive pattern (see page 05-26 ).
TID (Test Identification Data) is assigned to each emissions-related component.
TLT (Test Limit Type): If TLT is 0, the component is malfunctioning when the test value is higher than the test limit. If TLT is 1, the component is malfunctioning when the test value is lower than the test limit.
CID (Component Identification Data) is assigned to each test value.
Unit Conversion is used to calculate the test value indicated on generic OBD ll scan tools. TID $06: A/F sensor TLT 0 CID $01 Unit Conversion Multiply by 0.000244 (no dimension) Description of Test Data Description of Test Limit Parameter for identify A/F sensor response rate Malfunction threshold for A/F sensor deterioration WIRING DIAGRAM Refer to DTC P2195 on page 05-269 . INSPECTION PROCEDURE HINT: Hand-held tester only: The malfunctioning area can be found by the ACTIVE TEST A/F CONTROL operation. The A/F CONTROL operation can determine if the A/F sensor, heated oxygen sensor or other suspected trouble areas are malfunctioning or not. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 493 05-304 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) (a) Perform the ACTIVE TEST A/F CONTROL operation. HINT: The A/F CONTROL operation lowers the injection volume by 12.5% or increases the injection volume by 25%. (1) Connect the hand-held tester to the DLC3 on the vehicle. (2) Turn the ignition switch ON. (3) Warm up the engine by running the engine at 2,500 rpm for approximately 90 seconds. (4) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (5) Perform the A/F CONTROL operation with the engine idling (press the right or left button). Result: A/F sensor reacts in accordance with increase and decrease of injection volume: +25 % → RICH output: Less than 3.0 V -12.5 % → LEAN output: More than 3.35 V Heated oxygen sensor reacts in accordance with increase and decrease of injection volume: +25 % → RICH output: More than 0.55 V -12.5 % → LEAN output: Less than 0.4 V NOTICE: The A/F sensor output has a few seconds of delay and the heated oxygen sensor output has about 20 seconds of delay at maximum. Output voltage of A/F sensor (sensor 1) Output voltage of heated oxygen sensor (sensor 2) Injection volume Injection volume +25 % +25 % -12.5 % -12.5 % Case 1 Output voltage More than 3.35 V Less than 3.0 V OK More than 0.55 V Injection volume +25 % -12.5 % -12.5 % Case 2 Output voltage A/F sensor (A/F sensor, heater, A/F sensor circuit) Output voltage NG Injection volume More than 0.55 V OK Less than 0.4V Injection volume +25 % +25 % -12.5 % -12.5 % Case 3 Output voltage Output voltage More than 3.35 V OK Injection volume Almost No reaction NG Injection volume +25 % +25 % -12.5 % -12.5 % Case 4 Output voltage Almost No reaction OK Less than 0.4V +25 % Less than 3.0V  Output voltage Injection volume Almost No reaction Main suspect trouble area Output voltage NG Almost No reaction NG Heated oxygen sensor (heated oxygen sensor, heater, heated oxygen sensor circuit) Extremely rich or lean actual air-fuel ratio (Injector, fuel pressure, gas leakage in exhaust system, etc.) The following A/F CONTROL procedure enables a technician to check and graph the voltage outputs of both the A/F sensor and the heated oxygen sensor. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 494 05-305 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) For displaying the graph, enter ”ACTIVE TEST / A/F CONTROL / USER DATA”, select ”AFS B1S1 and O2S B1S2” by pressing ”YES” and push ”ENTER”. Then press ”F4”. HINT:
DTC P2A00 may be also detected, when the air fuel ratio is stuck rich or lean.
A low A/F sensor voltage could be caused by a RICH air-fuel mixture. Check for conditions that would cause the engine to run with a RICH air-fuel mixture.
A high A/F sensor voltage could be caused by a LEAN air-fuel mixture. Check for conditions that would cause the engine to run with a LEAN air-fuel mixture.
Read freeze frame data using the hand-held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 (a) CHECK OTHER DTC OUTPUT (IN ADDITION TO A/F SENSOR DTC) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display Proceed to Only P2A00 is output A P2A00 and other codes is output B HINT: If any other codes besides P2A00 is output, perform the troubleshoot on that DTC before. B GO TO RELEVANT DTC CHART (See page 05-48 ) A 2 (a) (b) (c) (d) (e) (f) (g) READ VALUE OF OBD II SCAN TOOL OR HAND-HELD TESTER (OUTPUT VOLTAGE OF A/F SENSOR) Connect the hand-held tester or the OBD II scan tool to the DLC3. Warm up the A/F sensor (bank 1 sensor 1) by running the engine at 2,500 rpm for approximately 90 seconds. Read the A/F sensor voltage output on the the hand-held tester or OBD II scan tool. Hand-held tester only: On the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / SNAPSHOT / MANUAL SNAPSHOT / USER DATA. Read the values. Select ”AFS B1 S1 / ENGINE SPD” and press YES. Monitor the A/F sensor voltage carefully. Check the A/F sensor voltage output under the following conditions: (1) Allow the engine to idle for 30 seconds. (2) Run the engine at approximately 2,500 rpm. Do not suddenly change the rpm. (3) Raise the engine speed to 4,000 rpm and quickly release the accelerator pedal so that the throttle is fully closed. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 495 05-306 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) Standard: Condition (1) and (2) Voltage change of 3.3 V (0.66 V)* (between approximately 3.1 to 3.5 V) as shown in the illustration. Condition (3) A/F sensor voltage increases to 3.8 V (0.76 V)* or more when fuel is cut during engine deceleration as shown in the illustration. *: Voltage when using the OBD II scan tool. Normal Condition Malfunction Condition (3) Approximately 4,000 rpm (3) Approximately 4,000 rpm (2) Approximately 2,500 rpm (1) Idle (2) Approximately 2,500 rpm A/F Sensor Voltage (1) Idle (1) Idle (1) Idle Engine RPM Engine RPM ”Condition (3)” 3.8 V or More A/F Sensor Voltage Fuel Cut Fuel Cut When A/F sensor circuit is malfunctioning, voltage output does not change ”Condition (1), (2)” Change of approximately 3.3 V A72304 HINT:
Whenever the A/F sensor output voltage remains at approximately 3.3 V (0.660 V)* (see ”Malfunction Condition” graphic) under any condition as well as the above conditions, the A/F sensor may have an open circuit. This will happen also when the A/F sensor heater has an open circuit.
Whenever the A/F sensor output voltage remains at a certain value of approximately 3.8 V (0.76 V)* or more, or 2.8 V (0.56 V)* or less (see ”Malfunction Condition” graphic) under any condition as well as the above conditions, the A/F sensor may have a short circuit.
The ECM will stop fuel injection (fuel is cut) during engine deceleration. This will cause a LEAN condition and should result in a momentary increase in the A/F sensor output voltage.
The ECM must establish a closed throttle position learned value to perform fuel cut. If the battery terminal has been disconnected, the vehicle must be driven over 10 mph (16 km/h) to allow the ECM to learn the closed throttle position.
When the vehicle is driven: The output voltage of the A/F sensor may be below 2.8 V (0.76 V)* during fuel enrichment. For the vehicle, this translates to a sudden increase in speed with the accelerator pedal fully depressed when trying to overtake another vehicle. The A/F sensor is functioning normally.
The A/F sensor is a current output element, and therefore the current is converted into voltage inside the ECM. If measuring voltage at connectors of the A/F sensor or ECM, you will observe a constant voltage. *: Voltage when using the OBD II scan tool. OK Go to step 14 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 496 05-307 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) NG 3 INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) (b) A6 A/F sensor Disconnect the A6 A/F sensor connector. Measure the resistance of the A/F sensor terminals. Standard: Tester Connection Condition Specified Condition 1 (HT) - 2 (+B) 20C (68F) 1.8 to 3.4 Ω 1 (HT) - 4 (AF-) - 10 kΩ or higher AF+ AF- A52607 NG REPLACE AIR FUEL RATIO SENSOR OK 4 INSPECT RELAY (EFI) 1 3 1 5 2 2 5 (a) (b) Remove the EFI relay from the engine room J/B. Measure the resistance of the EFI relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 3 B60778 NG REPLACE RELAY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 497 05-308 DIAGNOSTICS 5 - SFI SYSTEM (2AZ-FE) CHECK WIRE HARNESS (A/F SENSOR - ECM) (a) Wire Harness Side A6 A/F Sensor HT AF+ +B 1 3 2 4 AF- Check the wire harness between the ECM and A/F sensor. (1) Disconnect the A6 A/F sensor connector. (2) Disconnect the E8 ECM connector. (3) Measure the resistance of the wire harness side connectors. Standard: E8 ECM Tester Connection Specified Condition A6-3 (AF+) - E8-23 (A1A+) A6-4 (AF-) - E8-31 (A1A-) A6-1 (HT) - E8-5 (HA1A) Below 1 Ω A6-3 (AF+) or A1A+ (E8-23) - Body ground A6-4 (AF-) or A1A- (E8-31) - Body ground A6-1 (HT) or HA1A (E8-5) - Body ground 10 kΩ or higher A1A+ A1A- HA1A A76787 A81695 A86849 Reference A/F Sensor EFI Relay From Battery EFI NO. 1 Fuse ECM +B Heater HT EFI NO. 2 Fuse AF- Sensor AF+ HA1A A1A+ Duty Control A1AMREL A90346 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 6 (a) CHECK AIR INDUCTION SYSTEM Check for vacuum leaks in the air induction system. OK: There is no leak in the air induction system. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 498 05-309 DIAGNOSTICS 7 - SFI SYSTEM (2AZ-FE) CHECK CONNECTION OF PCV HOSE OK: PCV hose is connected correctly and PCV hose has no damage. NG REPAIR OR REPLACE PCV HOSE OK 8 (a) CHECK FUEL PRESSURE (See page 11-4 ) Check fuel pressure (high or low fuel pressure). Standard: Item Specified Condition Fuel pressure 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 55 psi) NG REPAIR OR REPLACE FUEL SYSTEM OK 9 (a) INSPECT FUEL INJECTOR ASSY (See page 11-7 ) Check injector injection (high or low fuel injection quantity or poor injection pattern). Standard: Injection Volume Difference Between Each Injector 76 to 91 cm3 (4.6 to 5.5cu in.) / 15 seconds 15 cm3 (0.9 cu in.) or less NG REPLACE FUEL INJECTOR ASSY (See page 11-10 ) OK 10 REPLACE AIR FUEL RATIO SENSOR GO 11 PERFORM CONFIRMATION DRIVING PATTERN (See page 05-269 ) HINT: Clear all DTCs prior to performing the confirmation driving pattern (see page 05-269 ). GO 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 499 05-310 DIAGNOSTICS 12 (a) - SFI SYSTEM (2AZ-FE) READ OUTPUT DTC (A/F SENSOR DTC OUTPUT AGAIN) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display Proceed to DTC P2A00 is not output A DTC P2A00 is output B B REPLACE ECM (See page 10-9 ) AND PERFORM CONFIRMATION DRIVING PATTERN (See page 05-269 ) A 13 CONFIRM IF VEHICLE HAS RUN OUT OF FUEL IN PAST NO CHECK FOR INTERMITTENT PROBLEMS (See page 05-9 ) YES DTC IS CAUSED BY RUNNING OUT OF FUEL 14 PERFORM CONFIRMATION DRIVING PATTERN (See page 05-269 ) HINT: Clear all DTCs prior to performing the confirmation driving pattern (see page 05-269 ). GO 15 (a) READ OUTPUT DTC (A/F SENSOR DTC OUTPUT AGAIN) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display Proceed to DTC P2A00 is output A DTC P2A00 is not output B B Go to step 19 A 16 REPLACE AIR FUEL RATIO SENSOR GO 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 500 05-31 1 DIAGNOSTICS 17 - SFI SYSTEM (2AZ-FE) PERFORM CONFIRMATION DRIVING PATTERN (See page 05-269 ) HINT: Clear all DTCs prior to performing the confirmation driving pattern (see page 05-269 ). GO 18 (a) READ OUTPUT DTC (A/F SENSOR DTC OUTPUT AGAIN) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display Proceed to DTC P2A00 is not output A DTC P2A00 is output B B REPLACE ECM (See page 10-9 ) AND PERFORM CONFIRMATION DRIVING PATTERN (See page 05-269 ) A 19 CONFIRM IF VEHICLE HAS RUN OUT OF FUEL IN PAST OK: Vehicle has run out of fuel in past. NO CHECK FOR INTERMITTENT PROBLEMS (See page 05-9 ) YES DTC IS CAUSED BY RUNNING OUT OF FUEL 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 501 05-26 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05ITC-02 READINESS MONITOR DRIVE PATTERN 1.



PURPOSE OF THE READINESS TESTS The On-Board Diagnostic (OBD II) system is designed to monitor the performance of emission-related components, and report any detected abnormalities with Diagnostic Trouble Codes (DTCs). Since various components need to be monitored during different driving conditions, the OBD II system runs separate monitoring programs called readiness monitors. The hand-held tester’s software must be version 9.0 or newer to view the readiness monitor status. From the ”ENHANCED OBD II” menu, select ”MONITOR STATUS” to view the readiness monitor status. A generic OBD II scan tool can also be used to view the readiness monitor status. When the readiness monitor status reads ”complete”, the necessary conditions have been met for running performance tests for that readiness monitor. HINT: Many state Inspection and Maintenance (I/M) programs require a vehicle’s readiness monitor status to show ”complete”.
The readiness monitor will be reset to ”incomplete” if:
The ECM has lost battery power or blown a fuse.
DTCs have been cleared.
The conditions for running the readiness monitor have not been met.
If the readiness monitor status shows ”incomplete”, follow the appropriate readiness monitor drive pattern to change the status to ”complete”. CAUTION: Strictly observe posted speed limits, traffic laws, and road conditions when performing these drive patterns. NOTICE: The following drive patterns are the fastest method of completing all the requirements necessary for making the readiness monitor status read ”complete”. If forced to momentarily stop a drive pattern due to traffic or other factors, the drive pattern can be resumed. Upon completion of the drive pattern, in most cases, the readiness monitor status will change to ”complete”. Sudden changes in vehicle load and speed, such as driving up and down hills and/or sudden acceleration, hinder readiness monitor completion. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 216 05-27 DIAGNOSTICS 2. - SFI SYSTEM (2AZ-FE) CATALYST MONITOR (A/F SENSOR TYPE) 64 to 88 km/h (40 to 55 mph) 64 to 80 km/h (40 to 50 mph) Idling Ignition Switch OFF Warm up time (idle speed) 4 minutes 16 minutes A82401 (a) Preconditions The monitor will not run unless:
The MIL is OFF.
Engine Coolant Temperature (ECT) is 75°C (167°F) or higher.
Intake Air Temperature (IAT) is -10°C (14°F) or higher.* NOTICE: * 2002 and later MY vehicles: To complete the readiness test in cold ambient conditions (less than -10°C/14°F), turn the ignition switch OFF and then back to ON. Perform the drive pattern a second time. (b) Drive Pattern (1) Connect the OBD II scan tool to the DLC3 to check readiness monitor status and preconditions (refer to step (a)). (2) Drive the vehicle at 40 to 55 mph (64 to 88 km/h) for approximately 4 minutes. NOTICE: Drive with smooth throttle operation and avoid sudden acceleration. If IAT was less than 10°C (50°F) when the engine was started, drive the vehicle at 40 to 55 mph (64 to 88 km/h) for an additional 4 minutes. (3) Drive the vehicle allowing speed to fluctuate between 40 to 50 mph (64 to 80 km/h) for about 16 minutes. NOTICE: Drive with smooth throttle operation and avoid sudden closure of the throttle. (4) Check the status of the readiness monitor on the scan tool display. If the readiness monitor status did not switch to complete, ensure preconditions are met, turn the ignition OFF, and then repeat steps (2) and (3). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 217 05-28 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 3. (a) EVAP MONITOR (KEY-OFF MONITOR) Preconditions The monitor will run when all of the following conditions are met:
The fuel level is less than 90 %.
The altitude is less than 8,000 ft. (2,450 m).
The vehicle is stopped.
The Engine Coolant Temperature (ECT) is between 4.4 and 35°C (40 to 95°F).
The Intake Air Temperature (IAT) is between 4.4 and 35°C (40 to 95 °F). (b) Monitor condition (1) Allow the engine to idle for 300 seconds or more. (2) Turn the ignition switch OFF and wait for 6 hours. (3) Connect the scan tool to the DLC3 to check the monitor status and the preconditions. (4) Check the readiness monitor status. If ”INCMP” is displayed , the monitor is not completed. Turn the ignition switch OFF, confirm the preconditions and perform the monitor condition again. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 218 05-29 DIAGNOSTICS 4. - SFI SYSTEM (2AZ-FE) OXYGEN / AIR FUEL RATIO SENSOR MONITOR (FRONT A/F SENSOR AND REAR O2S SYSTEM) 112 km/h (70 mph) (under 3200 rpm) 64 km/h (40 mph) (over 1400 rpm) Once Twice 10 times 40 km/h (25 mph) (over 900 rpm) Idling Ignition Switch OFF Over Over Over Over 2 minutes 150 seconds 40 seconds 40 seconds Over Over Over 10 seconds 10 seconds 10 seconds (a) (b) Over 40 seconds A82400 Preconditions The monitor will not run unless: The MIL is OFF. Drive Pattern (1) Connect the OBD II scan tool to the DLC3 to check monitor status and preconditions (refer to step (a)). (2) Start the engine and allow it to idle for 2 minutes or more. (3) Drive the vehicle at 64 to 112 km/h (40 to 70 mph) for at least 150 seconds. (4) Stop the vehicle and allow the engine to idle for 10 seconds or more. (5) Drive the vehicle at 40 to 64 km/h (25 to 40 mph) for at least 40 seconds. (6) Stop the vehicle and allow the engine to idle for 10 seconds or more. (7) Perform steps (5) and (6) ten times. (8) Check the readiness monitor status. If the readiness monitor status did not change to ”complete”, check the preconditions, turn the ignition switch OFF, and repeat steps (1) to (6). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 219 05-30 DIAGNOSTICS 5. - SFI SYSTEM (2AZ-FE) OXYGEN / A/F SENSOR HEATER MONITOR 40 km/h (25 mph) Idling Ignition Switch OFF Over 500 seconds Over 2 minutes A78886 (a) (b) Preconditions The monitor will not run unless: The MIL is OFF. Drive Pattern (1) Connect the OBD II scan tool to the DLC3 to check monitor status and preconditions (refer to step (a)). (2) Start the engine and allow it to idle for 500 seconds or more. (3) Drive the vehicle at 40 km/h (25 mph) or more for at least 2 minutes. (4) Check the readiness monitor status. If the readiness monitor status did not change to ”complete”, check preconditions, turn the ignition switch OFF, and repeat steps (2) and (3). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 220 05-12 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05MOI-01 REGISTRATION NOTICE: The Vehicle Identification Number (VIN) must be input into the replaced ECM. HINT: The VIN is a 17-digit alphanumeric vehicle identification number. A hand-held tester is required to register the VIN. 1. DESCRIPTION This registration section consists of three parts, Input Instructions, Read VIN and Write VIN. (a) Input Instructions: Explains the general VIN input instructions using a hand-held tester. (b) Read VIN: Explains the VIN reading process in a flowchart. This process allows the VIN stored in the ECM to be read, in order to confirm that the two VINs, provided with the vehicle and stored in the vehicle’s ECM, are the same. (c) Write VIN: Explains the VIN writing process in a flowchart. This process allows the VIN to be input into the ECM. If the ECM is changed, or the VINs do not match, the VIN can be registered, or overwritten in the ECM by following this procedure. 2. INPUT INSTRUCTIONS (a) Hand-held tester (1) The arrow buttons (UP, DOWN, RIGHT and LEFT) and numerical buttons (0 to 9) are used, in order to input the VIN. (b) Cursor Operation (1) To move the cursor around the tester screen, press the RIGHT and LEFT buttons. (c) Alphabetical Character Input (1) Press the UP and DOWN buttons to select the desired alphabetical character. (2) After selection, the cursor should move. (d) Numeric Character Input (1) Press the numerical button corresponding to the number that you want to input. (2) After input, the cursor should move. HINT: Numerical characters can be selected by using the UP and DOWN buttons. (e) Correction (1) When correcting the input character(s), put the cursor onto the character using the RIGHT or LEFT button. (2) Select or input the correct character using the UP/DOWN buttons, or the numerical buttons. (f) Finishing Input Operation (1) Make sure that the input VIN matches the vehicle VIN after input. (2) Press the ENTER button on the tester. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 202 05-13 DIAGNOSTICS 3. (a) - SFI SYSTEM (2AZ-FE) READ VIN (Vehicle Identification Number) Read VIN using a hand-held tester. READ: START Confirm vehicle VIN Preparation: 1. Connect hand-held tester to DLC3 2. Turn ignition switch to ON 3. Turn tester ON Hand-held tester operation: 1. Select DIAGNOSIS 2. Select ENHANCED OBD ll 3. Select VIN Menu Screen: VIN Select VIN READ 1. VIN READ 2. VIN WRITE DTC P0630 Set ERROR DTC P0630 was detected. P0630 [VIN Not Programmed or Mismatch - ECM/PCM] ERROR ********************************* [ VIN ] ********************************* [EXIT] ECM does not respond the VIN. 17-digit VIN displayed Please input the VIN. PRESS [EXIT] VIN Not Stored VIN Previously Stored PRESS [EXIT] Possible cause: 1: VIN is not written yet. 2: Vehicle does not support this function. PRESS [EXIT] [EXIT] [EXIT] To Menu Screen 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 203 05-14 DIAGNOSTICS 4. (a) - SFI SYSTEM (2AZ-FE) WRITE VIN Write VIN using the hand-held tester. Write: START Confirm vehicle VIN Preparation: 1. Connect hand-held tester to DLC3 2. Turn ignition switch to ON 3. Turn tester ON Hand-held tester operation: 1. Select DIAGNOSIS 2. Select ENHANCED OBD ll 3. Select VIN Menu Screen: VIN Select VIN WRITE 1. VIN READ 1. READ 2. VIN WRITE CONFIRMATION This function will erase the DTCs automatically after writing the VIN. VIN Previously Stored NOTICE This function overwrites the following VIN with a new VIN. ********************************* Do you wish to continue? [ VIN ] ********************************* [YES] or [NO] Do you wish to continue? [NO] [YES] [YES] to Continue [NO] to EXIT [YES] 17-digit VIN displayed To Menu Screen Continued on next page [YES] [NO] To Menu Screen 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 204 05-15 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) Continued from previous page New Registration SET NEW VIN VIN input method CONFIRMATION Vehicle is stopped. Engine is not running. Input Instructions [ENTER] Press [RIGHT]/[LEFT] to shift the cursor right/left. Press [UP]/[DOWN] to increase/decrease value. Or, input digit with the 10 key. PRESS [ENTER] PRESS [ENTER] [ENTER] Input a new VIN If you want to clear the VIN, press [NO] key. PRESS [ENTER] [ENTER] Input Error INPUT ERROR Your VIN is incorrect. Please enter the VIN again. NOW WRITING [EXIT] [EXIT] to RETURN Writing Succeeded WRITING COMPLETE Writing Error Communication Error WRITING FAILED COMMUNICATION ERROR Turn IG OFF, then ON. Please try again. Turn IG OFF, then ON. PRESS [EXIT] PRESS [EXIT] [EXIT] [EXIT] The following VIN has been written correctly. The DTCs have been erased correctly. PRESS [ENTER] [ENTER] To Menu Screen To Menu Screen To Menu Screen 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 205 05-2 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 05ESJ-05 PART AND SYSTEM NAME LIST This reference list indicates the part names used in this manual along with their definitions. TOYOTA/LEXUS name Definition Toyota HCAC system, Hydro-carbon Adsorptive Catalyst (HCAC) system, HC adsorptive three-way catalyst HC adsorptive three-way catalytic converter Variable valve timing sensor, VVT sensor Camshaft position sensor Variable valve timing system, VVT system Camshaft timing control system Camshaft timing oil control valve, Oil control valve, OCV, VVT, VSV Camshaft timing oil control valve Variable timing and lift, VVTL Camshaft timing and lift control Crankshaft position sensor ”A” Crankshaft position sensor Engine speed sensor Crankshaft position sensor THA Intake air temperature Knock control module Engine knock control module Knock sensor Engine knock sensor Mass or volume air flow circuit Mass air flow meter circuit Vacuum sensor Manifold air pressure sensor Internal control module, Control module, Engine control ECU, PCM Power train control module FC idle Deceleration fuel cut Idle air control valve Idle speed control CCV, Canister close valve VSV for canister control Evaporative emissions canister vent valve EVAP VSV, Vacuum switching valve assembly No. 1, EVAP VSV, Purge VSV Evaporative emissions canister purge valve VSV for pressure switching valve, Bypass VSV Evaporative emission pressure switching valve Vapor pressure sensor, EVAP pressure sensor, Evaporative emission control system pressure sensor Fuel tank pressure sensor Charcoal canister Evaporative emissions canister ORVR system On-board refueling vapor recovery system Intake manifold runner control Intake manifold tuning system Intake manifold runner valve, IMRV, IACV (runner valve) Intake manifold tuning valve Intake control VSV Intake manifold tuning solenoid valve AFS Air fuel ratio sensor O2 sensor Heater oxygen sensor Oxygen sensor pumping current circuit Oxygen sensor output signal Oxygen sensor reference ground circuit Oxygen sensor signal ground Accel position sensor Accelerator pedal position sensor Throttle actuator control motor, Actuator control motor, Electronic throttle motor, Throttle control motor Electronic throttle actuator Electronic throttle control system, Throttle actuator control system Electronic throttle control system Throttle/pedal position sensor, Throttle/pedal position switch, Throttle position sensor/switch Throttle position sensor Turbo press sensor Turbocharger pressure sensor Turbo VSV Turbocharger pressure control solenoid valve P/S pressure switch Power-steering pressure switch VSV for ACM Active control engine mount Speed sensor, Vehicle speed sensor ”A”, Speed sensor for skid control ECU Vehicle speed sensor ATF temperature sensor, Trans. fluid temp. sensor, ATF temperature sensor ”A” Transmission fluid temperature sensor Electronic controlled automatic transmission, ECT Electronically controlled automatic Intermediate shaft speed sensor ”A” Counter gear speed sensor 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 192 05-3 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) TOYOTA/LEXUS name Definition Output speed sensor Output shaft speed sensor Input speed sensor, Input turbine speed sensor ”A”, Speed sensor (NT), Turbine speed sensor Input turbine speed sensor PNP switch, NSW Park/neutral position switch Pressure control solenoid Transmission pressure control solenoid Shift solenoid Transmission shift solenoid valve Transmission control switch, Shift lock control unit Shift lock control module Engine immobilizer system, Immobilizer system Vehicle anti-theft system 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 193 05-8 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 051ZG-11 CUSTOMER PROBLEM ANALYSIS CHECK Inspector’s Name SFI SYSTEM Check Sheet VIN Date Vehicle Brought in Production Date Licence Plate No. Odometer Reading Problem Symptoms Customer’s Name Engine Does Not Start Engine does not crank Difficult to Start Engine cranks slowly Other Poor Idling Incorrect first idle Idling rpm is abnormal Rough idling Other Poor Driveability Hesitation Knocking Engine Stall Soon after starting After accelerator pedal depressed After accelerator pedal released During A/C operation Shifting from N to D Other km miles No initial combustion Backfire Other No complete combustion High ( rpm) Low ( Muffler explosion (after-fire) rpm) Surging Other Date Problem Occurred Condition When Problem Occurs Problem Frequency Constant Other Sometimes ( times per Weather Fine Cloudy Rainy Outdoor Temperature Hot Warm Cool Place Highway Rough road Engine Temp. Cold Engine Operation Just after starting ( Starting Driving Constant speed A/C switch ON/OFF Other Suburbs Other Warming up Condition of Malfunction Indicator Lamp (MIL) Normal Mode (Pre-check) day/month) Snowy Various/Other
C/ Cold (approx. Inner City After Warming up Once only Uphill Any temp. min.) Idling Acceleration
F) Downhill Other Racing Deceleration Remains on Sometimes lights up Does not light up Normal Malfunction code(s) (code Freeze frame data ( ) Malfunction code(s) (code Freeze frame data ( ) ) DTC Inspection Check Mode Normal ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 198 05-48 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 051ZH-16 DIAGNOSTIC TROUBLE CODE CHART HINT: Parameters listed in the chart may be different than your readings depending on the type of instrument used and other factors. During the DTC check, refer to the table below if a malfunction code is displayed. For details about each code, refer to the page number in the DTC chart’s left column. DTC No. (See Page) Detection Item Trouble Area MIL*1 Memory P0010 (05-55 ) Camshaft Position ”A” Actuator Circuit (Bank 1)
Open or short in OCV circuit
OCV valve
ECM   P0011 (05-61 ) Camshaft Position ”A” -Timing Over - Advanced or System Performance (Bank 1)
Valve timing
OCV
VVT controller assembly
ECM   P0012 (05-61 ) Camshaft Position ”A” -Timing Over- Retarded (Bank 1)
Same as DTC No. P0011   P0016 (05-69 ) Crankshaft Position - Camshaft Position Correlation (Bank 1 Sensor 1)
Mechanical system (jumped tooth of timing chain, chain stretched)
ECM   P0031*3 (05-71 ) Oxygen (A/F) Sensor Heater Circuit Low (Bank 1 Sensor 1)
Open in heater circuit of A/F sensor
A/F sensor heater
EFI relay
ECM   P0032*3 (05-71 ) Oxygen (A/F) Sensor Heater Circuit High (Bank 1 Sensor 1)
Short in heater circuit of A/F sensor
A/F sensor heater
EFI relay
ECM   P0037 (05-76 ) Oxygen Sensor Heater Control Circuit Low (Bank 1 Sensor 2)
Open or short in heater circuit of heated oxygen sensor
Heated oxygen sensor heater
EFI relay
ECM   P0038 (05-76 ) Oxygen Sensor Heater Control Circuit High (Bank 1 Sensor 2)
Same as DTC No. P0037   P0100 (05-81 ) Mass or Volume Air Flow Circuit
Open or short in mass air flow meter circuit
Mass air flow meter
ECM   P0101 (05-88 ) Mass or Volume Air Flow Circuit Range/Performance Problem
Mass air flow meter   P0102 (05-81 ) Mass or Volume Air Flow Circuit Low Input
Same as DTC No. P0100   P0103 (05-81 ) Mass or Volume Air Flow Circuit High Input
Same as DTC No. P0100   P0110 (05-90 ) Intake Air Temperature Circuit
Open or short in intake air temperature sensor circuit
Intake air temperature sensor (built-in mass air flow meter)
ECM   P0112 (05-90 ) Intake Air Temperature Circuit Low Input
Same as DTC No. P0110   P0113 (05-90 ) Intake Air Temperature Circuit High Input
Same as DTC No. P0110   P0115 (05-95 ) Engine Coolant Temperature Circuit
Open or short in engine coolant temperature sensor circuit
Engine coolant temperature sensor
ECM   P0116 (05-100 ) Engine Coolant Temperature Circuit Range/Performance Problem
Cooling system
Engine coolant temperature sensor   P0117 (05-95 ) Engine Coolant Temperature Circuit Low Input
Same as DTC No. P0115   2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 238 05-49 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) P0118 (05-95 ) Engine Coolant Temperature Circuit High Input
Same as DTC No. P0115   P0120 (05-102 ) Throttle/Pedal Position Sensor/ Switch ”A” Circuit
Throttle position sensor (built-in throttle body)
ECM   P0121 (05-111) Throttle/Pedal Position Sensor/ Switch ”A” Circuit Range/Performance Problem
Throttle body assy (Throttle position sensor)   P0122 (05-102 ) Throttle/Pedal Position Sensor/ Switch ”A” Circuit Low Input
Throttle position sensor (built-in throttle body)
Short in VTA1 circuit
Open in VC circuit
ECM   P0123 (05-102 ) Throttle/Pedal Position Sensor/ Switch ”A” Circuit High Input
Throttle position sensor (built-in throttle body)
Open in VTA1 circuit
Open in E2 circuit
VC and VTA1 circuits are short-circuited
ECM   P0125 (05-113) Insufficient Coolant Temperature for Closed Loop Fuel Control
Cooling system
Engine coolant temperature sensor
Thermostat   P0128 (05-115) Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature)
Thermostat
Cooling system
Engine coolant temperature sensor
ECM   P0136 (05-118) Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2)
Open or short in heated oxygen sensor (bank 1 sensor 2) circuit
Heated oxygen sensor (bank 1 sensor 2)
Heated oxygen sensor heater (bank 1 sensor 2)
A/F sensor
A/F sensor heater
EFI relay   P0137 (05-118) Oxygen Sensor Circuit Low Voltage (Bank 1 Sensor 2)
Open or short in heated oxygen sensor circuit (sensor to ECM)
Open or short in heated oxygen sensor internal circuit   P0138 (05-118) Oxygen Sensor Circuit High Voltage (Bank 1 Sensor 2)
Short in heated oxygen sensor (bank 1 sensor 2) circuit
Short in heated oxygen sensor (bank 1 sensor 2) internal circuit
ECM internal circuit malfunction   System too Lean (Bank 1)
Air induction system
Injector blockage
Mass air flow meter
Engine coolant temperature sensor
Fuel pressure
Gas leakage in exhaust system
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
PCV hose connection
PCV hose   System too Rich (Bank 1)
Injector leak, blockage
Mass air flow meter
Engine coolant temperature sensor
Ignition system
Fuel pressure
Gas leakage in exhaust system
Open or short in A/F sensor circuit
A/F sensor
A/F sensor heater
Open or short in A/F sensor heater and EFI relay circuits
EFI relay   P0171 (05-132 ) P0172 (05-132 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 239 05-50 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) P0220 (05-102 ) Throttle/Pedal Position Sensor/ Switch ”B” Circuit
Throttle position sensor (built-in throttle body)
ECM   P0222 (05-102 ) Throttle/Pedal Position Sensor/ Switch ”B” Circuit Low Input
Throttle position sensor (built-in throttle body)
Short in VTA2 circuit
Open in VC circuit
ECM   Throttle/Pedal Position Sensor/ Switch ”B” Circuit High Input
Throttle position sensor (built-in throttle body)
Open in VTA2 circuit
Open in E2 circuit
VC and VTA2 circuits are short-circuited
ECM   P0300 (05-146 ) Random/Multiple Cylinder Misfire Detected
Open or short in engine wire
Connector connection
Vacuum hose connection
Ignition system
Injector
Fuel pressure
Mass air flow meter
Engine coolant temp. sensor
Compression pressure
Valve clearance
Valve timing
PCV hose connection
PCV hose
ECM *2  P0301 (05-146 ) Cylinder 1 Misfire Detected
Same as DTC No. P0300 *2  P0302 (05-146 ) Cylinder 2 Misfire Detected
Same as DTC No. P0300 *2  P0303 (05-146 ) Cylinder 3 Misfire Detected
Same as DTC No. P0300 *2  P0304 (05-146 ) Cylinder 4 Misfire Detected
Same as DTC No. P0300 *2  P0325 (05-161 ) Knock Sensor 1 Circuit (Bank 1 or Single Sensor)
Open or short in knock sensor circuit
Knock sensor (under-torqued or loose)
ECM   P0327 (05-161 ) Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor)
Short in knock sensor circuit
Knock sensor
ECM   P0328 (05-161 ) Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor)
Open in knock sensor circuit
Knock sensor
ECM   P0335 (05-166 ) Crankshaft Position Sensor ”A” Circuit
Open or short in crankshaft position sensor circuit
Crankshaft position sensor
Signal plate (Crankshaft position sensor plate No. 1)
ECM   P0339 (05-166 ) Crankshaft Position Sensor ”A” Circuit Intermittent
Same as DTC No. P0335 -  P0340 (05-170 ) Camshaft Position Sensor ”A” Circuit (Bank 1 or Single Sensor)
Open or short in camshaft position sensor circuit
Camshaft position sensor
Camshaft timing gear
Timing chain has a jumped tooth
ECM   P0341 (05-170 ) Camshaft Position Sensor ”A” Circuit Range/Performance (Bank 1 or Single Sensor)
Same as DTC No. P0340   P0223 (05-102 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 240 05-51 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) P0351 (05-174 ) Ignition Coil ”A” Primary/Secondary Circuit
Ignition system
Open or short in IGF and IGT1 to 4 circuits from ignition coil with igniter assy to ECM
No.1 - 4 ignition coil assy
ECM P0352 (05-174 ) Ignition Coil ”B” Primary/Secondary Circuit
Same as DTC No. P0351   P0353 (05-174 ) Ignition Coil ”C” Primary/Secondary Circuit
Same as DTC No. P0351   P0354 (05-174 ) Ignition Coil ”D” Primary/Secondary Circuit
Same as DTC No. P0351   P0420 (05-184 ) Catalyst System Efficiency Below Threshold (Bank 1)
Gas leakage on exhaust system
A/F sensor
Heated oxygen sensor
Exhaust manifold converter (Three way catalytic converter)   P043E (05-190 ) Evaporative Emission System Reference Orifice Clog Up
Pump module
Connector/Wire harness (Pump module - ECM)
ECM
Leakage from EVAP system   P043F (05-190 ) Evaporative Emission System Reference Orifice High Fow
Pump module
Connector/Wire harness (Pump module - ECM)
ECM
Leakage from EVAP system   P0441 (05-196 ) Evaporative Emission Control System Incorrent Purge Flow
Purge VSV
Connector/wire harness (Purge VSV - ECM)
ECM
Pump module
Leakage from EVAP system
Leakage from EVAP line (Purge VSV - Intake manifold)   P0450 (05-202 ) Evaporative Emission Control System Pressure sensor/Switch
Pump module
ECM   P0451 (05-202 ) Evaporative Emission Control System Pressure sensor Range/ Performance
Pump module
Connector/Wire harness (Pump module - ECM)
ECM   P0452 (05-202 ) Evaporative Emission Control System Pressure sensor/Switch Low Input
Pump module
Connector/Wire harness (Pump module to ECM)
ECM   P0453 (05-202 ) Evaporative Emission Control System Pressure sensor/Switch High Input
Pump module
Connector/Wire harness (Pump module to ECM)
ECM   P0455 (05-211) Evaporative Emission Control System Leak Detected (gross leak)
Fuel tank cap (loose)
Leakage from EVAP line (Canister - Fuel tank)
Leakage from EVAP line (Purge VSV - Canister)
Pump module
Leakage from fuel tank
Leakage from canister   P0456 (05-211) Evaporative Emission Control System Leak Detected (small leak)
Same above   P0500 (05-216 ) Vehicle Speed Sensor ”A”
Combination meter
Open or short in speed sensor circuit
Vehicle speed sensor
ECM
Skid control ECU   P0503 (05-216 ) Vehicle Speed Sensor ”A” Intermittent/Erratic/High
Same as DTC No. P0500 -  Brake Switch Correlation
Short in stop lamp switch signal circuit
STOP fuse
Stop lamp switch
ECM -  P0504 (05-219 )   2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 241 05-52 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) P0505 (05-226 ) Idle Control System
Electronic throttle control system
Air induction system
PCV hose connection
ECM P0560 (05-229 ) System Voltage
Open in back-up power source circuit
ECM   P0604 (05-233 ) Internal Control Module Random Access Memory (RAM) Error
ECM   P0606 (05-233 ) ECM/PCM Processor
Same as DTC No. P0604   P0607 (05-233 ) Control Module Performance
Same 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 Mismatch - ECM/PCM
ECM   P0657 (05-233 ) Actuator Supply Voltage Circuit / Open
Same as DTC No. P0604   P0705 (05-242 ) Transmission Range Sensor Circuit Malfunction (PRNDL Input)
Short in PNP switch circuit
PNP switch
ECM   P0710 (05-928 ) Transmission Fluid Temperature Sensor ”A” circuit
Electronic controlled automatic transmission (ECT)   P0711 (05-933 ) Transmission Fluid Temperature Sensor ”A” Performance
Electronic controlled automatic transmission (ECT)   P0712 (05-928 ) Transmission Fluid Temperature Sensor ”A” Circuit Low Input
Electronic controlled automatic transmission (ECT)   P0713 (05-928 ) Transmission Fluid Temperature Sensor ”A” Circuit High Input
Electronic controlled automatic transmission (ECT)   P0717 (05-937 ) Input/Turbine Speed Sensor ”A” Circuit No Signal
Electronic controlled automatic transmission (ECT)   P0724 (05-940 ) Brake Switch ”B” Circuit High
Electronic controlled automatic transmission (ECT)   P0741 (05-944 ) Torque Converter Clutch Circuit Performance or Stuck Off
Electronic controlled automatic transmission (ECT)   P0746 (05-949 ) Pressure Control Solenoid ”A” Performance (Shift Solenoid Valve SL1)
Electronic controlled automatic transmission (ECT)   P0748 (05-953 ) Pressure Control Solenoid ”A” Electrical (Shift Solenoid Valve SL1)
Electronic controlled automatic transmission (ECT)   P0766 (05-949 ) Shift Solenoid ”D” Performance (Shift Solenoid Valve S4)
Electronic controlled automatic transmission (ECT)   P0776 (05-949 ) Pressure Control Solenoid ”B” Performance (Shift Solenoid Valve SL2)
Electronic controlled automatic transmission (ECT)   P0778 (05-953 ) Pressure Control Solenoid ”B” Electrical (Shift Solenoid Valve SL2)
Electronic controlled automatic transmission (ECT)   P0793 (05-967 ) Intermediate Shaft Speed Sensor ”A” Circuit No Signal
Electronic controlled automatic transmission (ECT)   P0982 (05-953 ) Shift Solenoid ”D” Control Low
Electronic controlled automatic transmission (ECT)   P0983 (05-953 ) Shift Solenoid ”D” Control High
Electronic controlled automatic transmission (ECT)     2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 242 05-53 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) Throttle Actuator Control Motor Circuit Low
Open 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 Closed
Same as DTC No. P2111   P2118 (05-250 ) Actuator Control Motor Current Range/Performance
Open in ETCS power source circuit
ECM   P2119 (05-255 ) Throttle Actuator Control Throttle Body Range/Performance
Electronic throttle control system
ECM   P2120 (05-257 ) Throttle/Pedal Position Sensor/ Switch ”D” Circuit
Accelerator pedal position sensor
Open in VCP1 circuit
VPA circuit open or ground short
ECM   P2121 (05-265 ) Throttle/Pedal Position Sensor/ Switch ”D” Circuit Range/Performance
Open or short in Accelerator pedal position sensor circuit
Accelerator pedal position sensor
ECM   P2122 (05-257 ) Throttle/Pedal Position Sensor/ Switch ”D” 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 ”D” Circuit High Input
Accelerator pedal position sensor
Open in EPA circuit
ECM   P2125 (05-257 ) Throttle/Pedal Position Sensor/ Switch ”E” Circuit
Accelerator pedal position sensor
ECM   P2127 (05-257 ) Throttle/Pedal Position Sensor/ Switch ”E” 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 ”E” Circuit High Input
Accelerator pedal position sensor
Open in EPA2 circuit
ECM   P2135 (05-102 ) Throttle Pedal Position Sensor/ Switch ”A”/”B” Voltage Correlation
Same as DTC No. P0120   P2138 (05-257 ) Throttle Pedal Position Sensor/ Switch ”D”/”E” Voltage Correlation
VPA 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   P2102 (05-243 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 243 05-54 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 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 sensor) (Bank 1 Sensor 1)
Same as DTC No. P2238   P2253*3 (05-282 ) Oxygen Sensor Reference Ground Circuit High (for A/F sensor) (Bank 1 Sensor 1)
Same as DTC No. P2238   P2401 (05-288 ) Evaporative Emission System Leak Detection Pump Control Circuit Low
Pump module
Connector/Wire harness (Pump module - ECM)
ECM
Leakage from EVAP system   P2402 (05-288 ) Evaporative Emission System Leak Detection Pump Control Circuit High
Pump module
Connector/Wire harness (Pump module - ECM)
ECM   P2419 (05-294 ) Evaporative Emission System Switching Valve Control Circuit Low
Pump module
Connector/Wire harness (Pump module - ECM)
ECM   P2420 (05-294 ) Evaporative Emission System Switching Valve Control Circuit High
Pump module
Connector/Wire harness (Pump module - ECM)
ECM
Leakage from EVAP system   P2610 (05-300 ) ECM/PCM Internal Engine Off Timer Performance
ECM   P2716 (05-974 ) Pressure Control Solenoid ”D” Electrical
Electronic controlled automatic transmission (ECT)   P2A00 (05-302 ) A/F Sensor Circuit Slow Response (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 Low
Electronic controlled automatic transmission (ECT)   P2770 (05-978 ) DSL Solenoid Circuit High
Electronic controlled automatic transmission (ECT)   B2799 (05-2010 ) Engine Immobilizer System Malfunction
Immobilizer system -    HINT: *1: MIL illuminates *2: MIL illuminates or flashes continuously *3: Although the title (DTC description) says ”oxygen sensor”, this DTC is related to the ”A/F sensor”. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 244 05-5 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 051ZF-14 HOW TO PROCEED WITH TROUBLESHOOTING The hand-held tester is used in steps 3, 4, 5, 7 and 10. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (See page 05-8 ) NEXT 3 CONNECT HAND-HELD TESTER TO DLC3 HINT: If the display indicates a communication fault in the tool, inspect the DLC3. NEXT 4 CHECK DTC AND FREEZE FRAME DATA (See page 05-38 ) HINT: Record or print DTC and freeze frame data, if needed. NEXT 5 CLEAR DTC AND FREEZE FRAME DATA (See page 05-38 ) NEXT 6 VISUAL INSPECTION NEXT 7 SETTING CHECK (TEST) MODE DIAGNOSIS (See page 05-40 ) NEXT 8 PROBLEM SYMPTOM CONFIRMATION HINT: If the engine does not start, perform steps 10 and 12 first. B Malfunction does not occur A Malfunction occurs B Go to step 10 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 195 05-6 DIAGNOSTICS 9 - SFI SYSTEM (2AZ-FE) SYMPTOM SIMULATION NEXT 10 DTC CHECK (See page 05-38 ) Malfunction code A No code B B Go to step 12 A 11 DTC CHART (See page 05-48 ) NEXT Go to step 14 12 BASIC INSPECTION (See page 05-10 ) B Wrong parts not confirmed A Wrong parts confirmed B Go to step 17 A 13 PROBLEM SYMPTOMS TABLE (See page 05-31 ) B Wrong circuit confirmed A Wrong parts confirmed B Go to step 17 A 14 CHECK ECM POWER SOURCE CIRCUIT (See page 05-312 ) NEXT 15 CIRCUIT INSPECTION B Malfunction not confirmed A Malfunction confirmed B Go to step 18 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 196 05-7 DIAGNOSTICS 16 - SFI SYSTEM (2AZ-FE) CHECK FOR INTERMITTENT PROBLEMS (See page 05-9 ) NEXT Go to step 18 17 PARTS INSPECTION NEXT 18 IDENTIFICATION OF PROBLEM NEXT 19 ADJUSTMENT, REPAIR NEXT 20 CONFIRMATION TEST NEXT END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 197 05-4 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 051ZI-15 LOCATION Mass Air Flow Sensor Combination Meter Assy (Including Intake Air Temperature Sensor) ECM R/B Sub-assy:
C/OPN Relay EVAP VSV Passenger Side J/B Engine Room R/B No. 2 and Engine Room J/B Heated Oxygen Sensor
EFI Relay (Bank 1 Sensor 2)
STARTER Relay
EFI NO. 1 Fuse Accelerator Pedal Rod Assy DLC3
EFI NO. 2 Fuse (Accelerator Pedal Position Sensor)
ETCS Fuse Ignition Coil
AM2 Fuse with Igniter Camshaft Timing Oil
ALT Fuse Control Valve Assy
STARTER Fuse Injector Fuel Pump Instrument Panel J/B Assy
IGN Fuse
IG2 Fuse
STOP Charcoal Canister Assy Front Pump Module Throttle Body Assy (Throttle Position Sensor and Actuator) Camshaft Position Sensor Crankshaft Position Sensor Engine Coolant Temperature Sensor A/F Sensor (Bank 1 Sensor 1) Knock Sensor PNP Switch A90309 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 194 05-31 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 051ZK-13 PROBLEM SYMPTOMS TABLE Symptom Suspected Area See Page Engine does not crank (does not start) 1. Starter 2. STARTER relay 3. PNP switch 19-12 19-12 40-6 No initial combustion (does not start) 1. ECM power source circuit 2. Fuel pump control circuit 3. ECM 05-312 05-349 01-36 No complete combustion (does not start) 1. Fuel pump control circuit 05-349 Difficult to start (engine cranks normally) 1. Starter signal circuit 2. Fuel pump control circuit 3. Compression 05-235 05-349 14-1 Difficult to start with cold engine 1. Starter signal circuit 2. Fuel pump control circuit 05-235 05-349 Difficult to start with hot engine 1. Starter signal circuit 2. Fuel pump control circuit 05-235 05-349 High engine idle speed (poor idling) 1. A/C signal circuit (Compressor circuit) 2. ECM power source circuit 05-1190 05-312 Low engine idle speed (poor idling) 1. A/C signal circuit (Compressor circuit) 2. Fuel pump control circuit 05-1190 05-349 Rough idling (poor idling) 1. Compression 2. Fuel pump control circuit 14-1 05-349 Hunting (poor idling) 1. ECM power source circuit 2. Fuel pump control circuit 05-312 05-349 Hesitation/Poor acceleration (poor driveability) 1. Fuel pump control circuit 2. A/T faulty 05-349 05-904 Surging (poor driveability) 1. Fuel pump control circuit 05-349 Engine stalls soon after starting 1. Fuel pump control circuit 05-349 Engine stalls during A/C operation 1. A/C signal circuit (Compressor circuit) 2. ECM 05-1190 01-36 Unable to refuel/Difficult to refuel 1. ORVR system
2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 221 05-32 DIAGNOSTICS - SFI SYSTEM (2AZ-FE) 051ZJ-16 TERMINALS OF ECM E7 E9 E8 E6 E5 A53766 HINT: Each ECM terminal’s standard voltage is shown in the table below. In the table, first follow the information under ”Condition”. Next look under ”Symbols (Terminal No.)” for the terminals to be inspected. The standard voltage between the terminals is shown under ”Specific Condition”. Use the illustration above as a reference for the ECM terminals. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition BATT (E5-3) - E1 (E9-1) BR - BR Battery (for measuring battery voltage and for ECM memory) +BM (E6-6) - E1 (E9-1) W - BR Power source of throttle motor Always 9 to 14 V IGSW (E5-9) - E1 (E9-1) P - BR Ignition switch Ignition switch ON 9 to 14 V +B (E5-1) - E1 (E9-1) W - BR Power source of ECM Ignition switch ON 9 to 14 V +B2 (E5-2) - E1 (E9-1) W - BR Power source of ECM Ignition switch ON 9 to 14 V Camshaft timing oil control valve (OCV) Ignition switch ON Pulse generation (see page 05-55 ) OC1+ (E9-16) - OC1- (E9-15) G-W - G-R Always 9 to 14 V MREL (E5-8) - E1 (E9-1) B - BR EFI relay Ignition switch ON 9 to 14 V VC (E7-18) - E2 (E7-28) Y - BR Power source of sensor (specific voltage) Ignition switch ON 4.5 to 5.5 V VG (E7-30) - EVG (E7-29) R - L-W Mass air flow meter Idling, shift lever position P or N position, A/C switch OFF 0.5 to 3.0 V THA (E7-20) - E2 (E7-28) L-B - BR Intake air temperature sensor Idling, intake air temp. 20°C (68°F) 0.5 to 3.4 V THW (E7-19) - E2 (E7-28) G-B - BR Engine coolant temperature sensor Idling, engine coolant temp. 80°C (176°F) 0.2 to 1.0 V VTA1 (E7-21) - E2 (E7-28) B-W - BR Throttle position sensor (for engine control) Ignition switch ON, accelerator pedal released 0.3 to 1.0 V VTA1 (E7-21) - E2 (E7-28) B-W - BR Throttle position sensor (for engine control) Ignition switch ON, accelerator pedal depressed 3.2 to 4.9 V VTA2 (E7-31) - E2 (E7-28) B-R - BR Throttle position sensor (for sensor malfunction detection) Ignition switch ON, accelerator pedal released 2.1 to 3.1 V VTA2 (E7-31) - E2 (E7-28) B-R - BR Throttle position sensor (for sensor malfunction detection) Ignition switch ON, accelerator pedal depressed 4.5 to 5.5 V VPA (E5-22) - EPA (E5-28) B -R Accelerator pedal position sensor (for engine control) Ignition switch ON, accelerator pedal released 0.5 to 1.1 V VPA (E5-22) - EPA (E5-28) B -R Accelerator pedal position sensor (for engine control) Ignition switch ON, accelerator pedal depressed 2.6 to 4.5 V W - BR Accelerator pedal position sensor (for sensor malfunction detection) Ignition switch ON, accelerator pedal released 1.2 to 2.0 V VPA2 (E5-23) - EPA2 (E5-29) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 222 05-33 DIAGNOSTICS Symbols (Terminal No.) - SFI SYSTEM (2AZ-FE) Wiring Color Terminal Description Condition Specified Condition VPA2 (E5-23) - EPA2 (E5-29) W - BR Accelerator pedal position sensor (for sensor malfunction detection) Ignition switch ON, accelerator pedal depressed 3.4 to 5.3 V VCPA (E5-26) - EPA (E5-28) G-R Power source of accelerator pedal position sensor (for VPA) Ignition switch ON 4.5 to 5.5 V VCP2 (E5-27) - EPA2 (E5-29) L - BR Power source of accelerator pedal position sensor (for VPA2) Ignition switch ON 4.5 to 5.5 V Below 3.0 V HA1A (E8-5) - E04 (E8-7) B-W - W-B A/F sensor heater Idling HA1A (E8-5) - E04 (E8-7) B-W - W-B A/F sensor heater Ignition switch ON 9 to 14 V A1A+ (E8-23) - E1 (E9-1) BR - BR A/F sensor Ignition switch ON 3.0 to 3.6 V A1A- (E8-31) - E1 (E9-1) Y - BR A/F sensor Ignition switch ON 2.7 to 3.3 V Idling Below 3.0 V HT1B (E8-21) - E1 (E9-1) R-Y - BR Heated oxygen sensor heater HT1B (E8-21) - E1 (E9-1) R-Y - BR Heated oxygen sensor heater IIgnition switch ON G - BR Heated oxygen sensor Maintain engine speed at 2,500 rpm for 2 minutes after warming up OX1B (E8-29) - O1B (E8-2) 9 to 14 V Pulse generation #1 #2 #3 #4 (E7-1) (E7-2) (E7 2) (E7-3) (E7-4) - E01 E01 E01 E01 (E7-7) (E7-7) (E7 7) (E7-7) (E7-7) L - W-B Y - W W-B B B - W-B W - W-B Injector IIgnition switch s itch ON #1 #2 #3 #4 (E7-1) (E7-2) (E7-3) (E7-4) - E01 E01 E01 E01 (E7-7) (E7-7) (E7-7) (E7-7) L - W-B Y - W-B B - W-B W - W-B Injector Idling Pulse generation (see page 05-146 ) 9 to 14 V KNK1 (E8-1) - FKNK1 (E8-28) B -W Knock sensor Maintain engine speed at 4,000 rpm after warming up Pulse generation (see page 05-161 ) G2+ (E9-27) - NE- (E9-24) Y -G Camshaft position sensor Idling Pulse generation (see page 05-166 ) NE+ (E9-25) - NE- (E9-24) R -G Crankshaft position sensor Idling Pulse generation (see page 05-166 ) Pulse generation (see page 05-174 ) IGT1 IGT2 IGT3 IGT4 (E7-8) - E1 (E9-1) (E7-9) - E1 (E9-1) (E7-10) - E1 (E9-1) (E7-11) - E1 (E9-1) R-W - BR P - BR Y-B - BR L-Y - BR Ignition coil with igniter (ignition signal) Idling IGF1 (E7-24) - E1 (E9-1) W-R - BR Ignition coil with igniter (ignition confirmation signal) IIgnition switch ON IGF1 (E7-24) - E1 (E9-1) W-R - BR Ignition coil with igniter (ignition confirmation signal) Idling PRG (E7-34) - E1 (E9-1) G - BR Purge valve Ignition switch ON 9 to 14 V Ignition switch ON 9 to 14 V 4.5 to 5.5 V Pulse generation (see page 05-174 ) VPMP (E7-27) - E1 (E9-1) Y-G - BR Vent valve (Build in pump module) MPMP (E5-4) - E1 (E9-1) LG - BR Vacuum pump (Build in pump module) Vacuum pump OFF 0 to 3 V MPMP (E5-4) - E1 (E9-1) LG - BR Vacuum pump (Build in pump module) Vacuum pump ON 9 to 14 V PPMP (E5-21) - E2 (E7-28) L - BR Pressure sensor (Build in pump module) Ignition switch ON 3 to 3.6 V SPD (E6-17) - E1 (E9-1) Y - BR Speed signal from combination meter Ignition switch ON, rotate driving wheel slowly Pulse generation (see page 05-216 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 223 05-34 DIAGNOSTICS Symbols (Terminal No.) Wiring Color - SFI SYSTEM (2AZ-FE) Terminal Description Condition Specified Condition Starter signal Shift lever position P or N, ignition switch START BR - BR Stop lamp switch Brake pedal is depressed 7 5 to 14 V 7.5 BR - BR Stop lamp switch Brake pedal is released Below 1.5 V ST1 (E6-12) - E1 (E9-1) V - BR Stop lamp switch Ignition switch ON, Brake pedal is depressed Below 1.5 V ST1 (E6-12) - E1 (E9-1) V - BR Stop lamp switch Ignition switch ON, Brake pedal is released 7.5 to 14 V NSW (E7-16) - E1 (E9-1) B-R - BR PNP switch Ignition switch ON, shift position at P or N 0 to 3.0 V NSW (E7-16) - E1 (E9-1) B-R - BR PNP switch Ignition switch ON, shift position is not P or N 9 to 14 V M+ (E9-3) - ME01 (E9-4) B - W-B Throttle actuator Idling Pulse generation M- (E9-2) - ME01 (E9-4) W - W-B Throttle actuator Idling Pulse generation STA (E7-17) - E1 (E9-1) B - BR STP (E6-19) (E6 19) - E1 (E9-1) (E9 1) STP (E6-19) - E1 (E9-1) 9 to 14 V FC (E5-10) - E1 (E9-1) Y - BR Fuel pump control Ignition switch ON 9 to 14 V W (E5-11) - E1 (E9-1) SB - BR MIL Ignition switch ON Below 3.0 V W (E5-11) - E1 (E9-1) SB - BR MIL Idling ELS2 (E5-12) - E1 (E9-1) G - BR Electric load Power outlet OFF 0 to 1.5 V ELS2 (E5-12) - E1 (E9-1) G - BR Electric load Power outlet ON 7.5 to 14 V TC (E5-20) - E1 (E9-1) O - BR Terminal TC of DLC3 Ignition switch ON SIL (E5-18) - E1 (E9-1) R - BR Terminal SIL of DLC3 During charge of gears Pulse generation TACH (E5-5) - E1 (E9-1) B - BR Engine speed Idling Pulse generation PSW (E9-10) - E1 (E9-1) R-L - BR PS oil pressure switch Ignition switch ON 9 to 14 V 9 to 14 V 9 to 14 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 224 05-660 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EY4-05 ACIS CONTROL CIRCUIT CIRCUIT DESCRIPTION The ECM opens and closes the Intake Air Control (IAC) valve No. 2 in response to engine speed (RPM/NE). This system improves intake manifold tuning for better efficiency at low and high engine rpm. When the engine speed is 4,000 rpm or less and the throttle valve opening angle is 30 or more, the ECM turns the VSV ON to operate the IAC valve. HINT: ACIS stands for ”Acoustic Control Induction System”. Throttle Valve Opening Angle Valve closed (VSV: ON) IAC Valve No. 2 30° Throttle Valve 4,000 rpm Engine Speed A87796 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 850 05-661 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) WIRING DIAGRAM V2 VSV for IAC Valve No. 2 Engine Room R/B No. 2 EFI NO. 2 2 2 1 B-W 1 EB1 2 ECM R-Y B-R 1 2 13 IK3 B 15 ACIS E7 Y Engine Room J/B 3 2D 3 EFI Relay 1 5 2 5 2B P-L BR EFI NO. 1 1 2I 8 MREL E5 4 1 E7 E1 2F W 3 W-B F7 FL Block Assy 1 A A W J7 J/C J2 J/C A FL Main BR Battery ED EH A88701 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 851 05-662 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) INSPECTION PROCEDURE Hand-held tester: 1 PERFORM ACTIVE TEST USING HAND-HELD TESTER (OPERATE VSV FOR IAC VALVE NO. 2) VSV is ON Air VSV is OFF Air Air Filter (a) (b) (c) (d) Port F Port E Port F (e) Port E A67588 Disconnect the vacuum hose. Connect the hand-held tester to the DLC3. Turn the ignition switch ON and push the hand-held tester main switch ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / INTAKE CTL VSV1. Operate the VSV. Check the VSV operation when it is operated by the hand-held tester. OK: Tester Operation Specified Condition VSV is ON Air from port E flows out through port F VSV is OFF Air from port E flows out through the air filter OK Go to step 4 NG 2 CHECK VSV FOR IAC VALVE NO.2 (OPERATION) Air (a) (a) Check that air flows from port E to the air filter. (b) (c) Apply battery positive voltage across the terminals. Check that air flows from port E to port F. Air Filter Port E A54315 (b) Air Port E Port F Battery A54316 NG REPLACE VSV OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 852 05-663 DIAGNOSTICS 3 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS (VSV FOR IAC VALVE NO. 2 - ECM, VSF FOR IAC VALVE NO. 2 - EFI RELAY) (a) Wire Harness Side V2 VSV for IAC Valve No. 2 Check the wire harness between the VSV and ECM. (1) Disconnect the V2 VSV connector. (2) Disconnect the E7 ECM connector. (3) Check the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition V2-2 - E7-15 (ACIS) Below 1 Ω V2-2 or E7-15 (ACIS) - Body ground 10 kΩ or higher E7 ECM Y A85675 A81699 ACIS A87763 (b) Wire Harness Side V2 VSV for IAC Valve No. 2 Check the wire harness between the VSV and EFI relay. (1) Disconnect the V2 VSV connector. (2) Remove the EFI relay from the engine room J/B. (3) Check the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition V2-1 - J/B EFI relay terminal 3 Below 1 Ω Engine Room J/B EFI Relay A85448 A90291 A92391 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 853 05-664 DIAGNOSTICS 4 (a) - SFI SYSTEM (3MZ-FE) CHECK VACUUM HOSES (INTAKE MANIFOLD - INTAKE AIR CONTROL VALVE, INTAKE AIR CONTROL) Check that the vacuum hoses are:
Connected correctly.
Are not loose or disconnected.
Do not have cracks, holes or damage. NG REPAIR OR REPLACE VACUUM HOSES OK 5 INSPECT INTAKE AIR CONTROL VALVE (See page 13-2 ) NG REPLACE INTAKE AIR CONTROL VALVE OK REPLACE ECM (See page 10-24 ) OBD II scan tool (excluding hand-held tester): 1 INSPECT VSV FOR IAC VALVE NO.2 (OPERATION) (a) (b) Air (a) Air Filter Port E Disconnect the VSV connector. Check operation of the VSV when battery positive voltage is applied to the terminals of the VSV. OK: Battery positive voltage is not applied: Air from port E flows out through the air filter. Battery positive voltage is applied: Air from port E flows out through port F. (b) Air Port E Y A54315 A54316 Port F Battery A87791 NG REPLACE VSV OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 854 05-665 DIAGNOSTICS 2 - SFI SYSTEM (3MZ-FE) CHECK ECM (ACIS VOLTAGE) E1 (-) (a) (b) Start the engine. Check the voltage of the ECM connectors. Standard Tester Connection Condition E7-15 (ACIS) - E9-1 (E1) ACIS (+) E7 ECM E9 ECM A76903 OK Specified Condition
Engine speed is 4,000 rpm or less
Throttle valve opening angle is 30 or more 9 to 14 V Go to step 4 NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 855 05-666 DIAGNOSTICS 3 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS (VSV FOR IAC VALVE NO. 2 - ECM, VSV FOR IAC VALVE NO.2 - EFI RELAY) (a) Wire Harness Side V2 VSV for IAC Valve No. 2 Check the wire harness between the VSV and ECM. (1) Disconnect the V2 VSV connector. (2) Disconnect the E7 ECM connector. (3) Check the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition V2-2 - E7-15 (ACIS) Below 1 Ω V2-2 or E7-15 (ACIS) - Body ground 10 kΩ or higher E7 ECM Y A85675 A81699 ACIS A87763 (b) Wire Harness Side V2 VSV for IAC Valve No. 2 Check the wire harness between the VSV and EFI relay. (1) Disconnect the V2 VSV connector. (2) Remove the EFI relay from the engine room J/B. (3) Check the resistance OF the wire harness side connectors. Standard: Tester Connection Specified Condition V2-1 (VSV for ACIS) - J/B EFI relay terminal 3 Below 1 Ω Engine Room J/B EFI Relay A85448 A90291 A92391 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 856 05-667 DIAGNOSTICS 4 (a) - SFI SYSTEM (3MZ-FE) CHECK VACUUM HOSES (INTAKE MANIFOLD - INTAKE AIR CONTROL VALVE, INTAKE AIR CONTROL) Check that the vacuum hoses are:
Connected correctly.
Are not loose or disconnected.
Do not have cracks, holes or damage. NG REPAIR OR REPLACE VACUUM HOSE OK 5 INSPECT INTAKE AIR CONTROL VALVE (See page 13-2 ) NG REPLACE INTAKE AIR CONTROL VALVE OK REPLACE ECM (See page 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 857 05-668 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EXI-05 ACTIVE CONTROL ENGINE MOUNT LOCATION Vacuum Tank Air Cleaner Cap Engine Mounting Insulator FR Engine Room J/B EFI NO. 1 Fuse EFI Relay A87847 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 858 05-669 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) CIRCUIT DESCRIPTION The Active Control Engine Mount (ACM) system decreases engine vibration at low engine speed using the VSV for ACM. The VSV is controlled by a pulse signal transmitted to the VSV from the ECM. The frequency of this pulse signal is matched to the engine speed to decrease engine vibration. WIRING DIAGRAM ECM V5 VSV for ACM Engine Room R/B No. 2 EFI NO. 2 2 B-W 2 1 B 2 1 2 7 EB2 Y-G 6 ACM E9 Y Engine Room J/B 3 2D 5 2B 3 EFI Relay 1 5 2 P-L 13 IK3 B 8 MREL E5 EFI NO. 1 1 2I 4 2F W 3 W-B F7 FL Block Assy 1 A W J2 J/C FL Main Battery EH A88702 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 859 05-670 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) INSPECTION PROCEDURE 1 CHECK VACUUM HOSES Vacuum Tank IAC Valve Actuator (a) (b) (c) Air Cleaner Check if the vacuum hose cap is missing. If the hose is damaged, replace the vacuum hose assembly. Check the air and vacuum hoses for looseness, disconnection and blockage. ECM Engine A Cap B VSV Front Engine Mount Insulator C A61613 NG REPAIR OR REPLACE VACUUM HOSES OK 2 CHECK VACUUM (a) (b) (c) (d) A61611 Start the engine. Disconnect the vacuum hose from the vacuum tank. Check that the unconnected port located on the vacuum tank applies suction to your finger. Reconnect the vacuum hose. NG CHECK AND REPLACE VACUUM SOURCE AND HOSES OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 860 05-671 DIAGNOSTICS 3 - SFI SYSTEM (3MZ-FE) INSPECT ECM (ACM VOLTAGE) (a) ACM (+) E1 (-) (b) (c) (d) Connect the oscilloscope between terminals ACM and E1 of the E9 ECM connector. Warm up engine to normal operating temperature. Turn the A/C switch on. Measure the voltage between terminals ACM and E1 of the E9 ECM connector. Result: E9 ECM Condition Voltage Shift position is D range, and engine speed is 850 rpm or less Pulse generation Shift position is D range, and engine speed is 950 rpm or more 9 to 14 V Shift position is P range 9 to 14 V 5 V/ Division GND 10 V/Division A88570 OK Go to step 6 NG 4 INSPECT VSV FOR ACM (RESISTANCE) (a) (b) Disconnect the V5 VSV connector. Measure the resistance between the terminals 1 and 2. Standard: 19 to 21 Ω at 20
C (68
F) V5 VSV for ACM 2 1 C58536 NG REPLACE VSV OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 861 05-672 DIAGNOSTICS 5 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS (VSV FOR ACM - ECM, VSV FOR ACM - EFI RELAY) (a) Wire Harness Side V5 VSV for ACM Check the wire harness between the VSV and ECM. (1) Disconnect the V5 VSV connector for ACM. (2) Disconnect the E9 ECM connector. (3) Check the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition V5-2 - E9-6 (ACM) Below 1 Ω V5-2 or E9-6 (ACM) - Body ground 10 kΩ or higher E9 ECM ACM A87797 (b) Wire Harness Side V5 VSV for ACM Check the wire harness between the VSV and EFI relay. (1) Disconnect the V5 VSV connector. (2) Remove the EFI relay from the engine room J/B. (3) Check the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition V5-1 (VSV for ACM) - J/B EFI relay terminal 3 Below 1 Ω Engine Room J/B EFI Relay A85448 A90291 A92392 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE ECM (See page 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 862 05-673 DIAGNOSTICS 6 - SFI SYSTEM (3MZ-FE) INSPECT VSV FOR ACM (OPERATION) (a) (b) G E F HH G Remove the VSV. Check operation of the VSV when battery positive voltage is applied to the terminals of the VSV connector. OK: Battery positive voltage is not applied: The air from pipe G is flowing out through pipes E and H. Battery positive voltage is applied: The air from pipe F is flowing out through pipes E and H. E F HH A52014 NG REPLACE VSV FOR ACM OK 7 INSPECT TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR (a) (b) (c) (d) A51989 Disconnect the vacuum hose from the front engine mount insulator. Using MITYVAC (hand-held vacuum pump), apply a vacuum of 80 kPa (600 mmHg, 25 in.Hg) and wait for 1 minute. Make sure there is no needle movement on the MITYVAC. Check that there is no fluid leakage caused by a broken lower diaphragm. NG REPLACE TRANSVERSE MOUNTING INSULATOR ENGINE ENGINE OK SYSTEM OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 863 05-371 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EX3-05 BASIC INSPECTION When the malfunction is not confirmed in the DTC check, troubleshooting should be carried out in all the possible circuits considered as possible causes of the problem. In many cases, by carrying out the basic engine check shown in the following flowchart, the problem can be found quickly and efficiently. Therefore, using this check is essential in the engine troubleshooting. 1 CHECK BATTERY VOLTAGE NOTICE: Carry out the battery voltage check with the engine stopped and ignition switch OFF. Voltage NG OK NG 11 V or more Less than 11 V CHARGE OR REPLACE BATTERY OK 2 CHECK IF ENGINE WILL CRANK NG PROCEED TO PROBLEM SYMPTOMS TABLE ON PAGE 05-393 NG Go to step 6 OK 3 CHECK IF ENGINE STARTS OK 4 CHECK AIR FILTER Visually check if the air filter is not contaminated dirty or oily. NG CLEAN OR REPLACE OK 5 CHECK IDLE SPEED (See page 14-121 ) NG PROCEED TO PROBLEM SYMPTOMS TABLE ON PAGE 05-393 OK 6 CHECK FUEL PRESSURE (See page 11-38 ) NG PROCEED TO PAGE 05-393 AND CONTINUE TO TROUBLESHOOT OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 561 05-372 DIAGNOSTICS 7 - SFI SYSTEM (3MZ-FE) CHECK FOR SPARK (See page 18-7 ) NG PROCEED TO PAGE 05-393 AND CONTINUE TO TROUBLESHOOT OK PROCEED TO PROBLEM SYMPTOMS TABLE ON PAGE 05-393 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 562 05-385 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05MOM-01 CHECKING MONITOR STATUS NOTICE: The monitor status (mode 6) is not applicable to the heated oxygen sensor (HO2S). However, HO2S test values can be checked by O2S TEST RESULT (mode 5). Refer to page 05-383 1. Outline The monitor results and the test values can be checked with the OBDII scan tool. The engine control module (ECM) monitors the emissions-related components as the thermostat, catalyst converter and evaporative emissions (EVAP), and determines whether they are functioning normally or not. When finished monitoring, the ECM stores the monitor results and the test values. The monitor result indicates whether the component is functioning normally or not. The test value is the value that was used to determine the monitor result. If the test value is outside the test limit (malfunction criterion), the ECM determines the component is malfunctioning. Some emissions-related components have multiple test values to determine monitor result. If one of these test values is outside test limit, the ECM determines the component is malfunctioning. 2. Description The test value and test limit information are described as shown in the following table. This information is included under ”MONITOR RESULT” in the emissions-related DTC sections: TID $08: Thermostat TLT CID Unit Conversion 1 $01 Multiply by 0.625 and subtract 40 [C]



Description of Test Value Description of Test Limit ECT sensor output when estimated ECT Malfunction criterion for thermostat has reached to malfunction criterion TID (Test Identification Data) is assigned to each emissions-related component. TLT (Test Limit Type): If TLT is 0, the component is malfunctioning when the test value is higher than the test limit. If TLT is 1, the component is malfunctioning when the test value is lower than the test limit. CID (Component Identification Data) is assigned to each test value. Unit Conversion is used to calculate the test value indicated on generic OBDII scan tools. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 575 05-386 DIAGNOSTICS 3. (a) (b) (c) (d) - SFI SYSTEM (3MZ-FE) Procedure (using hand-held tester) Connect the hand-held tester to the DLC3. Turn the ignition switch and hand-held tester ON. Clear DTCs. Allow the vehicle to drive, in accordance with the applicable drive pattern described in the READINESS MONITOR DRIVE PATTERN section (see page 05-387 ). (e) MONITOR RESULT CATALYST#1 B1 . INCMP CATALYST#1 B2 . INCMP O2S HEAT B1S1 . INCMP
O2S HEAT B1S2 . INCMP O2S HEAT B2S1 . INCMP O2S HEAT B2S2 . INCMP THERMOSTAT . . . . . PASS

Press [ENTER] to Select the Label . Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBDII, MONITOR INFO and MONITOR RESULT. The monitor result appears after the component name. INCMP indicates the component has not been monitored yet. PASS indicates the component is functioning normally. FAIL indicates the component is malfunctioning. A82674 (f) Thermostat malfunction VAL. . . . . . . . . . . . . . 119.375C LMT. . . . . . . . . . . . . . . 75.000C


TLT. . . . . . . . . . . . . . . . . . . . . . 1 (g)
[HELP] to notice [EXIT] to return A82675

Select the component and press ENTER. If the monitor result has been PASS or FAIL, the accuracy test value appears. VAL indicates the test value. LMT indicates the test limit (malfunction criterion). TLT indicates the test limit type. Compare the test value with the test limit. If TLT is 0, the component is malfunctioning when the test value is higher than the test limit. If TLT is 1, the component is malfunctioning when the test value is lower than the test limit. If the test value is on the borderline of the test limit, a malfunction is concealed in the component. HINT: The monitor result might on rare occasions be PASS even if the malfunction indicator lamp (MIL) is illuminated. This indicates the system malfunctioned on a previous driving cycle. This might be caused by an intermittent problem. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 576 05-370 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EX2-05 CHECK FOR INTERMITTENT PROBLEMS HINT: Hand-held tester only: Inspect the vehicle’s ECM using check mode. Intermittent problems are easier to detect when the ECM is in check mode with hand-held tester. In check mode, the ECM uses 1 trip detection logic, which has a higher sensitivity to malfunctions than normal mode (default), which uses 2 trip detection logic. (a) Clear the DTCs (see page 05-400 ). (b) Set the check mode (see page 05-402 ). (c) Perform a simulation test (see page 01-26 ). (d) Check the connector and terminal (see page 01-36 ). (e) Wiggle the harness and the connector (see page 01-36 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 560 05-402 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05IQI-02 CHECK MODE PROCEDURE HINT: Hand-held tester only: Check mode has a higher sensitivity to detect malfunctions and can detect malfunctions that normal mode cannot detect. Check mode can also detect all the malfunctions that normal mode can detect. Hand-held Tester DLC3 A80020 1. (a) (b) (c) (d) CHECK MODE PROCEDURE Make sure that the items below are true: (1) Battery positive voltage 11 V or more (2) Throttle valve fully closed (3) Transmission in the P or N position (4) A/C switched OFF Turn the ignition switch OFF. Connect the hand-held tester to the DLC3. Turn the ignition switch ON. (e) 0.13 seconds ON OFF 0.13 seconds A76900 Change the ECM to check mode with the hand-held tester. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / CHECK MODE. Make sure the MIL flashes as shown in the illustration. NOTICE: All DTCs and freeze frame data recorded will be erased if: 1) the hand-held tester is used to change the ECM from normal mode to check mode or vice-versa; or 2) during check mode, the ignition switch is turned from ON to ACC or OFF. (f) Start the engine. The MIL should turn off after the engine starts. (g) Simulate the conditions of the malfunction described by the customer. (h) After simulating the malfunction conditions, use the hand-held tester diagnosis selector to check the DTC, freeze frame data and other data. (i) After checking the DTC, inspect the applicable circuit. 2. CLEAR DTC (Using the OBD II scan tool or hand-held tester) (a) Connect the OBD II scan tool or the hand-held tester to the DLC3. (b) Turn the ignition switch ON. (c) Erase DTCs and freeze frame data with the OBD II scan tool (complying with SAE J1978) or the hand-held tester. For the hand-held tester: 1) enter the following menus: DIAGNOSIS ENHANCED OBD II / DTC INFO / CLEAR CODES; and 2) press YES. For the OBD II scan tool, see its instruction manual. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 592 05-403 DIAGNOSTICS 3. Engine Room J/B (a) EFI NO. 1 Engine Room R/B No. 2 - SFI SYSTEM (3MZ-FE) CLEAR DTC (Not using the OBD II scan tool or handheld tester) Remove the EFI NO. 1 fuse from the engine room J/B and ETCS fuse from the engine room R/B No. 2 for more than 60 seconds.or, disconnect the battery cable for more than 60 seconds. After disconnecting the battery terminal, perform the ”INITIALIZE” procedure (see page 05-1005 ). ETCS A87843 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 593 05-362 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) SFI SYSTEM (3MZ-FE) 05EX0-05 DEFINITION OF TERMS Term Definition Monitor description Description of what the ECM monitors and how it detects malfunctions (monitoring purpose and its details). Related DTCs A group of diagnostic trouble codes that are output by the ECM based on the same malfunction detection logic. Typical enabling condition Preconditions that allow the ECM to detect malfunctions. With all preconditions satisfied, the ECM sets the DTC when the monitored value(s) exceeds the malfunction threshold(s). Sequence of operation The priority order that is applied to monitoring, if multiple sensors and components are used to detect the malfunction. When a sensor is being monitored, the next sensor or component will not be monitored until the current sensor monitoring is finished. Required sensor/components The sensors and components that are used by the ECM to detect malfunctions. Frequency of operation The number of times that the ECM checks for malfunctions per driving cycle. ”Once per driving cycle” means that the ECM detects the malfunction only one time during a single driving cycle. ”Continuous” means that the ECM detects the malfunction every time an enabling condition is met. Duration The minimum time that the ECM must sense a continuous deviation in the monitored value(s) before setting a DTC. This timing begins after the ”typical enabling conditions” are met. Malfunction thresholds Beyond this value, the ECM will conclude that there is a malfunction and set a DTC. MIL operation MIL illumination timing after a defect is detected. ”Immediately” means that the ECM illuminates the MIL the instant the ECM determines that there is a malfunction. ”2 driving cycle” means that the ECM illuminates the MIL if the same malfunction is detected again in the 2nd driving cycle. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 552 05-397 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EX6-05 DIAGNOSIS SYSTEM 1. FI0534 Hand-held Tester DLC3 DESCRIPTION
When troubleshooting On-Board Diagnostic (OBD II) vehicles, the vehicle must be connected to the OBD II scan tool (in compliance with SAE J1978) or the hand-held tester. Various data output from the vehicle’s ECM can then be read.
OBD II regulations require that the vehicle’s on-board computer illuminates the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in: 1) the emission control system / components, or 2) the powertrain control components (which affect vehicle emissions), or 3) the computer. In addition, the applicable Diagnostic Trouble Codes (DTCs) prescribed by SAE J2012 are recorded in the ECM memory (see page 05-412 ). If the malfunction does not reoccur in 3 consecutive trips, the MIL goes off automatically but the DTCs remain recorded in the ECM memory.
A80020
To check DTCs, connect the hand-held tester or OBD II scan tool to the Data Link Connector 3 (DLC3) of the vehicle. The hand-held tester or OBD II scan tool also enables you to erase the DTC and check the freeze frame data and various forms of engine data (see the instruction manual for the OBD II scan tool or the hand-held tester). The DTC includes SAE controlled codes and manufacturer controlled codes. SAE controlled codes must be set according to the SAE, while manufacturer controlled codes can be set by a manufacturer with certain restrictions (see the DTC chart on page 05-412 ). The diagnosis system operates in ”normal mode” during normal vehicle use. In ”normal mode”, 2 trip detection logic* is used to ensure accurate detection of malfunctions. A ”check mode”, is also available to technicians as an option. In ”check mode”, 1 trip detection logic is used for simulating malfunction symptoms and increasing the system’s ability to detect malfunctions, including intermittent malfunctions (hand-held tester only) (see page 05-402 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 587 05-398 DIAGNOSTICS - SFI SYSTEM (3MZ-FE)
*2 trip detection logic: When a malfunction is first detected, the malfunction is temporarily stored in the ECM memory (1st trip). If the ignition switch is turned OFF and then ON again, and the same malfunction is detected again, the MIL will illuminate (2nd trip).
Freeze frame data: The freeze frame data records the engine conditions (fuel system, calculated load, engine coolant temperature, fuel trim, engine speed, vehicle speed, etc.) when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. Priorities for troubleshooting: When multiple DTCs occur, find out the order in which the DTCs should be inspected by checking the component’s DTC chart. If no instructions are written in the DTC chart, check DTCs in the following order of priority: (a) DTCs other than fuel trim malfunction DTCs (P0171, P0172, P0174 and P0175) and misfire DTCs (P0300 to P0306). (b) Fuel trim malfunction DTCs (P0171, P0172, P0174 and P0175). (c) Misfire DTCs (P0300 to P0306). 2. DLC3 CG SG SIL 1 2 3 4 5 6 7 8 9 10 11 12 1314 1516 CHECK DLC3 The vehicle’s ECM uses the ISO 9141-2 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 9141-2 format. BAT A82779 Symbol Terminal No. Name Reference terminal Result Condition SIL 7 Bus ”+” line 5 - Signal ground Pulse generation During transmission CG 4 Chassis ground Body ground 1 Ω or less Always SG 5 Signal ground Body ground 1 Ω or less Always BAT 16 Battery positive Body ground 9 to 14 V Always 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 588 05-399 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) HINT: Connect the cable of the OBD II scan tool or the hand-held tester to the DLC3, turn the ignition switch ON and attempt to use the hand-held tester or the OBD II scan tool. If the screen displays UNABLE TO CONNECT TO VEHICLE, a problem exists in the vehicle side or the tester side.
If the communication is normal when the tool is connected to another vehicle, inspect the DLC3 on the original vehicle.
If the communication is still impossible when the tool is connected to another vehicle, the problem is probably in the tool itself. Consult the Service Department listed in the tool’s instruction manual. 3. CHECK BATTERY VOLTAGE Standard: 11 to 14 V If voltage is below 11 V, recharge the battery before proceeding. 4. CHECK MIL (a) The MIL turns on when the ignition switch is turned ON and the engine is not running. HINT: If the MIL does not turn on, troubleshoot the MIL circuit (see page 05-727 ). (b) When the engine is started, the MIL should not turn off. If the lamp remains on, the diagnosis system has detected a malfunction or abnormality in the system. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 589 05-406 DIAGNOSTICS - SFI SYSTEM (3MZ-FE)(From August, 2004) 05EXA-04 DATA LIST/ACTIVE TEST 1. DATA LIST HINT: Using the hand-held tester DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to shorten labor time. NOTICE: In the table below, the values listed under ”Normal Condition” are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the hand-held tester or the OBD II scan tool to the DLC3. (d) Turn the ignition switch ON. (e) Turn ON the hand-held tester. (f) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST. (g) According to the display on tester, read the ”DATA LIST”. Hand-held Tester Display Measurement Item/Range (Display) Normal Condition * Diagnostic Note INJECTOR Injection period of the No. 1 cylinder/ Minimum: 0 ms, Maximum: 32.64 ms Idling: 1.5 to 2.8 ms  IGN ADVANCE Ignition timing advance for No. 1 cylinder/ Minimum: -64 deg., Maximum: 63.5 deg. Idling: BTDC 5 to 25°  CALC LOAD Calculated load by ECM/ Minimum: 0 %, Maximum: 100 %
Idling: 10.4 to 15.6 %
Running without load (2,500 rpm): 12.1 to 18.2 %  Air flow rate from MAF meter/ Minimum: 0 gm/s, Maximum: 655 gm/s
Idling: 2.0 to 3.7 gm/s
Running without load (2,500 rpm): 2.4 to 4.3 gm/s If value is approximately 0.0 gm/s:
Mass air flow meter power source circuit open
VG circuit open or short If value is 160.0 gm/s or more:
E2G circuit open ENGINE SPD Engine speed/ Minimum: 0 rpm, Maximum: 16,383 rpm Idling: 580 to 750 rpm COOLANT TEMP Coolant temperature/ Minimum: -40C, Maximum: 140C After warming up: 80 to 97°C (176 to 207°F) INTAKE AIR Intake air temperature/ Minimum: -40C, Maximum: 140C Equivalent to ambient temp. (after cold soak) Absolute throttle position sensor/ Minimum: 0 %, Maximum: 100 %
Throttle fully closed: 10 to 24 %
Throttle fully open: 64 to 96 % Closed throttle position switch/ ON or OFF
Throttle fully closed: ON
Throttle open: OFF VEHICLE SPD Vehicle speed/ Minimum: 0 km/h, Maximum: 255 km/h Actual vehicle speed Speed indicated on speedometer ACCEL POS #1 Accelerator pedal position sensor No.1 output voltage/ Minimum: 0 V, Maximum: 5 V
Accelerator pedal released: 0.5 to 1.1 V
Accelerator pedal depressed: 2.6 to 4.5 V Read value with ignition switch ON (do not start engine) MAF THROTTLE POS CTP SW Author
: 
If value is -40C (-40F): sensor circuit is o open en
If value is 140C (284F or more): sensor circuit is shorted Read value with ignition switch ON (do not start engine)  Date
: 596 05-407 DIAGNOSTICS Hand-held Tester Display Measurement Item/Range (Display) - SFI SYSTEM (3MZ-FE)(From August, 2004) Normal Condition * Diagnostic Note ACCEL POS #2 Accelerator pedal position sensor No. 2 output voltage/ Minimum: 0 V, Maximum: 5 V
Accelerator pedal released: 1.2 to 2.0 V
Accelerator pedal depressed: 3.4 to 5.3 V Read value with ignition switch ON (do not start engine) THROTTLE POS #2 Throttle position sensor No. 2 output voltage/ Minimum: 0 V, Maximum: 5 V
Throttle fully closed: 2.1 to 3.1 V
Throttle fully open: 4.5 to 5.5 V Read value with ignition switch ON (do not start engine) THROTTLE TARGT Target position of throttle valve/ Minimum: 0 V, Maximum: 5 V Idling: 0.4 to 1.1 V THROTTLE OPN DUTY Throttle motor opening duty ratio/ Minimum: 0 %, Maximum: 100 %  Throttle fully closed: 0 %
When accelerator pedal is depressed, duty ratio is increased
Read value with ignition switch ON (do not start engine) THROTTLE CLS DUTY Throttle motor closed duty ratio/ Minimum: 0 %, Maximum: 100 % Throttle fully open: 0 %
When accelerator pedal is released quickly, duty ratio is increased
Read the value with ignition switch ON (do not start engine) THROTTLE MOT Whether or not throttle motor control is permitted/ ON or OFF Idling: ON Read value with ignition switch ON (do not start engine) +BM Whether or not electric throttle control system power is inputted/ ON or OFF Idling: ON  ACCEL IDL POS Whether or not accelerator pedal position sensor is detecting idle/ ON or OFF Idling: ON  Whether or not throttle position sensor is detecting idle/ ON or OFF Idling: ON  FAIL #1 Whether or not fail safe function is executed/ ON or OFF ETCS has failed: ON  FAIL #2 Whether or not fail safe function is executed/ ON or OFF ETCS has failed: ON  THROTTLE INITIAL Throttle fully closed (learned value) Minimum: 0 V, Maximum: 5 V 0.5 to 0.9 V  ACCEL LEARN VAL Accelerator fully closed (learned value) Minimum: 0 V, Maximum: 5 V 0.4 to 0.8 V  Throttle motor current Minimum: 0 A, Maximum: 20 A Idling: 0 to 3.0 A  O2S B1 S2 Heated oxygen sensor output voltage for bank 1 sensor 2/ Minimum: 0 V, Maximum: 1.0 V Driving (31 mph, 50 km/h): 0.1 to 0.9 V Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables the technician to check voltage output of each sensor O2S B2 S2 Heated oxygen sensor output voltage for bank 2 sensor 2/ Minimum: 0 V, Maximum: 1.0 V Driving (31 mph, 50 km/h): 0.1 to 0.9 V Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables the technician to check voltage output of each sensor AFS B1 S1 A/F sensor output voltage for bank 1 sensor 1/ Minimum: 0 V, Maximum: 7.999 V Idling 2.8 to 3.8 V Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables the technician to check voltage output of each sensor THROTTLE IDL POS THROTTLE MOT Author
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: 597 05-408 DIAGNOSTICS - SFI SYSTEM (3MZ-FE)(From August, 2004) Hand-held Tester Display Measurement Item/Range (Display) AFS B2 S1 A/F sensor output voltage for bank 2 sensor 1/ Minimum: 0 V, Maximum: 7.999 V Idling 2.8 to 3.8 V Performing INJ VOL or A/F CONTROL function of ACTIVE TEST enables the technician to check voltage output of each sensor VAPOR PRESS Vapor Pressure/ Minimum: -4.125 kPa, Maximum: 2.125 kPa Fuel tank cap removed: 0 kPa Pressure inside of fuel tank as read by the vapor pressure sensor SHORT FT #1 Short term fuel trim of bank 1/ Minimum: -100 %, Maximum: 100 % 0 ± 20 % This item is short-term fuel compensation used to maintain air-fuel ratio at stoichiometric air-fuel ratio This item is overall, long-term fuel compensation that helps to maintain air-fuel ratio at stoichiometric air-fuel ratio (steadies long term deviations of short-term fuel trim from central value) Normal Condition * Diagnostic Note LONG FT #1 Long term fuel trim of bank 1/ Minimum: -100 %, Maximum: 100 % 0 ± 20 % TOTAL FT #1 Total fuel trim of bank 1: Average value for fuel trim system of bank 1/ Minimum: 0.5, Maximum: 1.496 Idling: 0.5 to 1.4 SHORT FT #2 Short term fuel trim of bank 2/ Minimum: -100 %, Maximum: 100 % 0 ± 20 % This item is short-term fuel compensation used to maintain air-fuel ratio at stoichiometric air-fuel ratio This item is overall, long-term fuel compensation that helps to maintain air-fuel ratio at stoichiometric air-fuel ratio (steadies long term deviation of short-term fuel trim from central value)  LONG FT #2 Long term fuel trim of bank 2/ Minimum: -100 %, Maximum: 100 % 0 ± 20 % TOTAL FT #2 Total fuel trim of bank 2: Average value for fuel trim system of bank 2/ Minimum: 0.5, Maximum: 1.496 Idling: 0.5 to 1.4 O2FT B1 S2 Short term fuel trim associated with the bank 1 sensor 2/ Minimum: -100 %, Maximum: 100 % 0 ± 20 % Same as SHORT FT #1 O2FT B2 S2 Short term fuel trim associated with the bank 2 sensor 2/ Minimum: -100 %, Maximum: 100 % 0 ± 20 % Same as SHORT FT #2 AF FT B1 S1 Short term fuel trim associated with bank 1 sensor 1/ Minimum: 0, Maximum: 1.999
Value less than 1 (0.000 to 0.999) = Lean
Stoichiometric air-fuel ratio = 1
Value greater than 1 (1.001 to 1.999) = Rich  AF FT B2 S1 Short term fuel trim associated with bank 2 sensor 1/ Minimum: 0, Maximum: 1.999
Lean: 0
AF FT B2 S1 < 1
Stoichiometric air-fuel ratio = 1
Rich: 1
AF FT B2 S1< 1.999  Author
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: 598 05-409 DIAGNOSTICS Hand-held Tester Display Measurement Item/Range (Display) - SFI SYSTEM (3MZ-FE)(From August, 2004) Normal Condition * Diagnostic Note Idling after warming up: CL
OL (Open Loop): Has not yet satisfied conditions to go closed loop
CL (Closed Loop): Using heated oxygen sensor(s) as feed back for fuel control
OL DRIVE: Open loop due to driving conditions (fuel enrichment)
OL FAULT: Open loop due to detected system fault
CL FAULT: Closed loop but one of heated oxygen sensors, which is used for fuel control, is malfunctioning Fuel system status (Bank 2) / OL or CL or OL DRIVE or OL FAULT or CL FAULT Idling after warming up: CL
OL (Open Loop): Has not yet satisfied conditions to go closed loop
CL (Closed Loop): Using heated oxygen sensor(s) as feed back for fuel control
OL DRIVE: Open loop due to driving conditions (fuel enrichment)
OL FAULT: Open loop due to detected system fault
CL FAULT: Closed loop but one of heated oxygen sensors, which is used for fuel control, is malfunctioning Fuel cut idle/ ON or OFF Fuel cut operation: ON FC IDL = ON when throttle valve is fully closed and engine speed is over 1,500 rpm MIL status/ ON or OFF MIL ON: ON  Starter signal/ ON or OFF Cranking: ON  A/C signal/ ON or OFF A/C ON: ON  PNP switch signal/ ON or OFF P or N position: ON  ELECT LOAD SIG Electrical load signal/ ON or OFF
Taillamp switch ON: ON
Defogger switch ON: ON  STOP LIGHT SW Stop light switch/ ON or OFF
Brake pedal depressed: ON
Brake pedal released: OFF  Power steering oil pressure switch signal/ ON or OFF
While turning the steering wheel: ON
While not turning the steering wheel: OFF Idle-up control is performed when PS is ON Power steering signal/ ON or OFF When steering wheel is turned This signal is usually ON until the Ignition switch is turned OFF FUEL SYS #1 FUEL SYS #2 FC IDL MIL STARTER SIG A/C SIG PNP SW [NSW] PS OIL PRESS SW PS SIGNAL Fuel system status (Bank 1) / OL or CL or OL DRIVE or OL FAULT or CL FAULT INTAKE CTL VSV1 VSV status for intake control (bank VSV operation: ON 1)/ ON or OFF  INTAKE CTL VSV 2 VSV status for intake control (bank VSV operation: ON 2)/ ON or OFF  FUEL PUMP / SPD Fuel pump/speed status/ ON/H or OFF/M, L Idling: ON  A/C MAG CLUTCH A/C magnet clutch status/ ON or OFF A/C magnet clutch ON: ON  Author
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: 599 05-410 DIAGNOSTICS Hand-held Tester Display - SFI SYSTEM (3MZ-FE)(From August, 2004) Measurement Item/Range (Display) Normal Condition * Diagnostic Note EVAP VSV VSV status for EVAP control/ ON or OFF VSV operating: ON BOOST PRESS VSV VSV status for boost pressure control/ ON or OFF VSV operating: ON  Ignition counter/ Minimum: 0, Maximum: 600 0 to 600  Misfire ratio of cylinder 1 to 6/ Minimum: 0 %, Maximum: 50 % 0% MISFIRE LOAD Engine load for first misfire range/ Minimum: 0 g/rev, Maximum: 3.98 g/rev. Misfire 0: 0 g/rev.  MISFIRE RPM Engine RPM for first misfire range/ Minimum: 0 rpm, Maximum: 6,375 rpm Misfire 0: 0 rpm  FC TAU Fuel Cut TAU: Fuel cut during very light load/ ON or OFF Fuel cut operating: ON Fuel cut is being performed under very light load to prevent engine combustion from becoming incomplete Check mode/ ON or OFF Check mode ON: ON See step 3 IGNITION CYL #1, #2, #3, #4, #5, #6 CHECK MODE EVAP VSV is controlled by the ECM (ground side duty control) This item is displayed in only idling HINT: *: If no conditions are specifically stated for ”ldling”, the shift lever is in the N or P position, the A/C switch is OFF and all accessory switches are OFF. 2. ACTIVE TEST HINT: Performing the hand-held tester ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to shorten labor time. The DATA LIST can be displayed during the ACTIVE TEST. (a) Warm up the engine. (b) Turn the ignition switch OFF. (c) Connect the hand-held tester or the OBD II scan tool to the DLC3. (d) Turn the ignition switch ON. (e) Turn ON the hand-held tester or the OBD II scan tool. (f) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST. (g) According to the display on tester, perform the ”ACTIVE TEST”. Hand-held Tester Display INJ VOL A/F CONTROL Test Details Diagnostic Note [Test Details] Control injection volume Minimum: -12.5 %, Maximum: 25 % [Vehicle Condition] Engine speed: 3,000 rpm or less
All injectors are tested at once
Injection volume is gradually changed between -12.5 and 25 % [Test Details] Control injection volume -12.5 or 25 % (change injection volume -12.5 % or 25 %) [Vehicle Condition] Engine speed: 3,000 rpm or less Following A/F CONTROL procedure enables technician to check and graph voltage outputs of both the A/F sensor and heated oxygen sensor For displaying graph, enter ”ACTIVE TEST / A/F CONTROL / USER DATA”, select ”AFS B1S1 and O2S B1S2” by pressing ”YES” and push ”ENTER”. Then press ”F4” Author
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: 600 05-41 1 DIAGNOSTICS Hand-held Tester Display - SFI SYSTEM (3MZ-FE)(From August, 2004) Test Details Diagnostic Note [Test Details] Activate VSV for intake control ON or OFF  [Test Details] Activate VSV for canister control ON or OFF  EVAP VSV (ALONE) [Test Details] Activate EVAP VSV control ON or OFF  A/C MAG CLUTCH [Test Details] Control A/C magnet clutch ON or OFF  FUEL PUMP / SPD [Test Details] Control the fuel pump ON or OFF  INTAKE CTL VSV1 CAN CTRL VSV VVT CTRL B1 [Test Details] Active VVT system (bank 1) ON or OFF
ON: Rough idle or engine stall
OFF: Normal engine speed VVT CTRL B2 [Test Details] Active VVT system (bank 2) ON or OFF
ON: Rough idle or engine stall
OFF: Normal engine speed ACM INHIBIT [Test Details] Control ACM inhibit ON or OFF  [Test Details] Connect TC and TE1 ON or OFF  [Test Details] Control idle fuel cut prohibit ON or OFF  TC/TE1 FC IDL PROHBT Author
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: 601 05-400 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EX7-05 DTC CHECK/CLEAR NOTICE:
If no DTC appears in normal mode: On the OBD II scan tool or the hand-held tester, check the pending fault code using the Continuous Test Results function (Mode 7 for SAE J1979).
When the diagnosis system is changed from normal mode to check mode or vice-versa, all DTCs and freeze frame data recorded in normal mode will be erased. Before changing modes, always check and make a note of DTCs and freeze frame data. Hand-held Tester DLC3 A80020 1. CHECK DTC (Using the OBD II scan tool or hand-held tester) (a) Connect the OBD II scan tool or hand-held tester to the DLC3. (b) Turn the ignition switch ON. (c) Use the OBD II scan tool or the hand-held tester to check the DTCs and freeze frame data and then write them down. For the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CURRENT CODEDS. For the OBD II scan tool, see its instruction manual. (d) See page 05-412 to confirm the details of the DTCs. NOTICE:
When simulating a symptom with the OBD II scan tool (excluding hand-held tester) to check the DTCs, use the normal mode. For DTCs subject to ”2 trip detection logic”, perform either of the following actions.
Turn the ignition switch OFF after the symptom is simulated once. Then repeat the simulation process again. When the problem has been simulated again, the MIL illuminates and the DTCs are recorded in the ECM.
Check the pending fault code using the Continuous Test Results function (Mode 7 for SAE J1979) on the OBD II scan tool. 2. CLEAR DTC (Using the OBD II scan tool or hand-held tester) (a) Connect the OBD II scan tool or the hand-held tester to the DLC3. (b) Turn the ignition switch ON. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 590 05-401 DIAGNOSTICS SFI SYSTEM (3MZ-FE) (c) Erase DTCs and freeze frame data with the OBD II scan tool (complying with SAE J1978) or the hand-held tester For the hand-held tester: 1) enter the following menus: DIAGNOSIS / ENHANCED OBD II / DTC INFO / CLEAR CODES; and 2) press YES. For the OBD II scan tool, see its instruction manual. 3. CLEAR DTC (Not using OBD II scan tool or hand-held tester) Remove the EFI NO. 1 fuse from the engine room J/B and ETCS fuse from the engine room R/B No. 2 for more than 60 seconds, or disconnect the battery cable for more than 60 seconds. After disconnecting the battery terminal, perform the ”INITIALIZE” procedure (see page 05-1005 ). Engine Room J/B (a) EFI NO. 1 Engine Room R/B No. 2 - ETCS A87843 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 591 05-674 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EXJ-05 ECM POWER SOURCE CIRCUIT CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery voltage is applied to terminal IGSW of the ECM. The ECM ”MREL” output signal causes current to flow to the coil, closing the contacts of the EFI main relay (Marking: EFI) and supplying power to terminal +B of the ECM. If the ignition switch is turned OFF, the ECM holds the EFI main relay ON for a maximum of 2 seconds to allow for the initial setting of the throttle valve. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 864 05-675 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) WIRING DIAGRAM ECM I15 Ignition Switch Instrument Panel J/B Assy 1 1C GR 7 AM2 IG2 6 IGN Y 6 1G 10 IK2 W Passenger Side J/B W 4 4M 1 4E J3 J/C P E W 1 IC1 Engine Room J/B P E 9 IGSW E5 W 2 E5 +B2 W 1 +B E5 2B 4 EFI Relay L-Y 3 1 5 2 5 2B P-L 13 IK3 8 E5 B MREL 1 E7 E1 EFI NO. 1 2I 1 4 2F W 10 3 AM2 BR F7 FL Block Assy W-B 1 W A A J2 J/C FL Main J7 J/C A BR Battery EH ED A94485 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 865 05-676 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) INSPECTION PROCEDURE 1 INSPECT ECM (+B VOLTAGE) E1 (-) (a) (b) +B (+) E9 ECM E5 ECM Turn the ignition switch ON. Measure the voltage of the ECM connectors. Standard: OK A67446 Tester Connection Specified Condition E5-1 (+B) - E9-1 (E1) 9 to 14 V PROCEED TO NEXT CIRCUIT INSPECTION SHOWN ON PROBLEM SYMPTOMS TABLE (See page 05-393 ) NG 2 CHECK WIRE HARNESS (ECM - BODY GROUND) (a) (b) E9 ECM Disconnect the E9 ECM connector. Check the resistance of the wire harness side connectors. Standard: E1 A81698 NG Tester Connection Specified Condition E9-1 (E1) - Body ground Below 1 Ω REPAIR OR CONNECTOR REPLACE HARNESS AND OK 3 INSPECT ECM (IGSW VOLTAGE) E1 (-) E9 ECM IGSW (+) (a) (b) Turn the ignition switch ON. Check the voltage of the ECM connectors. Standard: Tester Connection Specified Condition E5-9 (IGSW) - E9-1 (E1) 9 to 14 V E5 ECM A67446 OK Go to step 6 NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 866 05-677 DIAGNOSTICS 4 - SFI SYSTEM (3MZ-FE) CHECK FUSE (IGN) (a) (b) Instrument Panel J/B Assy Remove the IGN fuse from the instrument panel J/B assy. Check the resistance of the IGN fuse. Standard: Below 1 Ω IGN Fuse A90344 NG REPLACE FUSE OK 5 INSPECT IGNITION OR STARTER SWITCH ASSY (a) IG1 AM1 ACC I15 Ignition Switch ST2 4 3 2 1 8 7 6 5 AM2 ST1 IG2 A56879 Check the resistance of the switch terminals shown in the chart below. Standard: Switch Condition Tester Connection Specified Condition LOCK 6 (IG2) - 7 (AM2) 10 kΩ or higher START 6 (IG2) - 7 (AM2) Below 1 Ω NG REPLACE IGNITION OR STARTER SWITCH ASSY OK CHECK AND REPAIR HARNESS AND CONNECTOR (BATTERY - IGNITION SWITCH, IGNITION SWITCH - ECM) 6 INSPECT ECM (MREL VOLTAGE) E1 (-) E9 ECM MREL (+) (a) (b) Turn the ignition switch ON. Measure the voltage of the ECM connectors. Standard: Tester Connection Specified Condition E5-8 (MREL) - E9-1 (E1) 9 to 14 V E5 ECM A67446 NG REPLACE ECM (See page 10-24 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 867 05-678 DIAGNOSTICS 7 (a) (b) - SFI SYSTEM (3MZ-FE) CHECK FUSE (EFI NO. 1) Remove the EFI NO. 1 fuse from the engine room J/B. Check the resistance of the EFI NO. 1 fuse. Standard: Below 1 Ω NG REPLACE FUSE OK 8 INSPECT RELAY (EFI) 1 3 (a) (b) 2 5 5 2 Remove the EFI relay from the engine room J/B. Check the resistance of the EFI relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 1 3 B60778 NG REPLACE RELAY OK 9 CHECK WIRE HARNESS (EFI RELAY - ECM, EFI RELAY - BODY GROUND) (a) Engine Room J/B EFI Relay (b) E5 ECM Check the wire harness between the EFI relay and ECM. (1) Remove the EFI relay from the engine room J/B. (2) Disconnect the E5 ECM connector. (3) Check the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition J/B EFI relay terminal 1 - E5-8 (MREL) Below 1 Ω J/B EFI relay terminal 1 or E5-8 (MREL) - Body ground 10 kΩ or higher Check the wire harness between the EFI relay and body ground. (1) Remove the EFI relay from the engine room J/B. (2) Check the resistance between the wire harness side connector and body ground. Standard: MREL A90291 A67445 A92393 OK Tester Connection Specified Condition J/B EFI relay terminal 2 - Body ground Below 1 Ω REPAIR OR CONNECTOR REPLACE HARNESS AND NG CHECK AND REPAIR HARNESS AND CONNECTOR (TERMINAL +B OF ECM - BATTERY POSITIVE TERMINAL) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 868 05-679 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05MOT-01 EVAP INSPECTION PROCEDURE CIRCUIT DESCRIPTION When predetermined conditions (closed loop, etc.) are met, the EVAP VSV is opened and stored fuel vapor in the canister is purged to the intake manifold. The ECM changes duty-cycle to the EVAP VSV to control purge flow volume. Purge flow volume is determined by the intake manifold pressure. Atmospheric pressure is allowed into the canister through the vent valve (CCV) to ensure that purge flow is maintained when negative pressure (vacuum) is applied to the canister. This EVAP system contains following components: Components Components Operation Canister Contains activated charcoal to absorb EVAP that is created in fuel tank. EVAP VSV Opens or closes line between canister and intake manifold to control EVAP purge flow. EVAP VSV is opened and purges fuel vapor absorbed by canister to intake manifold. ECM changes duty-cycle of purge VSV to control purge volume (ON is open, OFF is closed). Refueling Valve Controls EVAP pressure from fuel tank to canister. Valve has diaphragm, spring and restrictor. When fuel tank pressure increase, valve opens. When EVAP is purging, valve closes and restrictor prevents strong of vacuum from affecting pressure in fuel tank. When valve opens, refueling is possible. Service Port Used for connecting vacuum gauge for inspecting EVAP system. Vent Valve (CCV) Vents and seals EVAP system. When CCV is turned ON, EVAP system is closed. When CCV is turned OFF, EVAP system is vented. When vacuum introduction, EVAP VSV is opened and CCV is closed. Fuel Tank Pressure (FTP) Sensor Indicates pressure as voltage. 5 V is supplied by ECM. ECM detects EVAP system pressure using this voltage. Diagram Fuel Tank Pressure (FTP) Sensor ECM To Intake Manifold Canister EVAP VSV EVAP Service Port CCV (Vent Valve) Canister Filter A85820 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 869 05-680 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) MONITOR DESCRIPTION The EVAP monitor’s purpose is to check for EVAP leaks and EVAP VSV and CCV malfunctions. The monitor performs the check by first introducing the intake manifold’s negative pressure (vacuum) to the EVAP system. Then, the monitor records change in the EVAP system’s pressure levels. The monitor runs when the following conditions are met:  The engine coolant and intake air temperatures are 4 to 35C (40 to 90F).  The engine is idling or the vehicle is being driven at a steady speed.  The fuel tank pressure is stabilized. LEVII EVAP Monitor Process : Negative Pressure 1. Fuel Vapor Measurement 3. EVAP Leak Check EVAP VSV: OFF (Closed) EVAP VSV: OFF (Closed) FTP Sensor FTP Sensor Fuel Tank To Intake Manifold CCV: ON (Closed) Canister Fuel Tank To Intake Manifold CCV: ON (Closed) Canister 2. Vacuum Introduction 4. Restore EVAP VSV: OFF (Closed) EVAP VSV: ON (Open) FTP Sensor Fuel Tank To Intake Manifold CCV: ON (Closed) Canister FTP Sensor Fuel Tank To Intake Manifold Canister CCV: OFF (Open) A96702 Sequence Operation Description 1 Fuel vapor measurement EVAP VSV is turned OFF (closed) and EVAP pressure is measured. If EVAP pressure is not stable, EVAP monitor is canceled to prevent inaccurate monitor. 2 Vacuum introduction EVAP VSV is turned ON (open) and CCV is turned ON (closed). As a result, intake manifold pressure (vacuum) is introduced to EVAP system. 3 EVAP leak check EVAP VSV is turned OFF (closed) to seal EVAP system. EVAP pressure increase is measured for 5 seconds when EVAP pressure is -20 mmHg and -17 mmHg. If increase is large, ECM concludes EVAP system has leak. 4 Restore CCV is turned OFF (open) to finish EVAP monitor. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 870 05-681 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) LEV II EVAP Monitor Sequence Sequence Step 1 CCV (Vent Valve) ON OFF EVAP VSV ON OFF Step 2 Step 3 Step 4 Step 5 Step 6 CLOSE OPEN 30 sec. OPEN 15 sec. 30 sec. 300 sec. Atmospheric Pressure (CCV Stuck Closed) (Air Inlet Line Restriction) (CCV Stuck Open) (Medium Leak) (Medium Leak) (Small Leak) (Large Leak) (Purge Line Restriction) (CCV Stuck Open) (EVAP VSV Stuck Closed) Normal Fuel Tank Pressure A85206 Related DTCs DTCs Monitoring Item P0441 EVAP VSV stuck closed EVAP VSV stuck open P0442 EVAP small leak (0.04 inch) P0446 Vent valve (CCV) stuck closed CCV stuck open P0451 Fuel tank pressure (FTP) sensor malfunction P0452 FTP sensor low output P0453 FTP sensor high output P0455 EVAP gross leak P0456 EVAP small leak (0.02 inch) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 871 05-682 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) WIRING DIAGRAM V11 Vapor Pressure Sensor 1 G-R BI1 GND 1 3 BI1 BR VCC 3 17 BR BJ1 BR PTNK 2 16 BJ1 L 2 BI1 B 15 BR IO1 Y 12 BR IM1 L 7 IO1 12 BJ1 Y Short Connector 5 5 BR S28 S29 EFI NO. 2 2 1 Y B-W 1 EB1 Y 3 IO1 Engine Room R/B No. 2 2 13 IM1 P B-R B-R EFI Relay 1 5 1 34 PRG E7 L 27 CCV E7 2 14 IM1 IM1 GR SB 5 16 IO1 5 IO1 R V 2 PTNK G B-R 3 18 VC E7 21 E5 L Engine Room J/B 5 2B 28 E2 E7 V4 EVAP VSV 2 3 2D ECM P-L EFI NO. 1 18 BJ1 V14 CCV R 1 2I 4 2F F7 FL Block Assy 1 B 2 W 3 W-B 14 BJ1 1 13 IK3 B 8 E5 MREL A W J2 J/C Main Battery EH A88695 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 872 05-683 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) INSPECTION PROCEDURE HINT: Read freeze frame data. Freeze frame data records engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0441, P0442, P0446 AND/OR P0456) Result Display (DTC output) Proceed to Only P0441, P0442, P0446 and /or P0456 are output A P0451, P0452 and P453 are output B HINT: If any other DTCs besides P0441, P0442, P0446 and/or P0456 are output, perform the troubleshooting for those DTCs first (reference: P0451, P0452, P0453 are vapor pressure sensor malfunctions). B Go to RELEVANT DTC CHART (See page 05-412 ) A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 873 05-684 DIAGNOSTICS 2 - SFI SYSTEM (3MZ-FE) CHECK CURRENT AND PENDING DTC (a) Check current DTCs. Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBDII, DTC INFO and CURRENT DTCS. (b) Check pending DTCs. Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBDII, DTC INFO and PENDING DTCS. Result Current DTC Pending DTC Set Set Set - - Set Conclusion System has been malfunctioning. Problem can be specified. System was malfunctioning in previous driving cycle. Problem may be specified. System is malfunctioning. This is intermittent problem and caused by fuel tank cap loosening. Otherwise, this problem may be difficult to eliminate. HINT: The ECM stores the current DTC and illuminates the MIL when an emission-related component is malfunctioning in 2 consecutive driving cycles (2 trips). The MIL is turned OFF, if the component is functioning normally in 3 consecutive driving cycles. The ECM erases the current DTC, if the component is functioning normally in 40 consecutive driving cycles. The ECM stores the pending DTC when If the component is malfunctioning in present driving cycle (1 trip). The ECM erases the pending DTC, if the component is functioning normally in the next driving cycle. NEXT 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 874 05-685 DIAGNOSTICS 3 - SFI SYSTEM (3MZ-FE) PREDICT POSSIBLE MALFUNCTION AREA Predict possible malfunction area using the matrix below. EVAP DTC Matrix DTCs Malfunction Area P0441 EVAP VSV stuck closed
EVAP VSV stuck open
P0442 P0446 P0451 P0452 P0453
P0455 P0456

EVAP small leak (0.04 inch)
CCV stuck closed
CCV stuck open


FTP sensor malfunction
FTP sensor low output
FTP sensor high output
Gross leak

EVAP small leak (0.02 inch) DTCs
Suspected Malfunction Area P0441 only EVAP VSV stuck open P0446 only CCV (vent valve) stuck open P0442 and/or P0456 Small leak NEXT 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 875 05-686 DIAGNOSTICS 4 - SFI SYSTEM (3MZ-FE) PERFORM EVAP SYSTEM CHECK NOTICE: The EVAP system check can be used for confirmation after the EVAP system repair. Check DTCs after performing the EVAP system check. If no pending DTC is set, the EVAP system is functioning normally and the repair is complete. (a) Select the ”mmHg” unit. Select the hand-held tester menus: DIAGNOSIS, SETUP, UNIT CONVERSION and VAPOR PRESS. (b) Allow the engine to idle. (c) Perform the EVAP system check to find a malfunction area. Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBD ll, SYSTEM CHECK and LEV ll SYS CHECK. (d) Read NOTICE and press ENTER. HINT: The EVAP system check is most accurate when the following conditions are being set:  Atmospheric pressure is 762 mmHg (sea level).  The engine coolant and intake air temperatures are 4 to 35C (40 to 90F).  The fuel tank level is 1/4 to 3/4. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 876 05-687 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) Diagram of LEVII EVAP System Check Sequence Step 1 CCV (Vent Valve) ON OFF EVAP VSV ON OFF Step 2 Step 3 Step 4 Step 5 Step 6 CLOSE OPEN 30 sec. OPEN 15 sec. 30 sec. 300 sec. Atmospheric Pressure (CCV Stuck Closed) (Air Inlet Line Restriction) (CCV Stuck Open) (Medium Leak) (Medium Leak) (Small Leak) (Large Leak) (Purge Line Restriction) (CCV Stuck Open) (EVAP VSV Stuck Closed) Normal Fuel Tank Pressure A85206 NEXT 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 877 05-688 DIAGNOSTICS 5 - SFI SYSTEM (3MZ-FE) EVAP SYSTEM CHECK STEP 1 (INITIALIZE SYSTEM) Step 1. Initialize System EVAP Pressure Change during System Check Sequence EVAP VSV EVAP VSV Step 1 Close FTP Sensor CCV Open To Intake Manifold Positive VAPOR PRESS Fuel Tank Negative CCV (Vent Valve) Canister A97018 Wait for 30 seconds. A96682 NEXT 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 878 05-689 DIAGNOSTICS 6 - SFI SYSTEM (3MZ-FE) EVAP SYSTEM CHECK STEP 2 (CHECK FOR CCV) Step 2. Check for CCV EVAP VSV To Intake Manifold EVAP Pressure Change during System Check Sequence Step 2 EVAP VSV Open CCV Open FTP Sensor Normal VAPOR PRESS Fuel Tank Positive Negative CCV (Vent Valve) Canister CCV Stuck Closed A97019 (a) (b) Press RIGHT to go to step 2. Wait for 30 seconds and check VAPOR PRESS (EVAP pressure). A96683 Result VAPOR PRESS Conclusion Proceed to Higher than 752 mmHg-a (-10 mmHg-g) Trouble area has not been found yet. OK Lower than 752 mmHg-a (-10 mmHg-g) Following problems are suspected:  Air inlet line restriction  Canister filter restriction  CCV (vent valve) stuck closed NG HINT: In this step, the intake manifold pressure (vacuum) is applied to the EVAP system. However, the fuel tank pressure does not drop due to the CCV (vent valve) open. NG Go to step 11 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 879 05-690 DIAGNOSTICS 7 - SFI SYSTEM (3MZ-FE) EVAP SYSTEM CHECK STEP 3 (INITIALIZE SYSTEM) Step 3. Initialize System EVAP VSV To Intake Manifold EVAP Pressure Change during System Check FTP Sensor Sequence Step 3 EVAP VSV Close CCV Open Positive Negative VAPOR PRESS Fuel Tank CCV (Vent Valve) Canister A97020 (a) (b) Press RIGHT to go to step 3. Wait for 30 seconds. A96684 NEXT 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 880 05-691 DIAGNOSTICS 8 - SFI SYSTEM (3MZ-FE) EVAP SYSTEM CHECK STEP 4 (CHECK FOR EVAP VSV STUCK OPEN) Step 4. Check for EVAP VSV EVAP VSV To Intake Manifold EVAP Pressure Change during System Check Sequence Step 4 EVAP VSV Close CCV Close FTP Sensor Normal VAPOR PRESS Fuel Tank Positive Negative CCV (Vent Valve) Canister EVAP VSV Stuck Open A97021 (a) (b) Press RIGHT to go to step 4. Wait for 15 seconds and check VAPOR PRESS (EVAP pressure). A96685 Result VAPOR PRESS Conclusion Proceed to Higher than 758 mmHg-a (-4 mmHg-g) Trouble area has not been found yet. OK Lower than 758 mmHg-a (-4 mmHg-g) EVAP VSV stuck open NG NG Go to step 14 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 881 05-692 DIAGNOSTICS 9 - SFI SYSTEM (3MZ-FE) EVAP SYSTEM CHECK STEP 5 (APPLYING VACUUM) Step 5. Applying Vacuum EVAP VSV To Intake Manifold EVAP Pressure Change during System Check Sequence Step 5 EVAP VSV Open CCV Close FTP Sensor Positive Negative VAPOR PRESS Fuel Tank Fuel tank cap loosening CCV (Vent Valve) Gross leak Purge line blockage Canister EVAP VSV stuck closed CCV (vent valve) stuck closed Normal Medium Leak A97022 (a) (b) Press RIGHT to go to step 5. Wait for 30 seconds and check VAPOR PRESS (EVAP pressure). A96686 Result VAPOR PRESS Conclusion Proceed to Lower than 748 mmHg-a (-14 mmHg-g) Trouble area has not been found yet. A 756 to 768 mmHg-a (-6 to 6 mmHg-g) Following problems are suspected:  Fuel tank cap loosening  Gross leak  EVAP VSV stuck closed  CCV (vent valve) stuck open  Purge line blockage between fuel tank and canister B 748 to 755 mmHg-a (-14 to -7 mmHg-g) Medium leak C 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 882 05-693 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) NOTICE:  If the pressure is lower than 740 mmHg- a (- 22 mmHg-g), the hand-held tester closes the EVAP VSV. A96687  If the pressure is lower than 735 mmHg- a (- 27 mmHg-g), the hand-held tester cancels the EVAP system check. A85481 B Go to step 15 C Go to step 18 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 883 05-694 DIAGNOSTICS 10 - SFI SYSTEM (3MZ-FE) EVAP SYSTEM CHECK STEP 6 (LEAK CHECK FOR EVAP SYSTEM) Step 6. Leak Check for EVAP System EVAP Pressure Change during System Check EVAP VSV To Intake Manifold FTP Sensor Sequence Step 6 EVAP VSV Close CCV Close VAPOR PRESS Fuel Tank Positive Negative Medium leak CCV (Vent Valve) Canister Small Leak Normal A97023 (a) (b) Press RIGHT to go to step 6 when the VAPOR PRESS (EVAP pressure) is lower than 742 mmHg-a (-20 mmHgg). Wait for 300 seconds and check VAPOR PRESS (EVAP pressure). A96688 Result VAPOR PRESS Conclusion Proceed to Less than 758 mmHg-a (-4 mmHg-g) EVAP system is functioning normally. OK Higher than 758 mmHg-a (-4 mmHg-g) Leakage NG NG Go to step 18 OK Go to step 40 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 884 05-695 DIAGNOSTICS 11 - SFI SYSTEM (3MZ-FE) CHECK CCV CCV (Vent Valve) (a) (b) (c) (d) Canister Turn the ignition switch OFF. Turn the ignition switch ON. Switch the CCV (vent valve) using the hand-held tester. Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBD ll, ACTIVE TEST and CAN CTRL VSV. Touch the CCV and check the operation during switching the CCV. A96691 Result CCV (Vent Valve) Conclusion Proceed to CCV is operated CCV is functioning normally. OK CCV is not operated CCV is malfunctioning. NG NG Go to step 25 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 885 05-696 DIAGNOSTICS 12 - SFI SYSTEM (3MZ-FE) CHECK AIR INLET LINE RESTRICTION Canister (a) (b) Canister Filter CCV Disconnect the air inlet line from the CCV. Remove and reinstall the fuel tank cap to release the fuel tank pressure. Allow the engine to idle. (c) A96690 (d) (e) Perform step 2 of the EVAP system check. Wait for 30 seconds and check VAPOR PRESS (EVAP pressure). A96683 Result VAPOR PRESS Conclusion Proceed to Higher than 752 mmHg-a (-10 mmHg-g) Blockage in canister filter A Lower than 752 mmHg-a (-10 mmHg-g) Blockage in CCV (vent valve) or canister B (f) Reconnect the air inlet line to the CCV. B Go to step 13 A REPLACE CANISTER FILTER 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 886 05-697 DIAGNOSTICS 13 - SFI SYSTEM (3MZ-FE) CHECK CANISTER BLOCKAGE Canister Filter CCV Canister (a) (b) (c) Turn the ignition switch OFF. Remove the CCV from the canister. Remove and reinstall the fuel tank cap to release the fuel tank pressure. Allow the engine to idle. (d) A96690 (e) (f) Perform step 2 of the EVAP system check. Wait for 30 seconds and check VAPOR PRESS (EVAP pressure). A96683 Result VAPOR PRESS Conclusion Proceed to Higher than 752 mmHg-a (-10 mmHg-g) CCV (vent valve) stuck closed A Lower than 752 mmHg-a (-10 mmHg-g) Blockage in canister B B CHECK AND REPLACE CHARCOAL CANISTER (See page 12-28 ) A REPLACE CCV (VENT VALVE) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 887 05-698 DIAGNOSTICS 14 - SFI SYSTEM (3MZ-FE) CHECK EVAP VSV (FOR EVAP VSV STUCK OPEN) Engine : Idling Disconnect OK Stuck Open (a) (b) Turn the ignition switch OFF. Disconnect the purge hose of the canister from the EVAP VSV. Disconnect the EVAP VSV connector. Allow the engine to idle. Touch the EVAP VSV port to check the vacuum. (c) (d) (e) No Vacuum Vacuum A86478 Result EVAP VSV Conclusion Proceed to Vacuum is applied. EVAP VSV is malfunctioning. A No vacuum is applied. Electrical circuit of EVAP VSV is malfunctioning. B B Go to step 29 A REPLACE EVAP VSV 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 888 05-699 DIAGNOSTICS 15 - SFI SYSTEM (3MZ-FE) CHECK FUEL TANK CAP (a) (b) (c) Remove the fuel tank cap and reinstall it until a few click sound is heard. Clear the DTCs. Check pending DTCs after the EVAP system check If no pending DTC is set, the DTC(s) was set due to the fuel cap loosening. If necessary, replace the fuel cap. NG Go to step 16 OK REPAIR IS COMPLETE 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 889 05-700 DIAGNOSTICS 16 - SFI SYSTEM (3MZ-FE) CHECK EVAP VSV (FOR EVAP VSV STUCK CLOSED) (a) If EVAP VSV is functioning normally: VSV is ON Vacuum VSV is OFF No Vacuum A86478 (b) (c) Disconnect the purge hose of the canister from the EVAP VSV. Allow the engine to idle. Switch the EVAP VSV using the hand-held tester. Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBD ll, ACTIVE TEST and EVAP VSV. Touch the EVAP VSV port to check the vacuum. (d) HINT: The EVAP VSV can be tested with the EVAP Test Equipment (go to step 39). Result EVAP VSV Conclusion Proceed to Vacuum is applied when EVAP VSV is ON. No vacuum is applied when EVAP VSV is OFF. EVAP VSV is functioning normally. OK No vacuum is applied when EVAP VSV is ON. Electrical circuit of EVAP VSV is malfunctioning. NG NG Go to step 31 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 890 05-701 DIAGNOSTICS SFI SYSTEM (3MZ-FE) CHECK CCV (FOR CCV STUCK OPEN) CCV (a) (b) (c) Turn the ignition switch OFF. Remove the CCV (vent valve) and plug the canister. Allow the engine to idle. (d) Apply vacuum to the EVAP system with the EVAP system check. Perform step 5 ”Applying Vacuum”. Wait for 30 seconds and check the VAPOR PRESS (EVAP pressure). Canister 17 - A96850 (e) A96686 Result VAPOR PRESS Conclusion Proceed to Lower than 747 mmHg-a (-15 mmHg-g) CCV (vent valve) stuck open A Higher than 747 mmHg-a (-15 mmHg-g) Blockage in canister Blockage in purge line (Fuel tank - Canister) Blockage in purge line (Fuel tank -EVAP VSV) B B Go to step 20 A Go to step 24 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 891 05-702 DIAGNOSTICS 18 - SFI SYSTEM (3MZ-FE) CHECK FUEL TANK CAP (a) (b) (c) Remove the fuel tank cap and reinstall it until a few click sound is heard. Clear the DTCs. Check pending DTCs after the EVAP system check If no pending DTC is set, the DTC(s) was set due to the fuel cap loosening. If necessary, replace the fuel cap. NG Go to step 19 OK REPAIR IS COMPLETE 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 892 05-703 DIAGNOSTICS 19 - SFI SYSTEM (3MZ-FE) CHECK FILLER NECK DAMAGE (a) Remove the fuel tank cap. (b) Visually inspect the filler neck for damage. (c) Reinstall the fuel tank cap. HINT: A leak point may be found with the EVAP Test Equipment (go to step 36). A96690 NG REPLACE FUEL TANK INLET PIPE OK 20 CHECK PURGE LINE (CANISTER - FUEL TANK) (a) (b) (c) A77160 Check that the pipes and hoses are connected correctly. Check that the pipes and hoses are not loose or disconnected. Check the pipes and hoses have no damage or blockage. NG REPLACE PURGE HOSE OK 21 (a) (b) (c) CHECK PURGE LINE (CANISTER - EVAP VSV) Check that the pipes and hoses are connected correctly. Check that the pipes and hoses are not loose or disconnected. Check the pipes and hoses have no damage or blockage. NG REPLACE PURGE HOSE OK 22 INSPECT CANISTER (See page 12-23 ) NG REPLACE CANISTER OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 893 05-704 DIAGNOSTICS 23 (a) (b) (c) - SFI SYSTEM (3MZ-FE) INSPECT FUEL TANK Check that the fuel tank has no damage. Check the fuel inlet pipe has no damage. Check leakage from the fuel pump unit. NG REPAIR OR REPLACE DAMAGED PARTS DEFFECTIVE OR OK Go to step 40 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 894 05-705 DIAGNOSTICS 24 - SFI SYSTEM (3MZ-FE) CHECK CCV CCV (Vent Valve) (a) (b) Stop the engine and turn the ignition switch ON. Switch the CCV (vent valve) using the hand-held tester. Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBD ll, ACTIVE TEST and CAN CTRL VSV. Touch the CCV and check the operation during switching the CCV. (c) Canister A96691 Result CCV (Vent Valve) Conclusion Proceed to CCV is operated Electrical circuit of CCV is functioning normally. A CCV is not operated Electrical circuit of CCV is malfunctioning. B B Go to step 26 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 895 05-706 DIAGNOSTICS 25 - SFI SYSTEM (3MZ-FE) CHECK CCV If CCV (vent valve) is functioning normally: CCV is ON (Close) (a) (b) (c) (d) (e) Turn the ignition switch OFF. Remove the CCV (vent valve). Connect the CCV connector, Turn the ignition switch ON. Switch the CCV using the hand-held tester. Select the hand- held tester menus: DIAGNOSIS, ENHANCED OBD ll, ACTIVE TEST and CAN CTRL VSV. Apply air to the CCV port using an air gun and check the airflow. No Airflow (f) Air CCV is OFF (Open) Airflow Air A85442 Result CCV (Vent Valve) Conclusion Proceed to Air flows when CCV is OFF (open). Air does not flows when CCV is ON (close). CCV is functioning normally. Electrical circuit of CCV is malfunctioning. A Air flows when CCV is ON (close). Air does not flows when CCV is OFF (open). CCV is malfunctioning. B B REPLACE CCV (See page 12-28 ) A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 896 05-707 DIAGNOSTICS 26 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS AND CONNECTOR (CCV - POWER SOURCE) Wire Harness Side Connector of CCV Voltmeter (a) (b) (c) (d) Turn the ignition switch OFF. Disconnect the CCV connector. Turn the ignition switch ON. Measure the voltage between terminal 2 of the wire harness side connector and body ground. A96694 Result Voltage Conclusion Proceed to Battery voltage Wire harness (CCV - Power source) is OK. OK 0 to 3 V Wire harness (CCV - Power source) is short circuit. NG NG REPAIR OR REPLACE WIRE HARNESS OK 27 CHECK WIRE HARNESS AND CONNECTOR (CCV - ECM) (a) Wire Harness Side Connector of CCV Ohmmeter (b) Switch the CCV using the hand-held tester. Select the hand- held tester menus: DIAGNOSIS, ENHANCED OBD ll, ACTIVE TEST and CAN CTRL VSV. Measure the resistance between terminal 1 of the wire harness side connector and body ground. A96695 Result Resistance Conclusion Proceed to More than 10 kΩ when CCV is OFF. Less than 10 Ω when CCV is ON. ECM and wire harness (CCV - ECM) are OK. CCV is malfunctioning. OK No change Either of wire harness (CCV - ECM) or ECM is malfunctioning. NG NG Go to step 28 OK REPLACE CCV 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 897 05-708 DIAGNOSTICS 28 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS AND CONNECTOR (CCV - ECM) (a) (b) (c) (d) Check the wire harness between the ECM and CCV. Turn the ignition switch OFF. Disconnect the E7 ECM connector. Measure the resistance between the CCV and ECM wire harness side connectors. Standard Wire Harness Side Connector of CCV Tester Connection ECM Specified Condition 1 (CCV) - E7-27 (ECM) Less than 10 Ω 1 (CCV) - Body ground More than 10 kΩ E7-27 Y A72890 A81699 A87759 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK CHECK AND REPLACE ECM 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 898 05-709 DIAGNOSTICS 29 - SFI SYSTEM (3MZ-FE) CHECK EVAP VSV (a) (b) (c) Turn the ignition switch ON. Switch the EVAP VSV using the hand-held tester. Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBD ll, ACTIVE TEST and EVAP VSV (Alone). Listen to click sounds to check the EVAP VSV operation. A96855 Result EVAP VSV Conclusion Proceed to Operated Electrical circuit of EVAP VSV is functioning normally. OK Not operated Electrical circuit of EVAP VSV is malfunctioning. NG NG Go to step 32 OK 30 CHECK EVAP VSV (a) If EVAP VSV is functioning normally: VSV is ON Vacuum VSV is OFF No Vacuum A86478 (b) (c) Disconnect the purge hose of the canister from the EVAP VSV. Start the engine. Switch the EVAP VSV using the hand-held tester. Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBD ll, ACTIVE TEST and EVAP VSV. Touch the EVAP VSV port to check the vacuum. (d) HINT: The EVAP VSV can be tested with the EVAP Test Equipment (go to step 39). Result EVAP VSV Conclusion Proceed to Vacuum is applied when EVAP VSV is ON. No vacuum is applied when EVAP VSV is OFF. EVAP VSV is functioning normally. OK No vacuum is applied when EVAP VSV is ON. Electrical circuit of EVAP VSV is malfunctioning. NG NG Go to step 32 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 899 05-710 DIAGNOSTICS 31 - SFI SYSTEM (3MZ-FE) CHECK PURGE LINE (EVAP VSV - THROTTLE BODY) (a) (b) (c) A96856 Check that the vacuum hoses are connected correctly. Check that the vacuum hoses are not loose or disconnected. Check the vacuum hoses and tubes for cracks, holes, damage, or blockage. NG REPLACE PURGE HOSE OK REPLACE EVAP VSV 32 INSPECT EVAP VSV 26 to 30 Ω (a) Turn the ignition switch OFF. (b) Disconnect the EVAP VSV connector. (c) Measure the resistance of the EVAP VSV. Standard Tester Connection Specified Condition Between terminals 26 to 30 Ω at 20°C (68°F) Each terminal - Body ground 10 kΩ or more 10 kΩ or more A96698 NG REPLACE EVAP VSV OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 900 05-71 1 DIAGNOSTICS 33 - SFI SYSTEM (3MZ-FE) INSPECT EVAP VSV If EVAP VSV is functioning normally: (a) (b) Remove the EVAP VSV. Apply air to the EVAP VSV using an air gun, check the airflow. (c) (d) Apply battery positive voltage across the terminals. Apply air to the EVAP VSV using an air gun, check the airflow. EVAP VSV is OFF No Airflow Air A96920 If EVAP VSV is functioning normally: EVAP VSV is ON Airflow Air Battery A96700 Result EVAP VSV Conclusion Proceed to Air does not flow when EVAP VSV is OFF. Air flows when EVAP VSV is ON. EVAP VSV is functioning normally. OK Air flows when EVAP VSV is OFF. Air does not flow when EVAP VSV is ON. EVAP VSV is malfunctioning. NG NG REPLACE EVAP VSV OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 901 05-712 DIAGNOSTICS 34 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS AND CONNECTOR (EVAP VSV - POWER SOURCE) (a) (b) Wire Harness Side Connector of EVAP VSV Turn the ignition switch ON. Measure the voltage between the terminal 1 of the wire harness side and body ground. A96692 Result Voltage Conclusion Proceed to Battery voltage Wire harness (EVAP VSV - Power source) is OK. OK 0 to 3 V Wire harness (EVAP VSV - Power source) is short circuit. NG NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 35 CHECK WIRE HARNESS AND CONNECTOR (EVAP VSV - ECM) (a) (b) (c) (d) ECM Turn the ignition switch OFF. Disconnect the E7 ECM connector. Turn the ignition switch ON. Measure the voltage between the terminal 34 of the wire harness side and body ground. E7-34 A81699 Result Voltage Conclusion Proceed to Battery voltage Wire harness (EVAP VSV - ECM) is OK. OK 0 to 3 V Wire harness (EVAP VSV - ECM) is short circuit. NG NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK CHECK AND REPLACE ECM 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 902 05-713 DIAGNOSTICS 36 (a) (b) (c) (d) - SFI SYSTEM (3MZ-FE) CHECK FUEL TANK CAP Connect the fuel tank cap to the gas cap adaptor. Connect the pressure hose from the pump to the gas cap adaptor. Plug the gas cap adaptor port. Turn the pump ON and pressurize the gas cap adaptor by 24 - 28 mmHg. If the pressure does not reach to 24 mmHg within 45 seconds, stop the pump. The fuel tank cap is malfunctioning. Turn the pump OFF and seal the pressure line to maintain the pressure. Measure the pressure change for 2 minutes. If the pressure drops to lower than 15 mmHg, the fuel tank cap is malfunctioning. Standard: The fuel tank cap keeps the pressure that is 15 mmHg or higher. (e) (f) NG REPLACE FUEL TANK CAP OK 37 CHECK LEAK NOTICE: DO NOT apply the EVAP system to the pressure that is higher than 35 mmHg. The EVAP system will be damaged. (a) Connect the pressure line from the pump to the EVAP service port. (b) Turn the ignition switch ON but the engine is not running. (c) Turn the CCV (vent valve) is ON (close) using the hand-held tester. Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBD ll, ACTIVE TEST and CAN CTRL VSV. (d) Turn the pump ON and pressurize the EVAP system by 24 - 28 mmHg. (e) Turn the pump OFF and seal the pressure line to maintain the pressure. If the pressure does not reach to 24 mmHg within 45 seconds, stop the pump. A leakage is in the EVAP system. If the system has a small leak, a whistling sound may be heard. (f) Measure the pressure change for 2 minutes. If the pressure drops to lower than 15 mmHg, a leakage is in the EVAP system. Standard: The EVAP system keeps the pressure that is 15 mmHg or higher. NG Go to step 38 OK NO LEAKAGE IN EVAP SYSTEM 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 903 05-714 DIAGNOSTICS 38 - SFI SYSTEM (3MZ-FE) LOOK FOR LEAK POINT (a) (b) (c) (d) A96922 (e) (f) (g) Apply the soapy water on suspected components. Turn the CCV (vent valve) is ON (close) using the handheld tester. Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBD ll, ACTIVE TEST and CAN CTRL VSV. Turn the pump ON and pressurize the EVAP system by 24 - 28 mmHg. Turn the pump OFF and seal the pressure line to maintain the pressure. If the pressure does not reach to 24 mmHg within 45 seconds, stop the pump. Check bubbles to find the leak point:  EVAP service port  Canister  Hose connections/Lines  Fuel cap  Fuel filler neck  Purge line  EVAP VSV  CCV (vent valve)  Fuel pump sending unit Repair or replace the leak component. Perform the EVAP system check to confirm no leak. NEXT Go to step 4 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 904 05-715 DIAGNOSTICS 39 - SFI SYSTEM (3MZ-FE) CHECK EVAP VSV (a) Vacuum Gauge B06544 Connect the vacuum gauge to the EVAP service port. (1) Start the engine. (2) Switch the EVAP VSV using the hand-held tester. Select the hand-held tester menus: DIAGNOSIS, ENHANCED OBD ll, ACTIVE TEST and EVAP VSV. (3) Check the vacuum when switching the EVAP VSV. If the vacuum gauge indicates negative value when the EVAP VSV is ON, the EVAP VSV is functioning normally. OK: The vacuum gauge indicates negative value when the EVAP VSV is ON. NG Go to step 31 OK Go to step 17 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 905 05-716 DIAGNOSTICS 40 (a) (b) (c) (d) - SFI SYSTEM (3MZ-FE) CHECK MONITOR STATUS AND DTC Clear DTCs. Perform a drive pattern test (see page 05-387 ). Check that the monitor result is PASS. Confirm no pending DTC. NEXT REPAIR IS COMPLETE 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 906 05-404 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EX9-05 FAIL-SAFE CHART If any of the following codes are recorded, the ECM enters fail-safe mode. DTC No. Fail-Safe Operation Fail-Safe Deactivation Conditions P0031 P0032 P0037 P0038 P0051 P0052 P0057 P0058 Turn off heater Ignition switch OFF P0100 P0102 P0103 Ignition timing is calculated from engine RPM and TP (Throttle Position) ”Pass” condition detected P0110 P0112 P0113 IAT (Intake Air Temperature) is fixed at 20°C (68°F) ”Pass” condition detected P0115 P0117 P0118 ECT (Engine Coolant Temperature) is fixed at 80°C (176°F) ”Pass” condition detected P0120 P0121 P0122 P0123 P0220 P0222 P0223 P0604 P0606 P0607 P0657 P2102 P2103 P2111 P2112 P2118 P2119 P2135 If the Electronic Throttle Control System (ETCS) has a malfunction, the ECM cuts off current to the throttle control motor. The throttle control valve returns to a predetermined opening angle (approximately 16
) by the force of the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue at a minimal speed. If the accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly. If the accelerator pedal is depressed quickly, the vehicle may speed up and slow down erratically. ”Pass” condition is detected and then the ignition switch is turned OFF. P0325 P0327 P0328 P0330 P0332 P0333 Maximum ignition timing retardation Ignition switch OFF 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 594 05-405 DIAGNOSTICS DTC No. - SFI SYSTEM (3MZ-FE) Fail-Safe Operation Fail-Safe Deactivation Conditions P0351 P0352 P0353 P0354 P0355 P0356 Fuel is cut ”Pass” condition detected P2120 P2121 P2122 P2123 P2125 P2127 P2128 P2138 The accelerator pedal position sensor has two (main and sub) sensor circuits. If a malfunction occurs in either of the sensor circuits, the ECM detects the abnormal signal voltage difference between the two sensor circuits and switches to limp mode. In limp mode, the functioning circuit is used to calculate the accelerator pedal opening angle to allow the vehicle to continue driving. If both circuits malfunction, the ECM regards the opening angle of the accelerator pedal to be fully closed. In this case, the throttle valve will remain closed as if the engine is idling. ”Pass” condition is detected and the ignition switch is turned OFF. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 595 05-717 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EXK-05 FUEL PUMP CONTROL CIRCUIT CIRCUIT DESCRIPTION When the engine is cranked, current flows from the ignition switch terminal ST1 to the starter relay (Marking: STARTER), and current flows to terminal STA of ECM (STA signal). When the STA signal and NE signal are input to the ECM, Tr is turned ON, current flows to coil of the circuit opening relay, the relay switches on, power is supplied to the fuel pump and the fuel pump operates. While the NE signal is generated and the engine is running, the ECM keeps Tr ON (Circuit Opening relay ON) and the fuel pump also keeps operating. Circuit Opening Relay EFI Relay EFI NO. 1 Fuel Pump ECM FC Ignition Switch AM1 MREL ST1 IGN AM1 AM2 Tr IG2 ST2 IGSW PNP Switch (STA Signal) STA ALT AM2 Main S TAT E R Relay (NE Signal) NE Battery Starter A85447 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 907 05-718 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) WIRING DIAGRAM I15 Ignition Switch Instrument Panel J/B Assy 1 1C GR 7 AM2 IG2 6 Passenger Side J/B 6 1G IGN 4 4M W ECM 1 4F W Y R/B No.1 Engine Room J/B 1 IC1 1 2I EFI NO. 1 1 EFI Relay 5 3 1 2 8 2B W 2 IC2 1 B 5 2B 5 3 13 IK3 8 E5 B MREL 3 AM2 10 FC E5 1 4 2F P-L 10 2 Y Circuit Opening Relay L-Y W 1 1 BR F7 FL Block Assy BR W-B 1 1 E7 E1 8 IA2 W A A J2 J/C FL Main J7 J/C L A 4 F12 Fuel Pump 5 BR W-B Battery EH BC ED A88704 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 908 05-719 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) INSPECTION PROCEDURE Hand-held tester: 1 (a) (b) (c) (d) PERFORM ACTIVE TEST USING HAND-HELD TESTER (OPERATE C/OPN RELAY) Connect the hand-held tester to the DLC3. Turn the ignition switch ON and push the hand-held tester main switch ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD. Check the relay operation while operating it with the hand-held tester. Standard: Operating noise can be heard from the relay. OK Go to step 5 NG 2 INSPECT RELAY 1 3 (a) (b) 2 5 5 2 Remove the circuit opening relay from the R/B sub-assy. Check the resistance of the circuit opening relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 1 3 B60778 NG REPLACE RELAY OK 3 INSPECT ECM (FC VOLTAGE) E1 (-) E9 ECM (a) (b) FC (+) Turn the ignition switch ON. Measure the voltage of the ECM connectors. Standard: Tester Connection Specified Condition E5-10 (FC) - E9-1 (E1) 9 to 14 V E5 ECM A67446 OK REPLACE ECM (See page 10-24 ) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 909 05-720 DIAGNOSTICS 4 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS (ECM - CIRCUIT OPENING RELAY, CIRCUIT OPENING RELAY - IGNITION) (a) E5 ECM FC R/B Sub-assy Check the wire harness between the ECM and circuit opening relay. (1) Disconnect the E5 ECM connector. (2) Remove the circuit opening relay from the R/B subassy. (3) Check the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition E5-10 (FC) - R/B sub-assy circuit opening relay terminal 2 Below 1 Ω E5-10 (FC) or R/B sub-assy circuit opening relay terminal 2 - 10 kΩ or higher Body ground Circuit Opening Relay A67445 A92536 A92536 (b) Wire Harness Side R/B Sub-assy Circuit Opening Relay I15 Ignition Switch 1 5 A90342 A85676 IG2 2 6 3 7 4 8 A92537 Check the wire harness between the circuit opening relay and ignition switch. (1) Check the IGN fuse.
Remove the IGN fuse from the instrument panel J/B assy.
Check the resistance of the IGN fuse. Standard: Below 1 Ω
Reinstall the IGN fuse. (2) Remove the circuit opening relay from the R/B subassy. (3) Disconnect the I15 ignition switch connector. (4) Check the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition R/B sub-assy circuit opening relay terminal 1 - I15-6 Below 1 Ω I15-6 or R/B sub-assy circuit opening relay terminal 1 Body ground 10 kΩ or higher NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE ECM (See page 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 910 05-721 DIAGNOSTICS 5 - SFI SYSTEM (3MZ-FE) INSPECT FUEL PUMP ASSY (a) 3 2 1 5 4 F12 Fuel Pump A74356 Check the fuel pump resistance. (1) Measure the resistance between terminals 4 and 5. Standard: 0.2 to 3.0 Ω at 20C (68F) (b) Check the fuel pump operation (1) Apply battery voltage to both the terminals. Check that the pump operates. NOTICE:
These tests must be done quickly (within 10 seconds) to prevent the coil from burning out.
Keep fuel pump as far away from the battery as possible.
Always turn on and off the voltage on the battery side, not the fuel pump side. NG REPLACE FUEL PUMP ASSY (See page 11-55 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 911 05-722 DIAGNOSTICS 6 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS (CIRCUIT OPENING RELAY - FUEL PUMP, FUEL PUMP BODY GROUND) (a) Wire Harness Side R/B Sub-assy Circuit Opening Relay F12 Fuel Pump A90342 A85674 Check the wire harness between the circuit opening relay and fuel pump. (1) Remove the circuit opening relay from the R/B subassy. (2) Disconnect the F12 fuel pump connector. (3) Check the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition R/B sub-assy circuit opening relay terminal 3 - F12-4 Below 1 Ω R/B sub-assy circuit opening relay terminal 3 or F12-4 Body ground 10 kΩ or higher A92538 (b) Wire Harness Side F12 Fuel Pump A67586 Check the wire harness between the fuel pump and body ground. (1) Disconnect the F12 fuel pump connector. (2) Check the resistance the wire harness side connectors. Standard: OK Tester Connection Specified Condition F12-5 - Body ground Below 1 Ω REPAIR OR CONNECTOR REPLACE HARNESS AND NG REPLACE ECM (See page 10-24 ) OBD II scan tool (excluding hand-held tester): 1 CHECK FUEL PUMP OPERATION (See page 11-38 ) (a) Check if there is pressure in the fuel inlet hose. HINT: The pipe has fuel pressure if the sound of flowing fuel can be heard. OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN ON PROBLEM SYMPTOMS TABLE (See page 05-393 ) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 912 05-723 DIAGNOSTICS 2 - SFI SYSTEM (3MZ-FE) CHECK RELAY OPERATION (OPERATION) (a) E5 ECM When connecting between terminal FC of the E5 ECM connector and the body ground, check the relay operation. OK: Noise can be heard from the circuit opening relay. FC OK A53765 Go to step 6 NG 3 INSPECT RELAY 1 3 (a) (b) 2 5 5 2 Remove the circuit opening relay from the R/B sub-assy. Check the resistance of the circuit opening relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 1 3 B60778 NG REPLACE RELAY OK 4 INSPECT ECM (FC VOLTAGE) E1 (-) E9 ECM (a) (b) FC (+) E5 ECM A67446 Turn the ignition switch ON. Measure the voltage of the ECM connectors. Standard: OK Tester Connection Specified Condition E5-10 (FC) - E9-1 (E1) 9 to 14 V REPLACE ECM (See page 10-24 ) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 913 05-724 DIAGNOSTICS 5 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS (ECM - CIRCUIT OPENING RELAY, CIRCUIT OPENING RELAY - IGNITION) (a) E5 ECM FC R/B Sub-assy Check the wire harness between the ECM and circuit opening relay. (1) Disconnect the E5 ECM connector. (2) Remove the circuit opening relay from the R/B subassy. (3) Check the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition E5-10 (FC) - R/B sub-assy circuit opening relay terminal 2 Below 1 Ω E5-10 (FC) or R/B sub-assy circuit opening relay terminal 2 - 10 kΩ or higher Body ground Circuit Opening Relay A67445 A92536 A92536 (b) Wire Harness Side R/B Sub-assy Circuit Opening Relay I15 Ignition Switch 1 5 A90342 A85676 IG2 2 6 3 7 4 8 A92537 Check the wire harness between the circuit opening relay and ignition switch. (1) Check the IGN fuse.
Remove the IGN fuse from the instrument panel J/B assy.
Check the resistance of the IGN fuse. Standard: Below 1 Ω
Reinstall the IGN fuse. (2) Remove the circuit opening relay from the R/B subassy. (3) Disconnect the I15 ignition switch connector. (4) Check the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition R/B sub-assy circuit opening relay terminal 1 - I15-6 Below 1 Ω I15-6 or R/B sub-assy circuit opening relay terminal 1 Body ground 10 kΩ or higher NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE ECM (See page 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 914 05-725 DIAGNOSTICS 6 - SFI SYSTEM (3MZ-FE) INSPECT FUEL PUMP ASSY (a) 3 2 1 5 4 F12 Fuel Pump A74356 Check fuel pump resistance. (1) Measure the resistance between terminals 4 and 5. Standard: 0.2 to 3.0 Ω at 20C (68F) (b) Check fuel pump operation (1) Apply battery voltage to both the terminals. Check that the pump operates. NOTICE:
These tests must be done quickly (within 10 seconds) to prevent the coil from burning out.
Keep fuel pump as far away from the battery as possible.
Always turn on and off the voltage on the battery side, not the fuel pump side. NG REPLACE FUEL PUMP ASSY (See page 11-55 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 915 05-726 DIAGNOSTICS 7 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS (CIRCUIT OPENING RELAY - FUEL PUMP, FUEL PUMP BODY GROUND) (a) Wire Harness Side R/B Sub-assy Circuit Opening Relay F12 Fuel Pump A90342 A85674 Check the wire harness between the circuit opening relay and fuel pump. (1) Remove the circuit opening relay from the R/B subassy. (2) Disconnect the F12 fuel pump connector. (3) Check the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition R/B sub-assy circuit opening relay terminal 3 - F12-4 Below 1 Ω R/B sub-assy circuit opening relay terminal 3 or F12-4 Body ground 10 kΩ or higher A92538 (b) Wire Harness Side F12 Fuel Pump A67586 Check the wire harness between the fuel pump and body ground. (1) Disconnect the F12 fuel pump connector. (2) Check the resistance the wire harness side connectors. Standard: OK Tester Connection Specified Condition F12-5 - Body ground Below 1 Ω REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE ECM (See page 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 916 05-377 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05IQH-02 LIST OF DISABLE A MONITOR HINT: The table below shows the ECM monitoring status for the components listed in the top of the table when the DTCs on the left of the table are set. A92385 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 567 05-378 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) A92386 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 568 05-379 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) A92387 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 569 05-380 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) A92388 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 570 05-381 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) A92389 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 571 05-382 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) A92390 Note *1: Without input speed sensor Note *2: With input speed sensor 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 572 05-727 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 059UT-36 MIL CIRCUIT CIRCUIT DESCRIPTION The Malfunction Indicator Lamp (MIL) is used to indicate the ECM’s detection of a vehicle malfunction. The instrument panel GAUGE fuse provides circuit power and the ECM provides the circuit ground that illuminates the MIL. MIL operations should be checked visually: The MIL should be illuminated when the ignition is first turned on. If the MIL is always ON or OFF, use the hand-held tester or OBD II scan tool and follow the procedures below to determine the cause of the problem. WIRING DIAGRAM ECM Combination Meter 9 IL1 SB 13 C11 4 C12 MIL L 10 IL2 SB 11 E5 W P J3 J/C Passenger Side J/B P E E 1 4E 4 4M L-Y 1 AM2 W 6 1G IGN 1 1C I15 Ignition Switch F7 FL Block Assy W Instrument Panel J/B Assy 10 1 IC1 GR Y 7 AM2 IG2 6 FL Main Battery G38127 INSPECTION PROCEDURE HINT: Troubleshoot each trouble symptom in accordance with the chart below. MIL remains on Start inspection from step 1 MIL is not illuminated Start inspection from step 3 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 917 05-728 DIAGNOSTICS 1 (a) (b) (c) (d) (e) - SFI SYSTEM (3MZ-FE) CLEAR DTC Connect the hand-held tester or the OBD II scan tool to the DLC 3. Turn the ignition switch ON and push the hand-held tester or the OBD II scan tool main switch ON. Read the DTC (See page 05-400 ). Clear the DTC (See page 05-400 ). Check that MIL is not illuminated. OK: MIL is not illuminated OK REPAIR CIRCUIT INDICATED BY OUTPUT DTC (See page 05-412 ) NG 2 CHECK HARNESS AND CONNECTOR (CHECK FOR SHORT IN WIRE HARNESS) E5 ECM (a) (b) (c) (d) Disconnect the E5 ECM connector. Turn the ignition switch ON. Check that MIL is not illuminated. OK: MIL is not illuminated Reconnect the ECM connector. W A67445 OK REPLACE ECM (See page 10-24 ) NG CHECK AND REPAIR HARNESS AND CONNECTOR 3 (a) CHECK THAT MIL IS ILLUMINATED Check that the MIL is illuminated when turning the ignition switch ON. OK: MIL is illuminated OK SYSTEM OK NG 4 (a) INSPECT COMBINATION METER ASSY (MIL CIRCUIT) See the combination meter troubleshooting on page 05-1882 . NG REPAIR OR REPLACE BULB OR COMBINATION METER ASSEMBLY OK CHECK AND REPAIR HARNESS AND CONNECTOR (COMBINATION METER - ECM) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 918 05-383 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05F0A-05 O2S TEST RESULT 1. INTRODUCTION The O2S TEST RESULT refers to the results of the Engine Control Module (ECM) when it monitors the oxygen sensor (O2S), and it can be read using the hand-held tester or the generic OBD II scan tool. Based on this, you can find the O2S’s conditions. The ECM monitors the O2S for the various data. You can read the monitor result (TEST DATA) of each monitor item using the O2S TEST RESULT. However, the output value of the TEST DATA is the latest ”snapshot” value that is it taken after monitoring and therefore it is not dynamic. In this repair manual, the description of the O2S TEST RESULT (for O2S related DTCs) are written in a table. This table consists of 5 items: (1) TEST ID (a code applied to each TEST DATA) (2) Description of TEST DATA (3) Conversion Factor (When conversion factor has a value written in the table, multiply the TEST DATA value appearing on the scan tool by the conversion factor value. The result will be the required value.) (4) Unit (5) Standard Value If the TEST DATA value appearing on the scan tool is out of the standard value, the O2S is malfunctioning. If it is within the standard value, the O2S is functioning normally. However, if the value is on the borderline of the standard value, the O2S may malfunction very soon. 2. HOW TO READ O2S TEST RESULT USING HANDHELD TESTER (a) Connect the hand-held tester to the DLC3. (b) O2S TEST RESULT Screen 01 BANK 1 - SENSOR 1 On the tester screen, select the following menus: DIAGNOSIS/CARB OBDII/O2S TEST RESULT. A list of the O2S equipped on the vehicle will be displayed. 01 BANK 1 - SENSOR 2 01 BANK 2 - SENSOR 1 01 BANK 2 - SENSOR 2 A88567 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 573 05-384 DIAGNOSTICS (c) TEST DATA Screen LOW SW V ⋅ ⋅ ⋅ HIGH SW V ⋅ ⋅ ⋅ MIN O2S V ⋅ ⋅ ⋅ MAX O2S V ⋅ ⋅ ⋅ TIME $81 ⋅ ⋅ ⋅ ⋅ (d) 0.400 V 0.550 V 0.100 V 0.900 V 17 (e) A88568 - SFI SYSTEM (3MZ-FE) Select the desired O2S and press ENTER. The following screen will appear. Press HELP and
simultaneously. More information will appear. Example: (1) The hand-held tester displays ”17” as a value of the ”TIME $81” (see the illustration on the left). (2) Find the conversion factor value of ”TIME $81” in the O2S TEST RESULT chart below. 0.3906 is specified for $81 in this chart. (3) Multiply ”17” in step (1) by 0.3906 (conversion factor) in the step (2). 17 x 0.3906 = 6.6 % (4) If the answer is within the standard value, the ”TIME $81” can be confirmed to be normal. O2S TEST RESULT Chart TEST ID $81 Description of TEST DATA Percentage of monitoring time when the O2S voltage is less than 0.05V Conversion Factor Multiply 0.3906 Unit % Standard Value Within 60% 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 574 05-422 DIAGNOSTICS - SFI SYSTEM (3MZ-FE)(From August, 2004) 05EXB-05 DTC P0010 CAMSHAFT POSITION ”A” ACTUATOR CIRCUIT (BANK 1) DTC P0020 CAMSHAFT POSITION ”A” ACTUATOR CIRCUIT (BANK 2) CIRCUIT DESCRIPTION The Variable Valve Timing (VVT) system includes the ECM, the Oil Control Valve (OCV) and the VVT controller. The ECM sends a target duty-cycle control signal to the OCV. This control signal, sent to the OCV, regulates the oil pressure applied to the VVT controller. Camshaft timing control is performed based on engine operation conditions such as intake air volume, throttle position and engine coolant temperature. The ECM controls the OCV based on the signals output from several sensors. The VVT controller regulates the intake camshaft angle using oil pressure through the OCV. As a result, the relative position between the camshaft and the crankshaft is optimized. Also, the engine torque and, fuel economy improve, and exhaust emissions decrease. The ECM detects the actual valve timing using signals from the camshaft position sensor and the crankshaft position sensor. The ECM performs feedback control and verifies target valve timing. ECM Crankshaft Position Sensor MAF Meter OCV Target Valve Timing Throttle Position Sensor Feedback Duty Control ECT Sensor Correction Vehicle Speed Signal Camshaft Position Sensor Actual Valve Timing A71007 DTC No. P0010 P0020 DTC Detection Condition Open or short in OCV circuit Trouble Area
Open or short in OCV circuit
OCV
ECM MONITOR DESCRIPTION After the ECM sends the ”target” duty-cycle signal to the OCV, the ECM monitors the OCV current to establish an ”actual” duty-cycle. When the actual duty-cycle ratio varies from the target duty-cycle ratio, the ECM sets a DTC. Author
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: 612 05-423 DIAGNOSTICS - SFI SYSTEM (3MZ-FE)(From August, 2004) MONITOR STRATEGY Related DTCs P0010: VVT OCV (Bank 1) Range Check P0020: VVT OCV (Bank 2) Range Check Required sensors / components (Main) VVT OCV Required sensors / components (Related) - Frequency of operation Continuous Duration 1 second MIL operation Immediate Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-377 Battery voltage 11 V or more Target duty ratio for the OCV 70 % or less Starter OFF Current cut status for the OCV Not cut TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is met: Condition 1 or 2 1. OCV duty ratio 100 % (always ON) despite the target duty ratio is less than 70 % 2. OCV duty ratio when ECM supplies current to OCV 3 % or less despite the ECM supplying the current to the OCV COMPONENT OPERATING RANGE VVT OCV duty ratio 3 to 100 % WIRING DIAGRAM ECM C4 OCV (Bank 1) 1 G-W 16 OC1+ E9 2 G-R 15 OC1E9 1 L-R 14 OC2+ E9 2 G-B 13 OC2E9 C3 OCV (Bank 2) A86808 Author
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: 613 05-424 DIAGNOSTICS - SFI SYSTEM (3MZ-FE)(From August, 2004) INSPECTION PROCEDURE HINT:


If DTC P0010 is displayed, check the bank 1 VVT system circuit. If DTC P0020 is displayed, check the bank 2 VVT system circuit. Read freeze frame data using the hand-held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. Hand-held tester: 1 (a) (b) (c) (d) PERFORM ACTIVE TEST USING HAND-HELD TESTER (OCV OPERATION) Connect the hand-held tester to the DLC3. Start the engine and warm it up. Turn the ignition switch ON and push the hand-held tester main switch ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1 or VVT CTRL B2. Using the hand-held tester, operate the OCV and check the engine speed. Standard: (e) Tester Operation Specified Condition OCV is OFF Normal engine speed OCV is ON Rough idle or engine stall OK CHECK FOR INTERMITTENT PROBLEMS (See page 05-370 ) NG 2 INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSY (See page 10-13 ) OK: OCV has no contamination and moves smoothly. NG REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSY OK Author
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: 614 05-425 DIAGNOSTICS 3 - SFI SYSTEM (3MZ-FE)(From August, 2004) CHECK ECM (OCV SIGNAL) (a) E9 ECM OC1 + OC1- OC2 + During idling, check the waveform of the ECM connector using the oscilloscope. Standard: Tester Connection Specified Condition E9-16 (OC1+) - E9-15 (OC1-) E9-14 (OC2+) - E9-13 (OC2-) Correct waveform is as shown OC2- OCV Signal Waveform 5 V/ Division GND 1 msec./Division A87357 A67528 NG REPLACE ECM (See page 10-24 ) OK 4 CHECK WIRE HARNESS (OCV-ECM) (a) (b) (c) Wire Harness Side C4 (Bank 1) C3 (Bank 2) OCV Disconnect the C4 or C3 OCV connector. Disconnect the E9 ECM connector. Check the resistance of the wire harness side connectors. Standard: Tester Connection C4-1 C4-2 C3-1 C3-2 C4-1 C4-2 C3-1 C3-2 E9 ECM Y A54386 A81698 OC1+ OC2- OC1- OC2+ A85431 NG (OCV) (OCV) (OCV) (OCV) - Specified Condition E9-16 (OC1+) E9-15 (OC1-) E9-14 (OC2+) E9-13 (OC2-) (OCV) or E9-16 (OC1+) - Body (OCV) or E9-15 (OC1-) - Body (OCV) or E9-14 (OC2+) - Body (OCV) or E9-13 (OC2-) - Body REPAIR OR CONNECTOR Below 1 Ω ground ground ground ground REPLACE 10 kΩ or higher HARNESS AND OK CHECK FOR INTERMITTENT PROBLEMS (See page 05-370 ) Author
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: 615 05-426 DIAGNOSTICS - SFI SYSTEM (3MZ-FE)(From August, 2004) OBD II scan tool (excluding hand-held tester): 1 CHECK CAMSHAFT TIMING OIL CONTROL VALVE ASSY (OCV OPERATION) Wire Harness Side (a) (b) C4 (Bank 1) C3 (Bank 2) OCV (c) Disconnect the C4 or C3 OCV connector. Apply positive battery voltage between the terminals of the OCV. Check the engine speed. OK: Engine speed is rough idle or engine is stalled. NG A54386 REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSY OK 2 CHECK ECM (OCV SIGNAL) (a) E9 ECM OC1 + OC1- OC2 + During idling, check the waveform of the E9 ECM connector using the oscilloscope. Standard: Tester Connection Specified Condition E9-16 (OC1+) - E9-15 (OC1-) E9-14 (OC2+) - E9-13 (OC2-) Correct waveform is as shown OC2- OCV Signal Waveform 5 V/ Division GND 1 msec./Division A67528 A87357 NG REPLACE ECM (See page 10-24 ) OK Author
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: 616 05-427 DIAGNOSTICS 3 - SFI SYSTEM (3MZ-FE)(From August, 2004) CHECK WIRE HARNESS (OCV-ECM) (a) (b) (c) Wire Harness Side C4 (Bank 1) C3 (Bank 2) OCV Disconnect the C4 or C3 OCV connector. Disconnect the E9 ECM connector. Check the resistance of the wire harness side connectors. Standard: Tester Connection C4-1 C4-2 C3-1 C3-2 C4-1 C4-2 C3-1 C3-2 E9 ECM Y A54386 A81698 OC1+ OC2- OC1- OC2+ A85431 NG (OCV) (OCV) (OCV) (OCV) - Specified Condition E9-16 (OC1+) E9-15 (OC1-) E9-14 (OC2+) E9-13 (OC2-) (OCV) or E9-16 (OC1+) - Body (OCV) or E9-15 (OC1-) - Body (OCV) or E9-14 (OC2+) - Body (OCV) or E9-13 (OC2-) - Body REPAIR OR CONNECTOR Below 1 Ω ground ground ground ground REPLACE 10 kΩ or higher HARNESS AND OK CHECK FOR INTERMITTENT PROBLEMS (See page 05-370 ) Author
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: 617 05-428 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05AII-22 DTC P0011 CAMSHAFT POSITION ”A” -TIMING OVERADVANCED OR SYSTEM PERFORMANCE (BANK 1) DTC P0012 CAMSHAFT POSITION ”A” -TIMING OVERRETARDED (BANK 1) DTC P0021 CAMSHAFT POSITION ”A” - TIMING OVER-ADV ANCED OR SYSTEM PERFORMANCE (BANK 2) DTC P0022 CAMSHAFT POSITION ”A” - TIMING OVER-RET ARDED (BANK2) CIRCUIT DESCRIPTION Refer to DTC P0010 on page 05-422 DTC No. DTC Detection Condition Trouble Area P0011 P0021 After engine is warmed up and engine speed is at 500 to 4,000 rpm, condition (a) continues (1 trip detection logic) (e) Valve timing does not change from current valve timing (Problem of advanced valve timing)
Valve timing
OCV
Camshaft timing gear assy
ECM P0012 P0022 After engine is warmed up and engine speed is at 500 to 4,000 rpm, condition (a) continues (2 trip detection logic) (a) Valve timing does not change from current valve timing (Problem of retarded valve timing)
Valve timing
OCV
Camshaft timing gear assy
ECM MONITOR DESCRIPTION The ECM optimizes the valve timing using the Variable Valve Timing (VVT) system to control the intake valve camshaft. The VVT system includes the ECM, the Oil Control Valve (OCV) and the VVT controller. The ECM sends a target duty-cycle control signal to the OCV. This control signal, sent to the OCV, regulates the oil pressure applied to the VVT controller. The VVT controller can advance or retard the intake valve camshaft. Example: A DTC will be set if: 1) the difference between the ”target” and ”actual” valve timing is more than 5 degrees of the camshaft angle (CA) and the condition continues for more than 4.5 seconds; or 2) the OCV is forcibly activated 63 times or more. Advanced cam DTCs are subject to ”1 trip” detection logic. Retarded cam DTCs are subject to ”2 trip” detection logic. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 618 05-429 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) MONITOR STRATEGY Related DTCs P0011: Advanced Camshaft Timing (Bank 1) P0012: Retarded Camshaft Timing (Bank 1) P0021: Advanced Camshaft Timing (Bank 2) P0022: Retarded Camshaft Timing (Bank 2) Required sensors / components (Main) VVT OCV and VVT Actuators Required sensors / components (Related) CKP, CMP and ECT sensors Frequency of operation Once per driving cycle Duration Within 10 seconds MIL operation P0011 and P0021: Immediate P0012 and P0022: 2 driving cycles Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-377 Battery voltage 11 V or more Engine RPM 500 to 4,000 rpm ECT 75 to 100C (167 to 212F) Throttle position learning Completed TYPICAL MALFUNCTION THRESHOLDS Deviation of valve timing More than 5CA (Crankshaft Angle) OCV activation 63 times or more Response of valve timing 1 second/CA or more (valve timing does not change) If the difference between ”target” and ”actual”camshaft timing is larger than the specified value, the ECM operates the VVT actuator. The ECM then monitors the camshaft timing change for 5 seconds. WIRING DIAGRAM Refer to DTC P0010 on page 05-422 . INSPECTION PROCEDURE HINT: Abnormal bank Problem of advanced OCV Problem of retarded OCV Bank 1 P0011 P0012 Bank 2 P0021 P0022

If DTC P0011 and/or P0012 is displayed, check the right bank VVT system. If DTC P0021 and/or P0022 is displayed, check the left bank VVT system. Read freeze frame data using the hand-held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 619 05-430 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) Hand-held tester: 1 CHECK VALVE TIMING (CHECK FOR LOOSE OR JUMPED TOOTH OF TIMING BELT) (See page 14-206 ) OK: The matchmarks of crankshaft pulley and camshaft pulley are aligning. NG ADJUST VALVE TIMING (See page 14-206 ) OK 2 (a) (b) (c) (d) PERFORM ACTIVE TEST USING HAND-HELD TESTER (OCV OPERATION) Connect the hand-held tester to the DLC3. Start the engine and warm it up. Turn the ignition switch ON and push the hand-held tester main switch ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / VVT CTRL B1 or VVT CTRL B2. Using the hand-held tester, operate the OCV and check the engine speed. Standard: (e) Tester Operation Specified Condition OCV is OFF Normal engine speed OCV is ON Rough idle or engine stall NG Go to step 4 OK 3 (a) CHECK IF DTC OUTPUTS REOCCUR Clear the DTCs. (1) Erase the codes using one of the following methods: 1) use the hand held tester, 2) disconnect the battery cable, or 3) remove the EFI NO. 1 and ETCS fuses for more than 60 seconds. HINT: After disconnecting the battery cable, perform the ”INITIALIZE” procedure (see page 05-1005 ). (b) Start and warm up the engine. (c) Drive the vehicle for 10 minutes or more. (d) Read output DTC using the hand-held tester. OK: No DTC output. OK VVT SYSTEM OK* HINT: *: DTC P0011, P0012, P0021 or P0022 is output when a foreign object in the engine oil enters the system. These codes will stay registered even if the system returns to normal after a short time. Foreign objects are filtered out by the oil filter. NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 620 05-431 DIAGNOSTICS 4 - SFI SYSTEM (3MZ-FE) CHECK ECM (OCV SIGNAL) (a) E9 ECM OC1 + OC1- OC2 + During idling, check the waveform of the ECM connector using the oscilloscope. Standard: Tester Connection Specified Condition E9-16 (OC1+) - E9-15 (OC1-) E9-14 (OC2+) - E9-13 (OC2-) Correct waveform is as shown OC2- OCV Signal Waveform 5 V/ Division GND 1 msec./Division A87357 A67528 NG REPLACE ECM (See page 10-24 ) OK 5 CHECK OIL CONTROL VALVE FILTER OK: The filter is not clogged. NG REPLACE OIL CONTROL VALVE FILTER OK 6 CHECK CAMSHAFT TIMING OIL CONTROL VALVE ASSY (See page 10-13 ) OK: OCV has no contamination and moves smoothly. OK Go to step 8 NG 7 REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSY GO 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 621 05-432 DIAGNOSTICS 8 - SFI SYSTEM (3MZ-FE) CHECK CAMSHAFT TIMING GEAR ASSY (See page 14-213 or 14-224 ) OK: Camshaft timing gear rotate smoothly when apply pressure. OK Go to step 10 NG 9 REPLACE CAMSHAFT TIMING GEAR ASSY GO 10 CHECK FOR BLOCKAGE (OCV, OIL CHECK VALVE AND OIL HOLE) OK: No blockage. NG REPAIR OR REPLACE OK 11 (a) CHECK IF DTC OUTPUTS REOCCUR Clear the DTCs. (1) Erase the codes using one of the following methods: 1) use the hand held tester, 2) disconnect the battery cable, or 3) remove the EFI NO. 1 and ETCS fuses for more than 60 seconds. HINT: After disconnecting the battery cable, perform the ”INITIALIZE” procedure (see page 05-1005 ). (b) Start and warm up the engine. (c) Drive the vehicle around for 10 minutes or more. (d) Read output DTC using the hand-held tester. OK: No DTC output. OK VVT SYSTEM OK* HINT: *: DTC P0011, P0012, P0021 or P0022 is output when a foreign object in the engine oil enters the system. These codes will stay registered even if the system returns to normal after a short time. Foreign objects are filtered out by the oil filter. NG REPLACE ECM (See page 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 622 05-433 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) OBD II scan tool (excluding hand-held tester): 1 CHECK VALVE TIMING (CHECK FOR LOOSE OR JUMPED TOOTH OF TIMING BELT) (See page 14-206 ) OK: The matchmarks of crankshaft pulley and camshaft pulley are aligning. NG ADJUST VALVE TIMING (See page 14-206 ) OK 2 INSPECT OPERATION OF OCV (a) (b) C4 (Bank 1) C3 (Bank 2) OCV (-) Start the engine. Check the engine speed with (1) and (2). (1) Disconnect the C4 or C3 OCV connector. (2) Apply battery positive voltage between the terminals of the OCV. Result: Proceed to Check (1) Check (2) A Normal engine speed Rough idle or engine stall B Conditions other than A Conditions other than A (+) A76968 B Go to step 4 A 3 (a) CHECK IF DTC OUTPUTS REOCCUR Clear the DTCs. (1) Erase the codes using one of the following methods: 1) use the hand held tester, 2) disconnect the battery cable, or 3) remove the EFI NO. 1 and ETCS fuses for more than 60 seconds. HINT: After disconnecting the battery cable, perform the ”INITIALIZE” procedure (see page 05-1005 ). (b) Start and warm up the engine. (c) Drive the vehicle around for 10 minutes or more. (d) Read output DTC using the OBD II scan tool. OK: No DTC output. OK VVT SYSTEM OK* HINT: *: DTCs P0011, P0012, P0021 or P0022 is output when a foreign object in the engine oil enters the system. These codes will stay registered even if the system returns to normal after a short time. Foreign objects are filtered out by the oil filter. NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 623 05-434 DIAGNOSTICS 4 - SFI SYSTEM (3MZ-FE) CHECK ECM (OCV SIGNAL) (a) E9 ECM OC1 + OC1- OC2 + During idling, check the waveform of the ECM connector using the oscilloscope. Standard: Tester Connection Specified Condition E9-16 (OC1+) - E9-15 (OC1-) E9-14 (OC2+) - E9-13 (OC2-) Correct waveform is as shown OC2- OCV Signal Waveform 5 V/ Division GND 1 msec./Division A87357 A67528 NG REPLACE ECM (See page 10-24 ) OK 5 CHECK OIL CONTROL VALVE FILTER OK: The filter is not clogged. NG REPLACE OIL CONTROL VALVE FILTER OK 6 CHECK CAMSHAFT TIMING OIL CONTROL VALVE ASSY (See page 10-13 ) OK: OCV has no contamination and moves smoothly. OK Go to step 8 NG 7 REPLACE CAMSHAFT TIMING OIL CONTROL VALVE ASSY GO 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 624 05-435 DIAGNOSTICS 8 - SFI SYSTEM (3MZ-FE) CHECK CAMSHAFT TIMING GEAR ASSY (See page 14-213 or 14-224 ) OK: Camshaft timing gear rotate smoothly when apply pressure. OK Go to step 10 NG 9 REPLACE CAMSHAFT TIMING GEAR ASSY GO 10 CHECK FOR BLOCKAGE (OCV, OIL CHECK VALVE AND OIL HOLE) OK: No blockage. NG REPAIR OR REPLACE OK 11 (a) CHECK IF DTC OUTPUTS REOCCUR Clear the DTCs. (1) Erase the codes using one of the following methods: 1) use the hand held tester, 2) disconnect the battery cable, or 3) remove the EFI NO. 1 and ETCS fuses for more than 60 seconds. HINT: After disconnecting the battery cable, perform the ”INITIALIZE” procedure (see page 05-1005 ). (b) Start and warm up the engine. (c) Drive the vehicle around for 10 minutes or more. (d) Read output DTC using the OBD II scan tool. OK: No DTC output. OK VVT SYSTEM OK* HINT: *: DTCs P0011, P0012, P0021 or P0022 is output when a foreign object in the engine oil enters the system. These codes will stay registered even if the system returns to normal after a short time. Foreign objects are filtered out by the oil filter. NG REPLACE ECM (See page 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 625 05-436 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05FFD-06 DTC P0016 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK 1 SENSOR A) DTC P0018 CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION (BANK 2 SENSOR A) CIRCUIT DESCRIPTION Refer to DTCs P0335 and P0339 on page 05-532 . DTC No. DTC Detection Condition Trouble Area P0016 Deviation in crankshaft position sensor signal and VVT sensor 1 signal (2 trip detection logic)
Mechanical system (timing belt has jumped tooth, belt stretched)
ECM P0018 Deviation in crankshaft position sensor signal and VVT sensor 2 signal (2 trip detection logic)
Mechanical system (timing belt has jumped tooth, belt stretched)
ECM MONITOR DESCRIPTION The ECM optimizes the valve timing using the Variable Valve Timing (VVT) system to control the intake valve camshaft. The VVT system includes the ECM, the Oil Control Valve (OCV) and the VVT controller. The ECM sends a target duty-cycle control signal to the OCV. This control signal, sent to the OCV, regulates the oil pressure applied to the VVT controller. The VVT controller can advance or retard the intake valve camshaft. The ECM calibrates the valve timing of the VVT system by setting the camshaft to the maximum retard angle when the engine is idling. The ECM closes the OCV to retard the cam. The ECM stores this value as a VVT learning value. When the difference between the target valve timing and the actual valve timing is 5 degrees or less, the ECM stores this in its memory. If the learning value meets both of the following conditions (”a” and ”b”), the ECM interprets this as a defect in the VVT system and sets a DTC. (a) The VVT learning value is less than 21CA (Bank 1)/22CA (Bank 2) or more than 46CA (Bank 1)/40CA (Bank 2). (b) The above condition continues for more than 18 seconds. MONITOR STRATEGY Related DTCs P0016: Camshaft Timing (Bank 1) Misalignment at Idling P0018: Camshaft Timing (Bank 2) Misalignment at Idling Required sensors / components (Main) VVT actuator Required sensors / components (Related) CMP and CKP sensors Frequency of operation Once per driving cycle Duration Within 60 seconds MIL operation 2 driving cycles Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present See page 05-377 Engine RPM 500 to 1,400 rpm 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 626 05-437 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) TYPICAL MALFUNCTION THRESHOLDS Duration that either of the following conditions 1 or 2 is met 18 seconds or more 1. VVT angle when camshaft is retarded maximum Less than 21 (Bank 1) Less than 22 (Bank 2) 2. VVT angle when camshaft is retarded maximum More than 46 (Bank 1) More than 40 (Bank 2) WIRING DIAGRAM Refer to DTCs P0335 and p0339 on page 05-532 . INSPECTION PROCEDURE HINT: Read freeze frame data using the hand-held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK VALVE TIMING (CHECK FOR LOOSE OR JUMPED TOOTH OF TIMING (See page 14-206 ) OK: The matchmarks of the crankshaft pulley and camshaft pulley are aligned. NG ADJUST VALVE TIMING (See page 14-206 ) OK REPLACE ECM (See page 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 627 05-438 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EXL-08 DTC P0031 OXYGEN (A/F) SENSOR HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1) DTC P0032 OXYGEN (A/F) SENSOR HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1) DTC P0051 OXYGEN (A/F) SENSOR HEATER CONTROL CIRCUIT LOW (BANK 2 SENSOR 1) DTC P0052 OXYGEN (A/F) SENSOR HEATER CONTROL CIRCUIT HIGH (BANK 2 SENSOR 1) HINT: Although the caption of detection item (DTC description) says ”oxygen sensor”, this DTC is related to the ”air fuel ratio sensor (A/F sensor)”. CIRCUIT DESCRIPTION Refer to DTC P2195 on page 05-629 . HINT: The ECM provides a pulse width modulated control circuit to adjust current through the heater. The A/F sensor heater circuit uses a relay on the +B side of the circuit. Reference (Bank 1 Sensor 1 System Drawing) A/F Relay From Battery A/F ECM A/F Sensor +B Heater HT AF- Sensor HA1H AF+ A1A+ Duty Control A1AMREL A87980 DTC No. DTC Detection Condition Trouble Area P0031 P0051 Heated current is 0.8 A or less when heater operates (1 trip detection logic)
Open or short in heater circuit of A/F sensor
A/F sensor heater
A/F relay
ECM P0032 P0052 Hybrid IC high current limiter port is fail (1 trip detection logic)
Open or short in heater circuit of A/F sensor
A/F sensor heater
A/F relay
ECM 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 628 05-439 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) HINT:



Bank 1 is the bank that includes cylinder No. 1. Bank 2 is the bank that does not include cylinder No. 1. Sensor 1 is the sensor closest to the engine assembly. Sensor 2 is the sensor farthest away from the engine assembly. MONITOR DESCRIPTION The ECM uses the Air-Fuel Ratio (A/F) sensor information to regulate the air-fuel ratio close to the stoichiometric ratio. This maximizes the catalytic converter’s ability to purify exhaust gas. The sensor detects oxygen levels in the exhaust gas and sends this signal to the ECM. The inner surface of the sensor element is exposed to outside air. The outer surface of the sensor element is exposed to exhaust gas. The sensor element is made of platinum coated zirconia and includes an integrated heating element. The zirconia element generates small voltage when there is a large difference in the oxygen concentrations of the exhaust and the outside air. The platinum coating amplifies the voltage generation. When heated, the sensor becomes very efficient. If the temperature of the exhaust is low, the sensor will not generate useful voltage signals without supplemental heating. The ECM regulates the supplemental heating using a duty-cycle approach to regulate the average current in the heater element. If the heater current is out of the normal range, the sensor’s output signals will be inaccurate and the ECM cannot regulate the air-fuel ratio properly. When the heater current is out of the normal operating range, the ECM interprets this as a malfunction and sets a DTC. MONITOR STRATEGY Related DTCs P0031: A/F Sensor Heater (Bank 1) Range Check (Low current) P0032: A/F Sensor Heater (Bank 1) Range Check (High current) P0051: A/F Sensor Heater (Bank 2) Range Check (Low current) P0052: A/F Sensor Heater (Bank 2) Range Check (High current) Required sensors / components (Main) A/F sensor heater Required sensors / components (Related) - Frequency of operation Continuous Duration 10 seconds MIL operation Immediate Sequence operation None TYPICAL ENABLING CONDITIONS P0031 and P0051 The monitor will run whenever these DTCs are not present See page 05-377 Battery voltage 10.5 V or more A/F sensor heater duty ratio 50 % or more Time after engine start 10 seconds or more P0032 and P0052 The monitor will run whenever these DTCs are not present See page 05-377 Time after engine start 10 seconds or more TYPICAL MALFUNCTION THRESHOLDS P0031 and P0051: A/F sensor heater current Less than 0.8 A P0032 and P0052: Hybrid IC high current limiter port Fail 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 629 05-440 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) COMPONENT OPERATING RANGE A/F sensor heater current 1.8 to 3.4 A at 20C (68F) MONITOR RESULT Refer to page 05-385 for detailed information. The test value and test limit information are described as shown in the following table. Check the monitor result and test values after performing the monitor drive pattern (see page 05-387 ).
TID (Test Identification Data) is assigned to each emissions-related component.
TLT (Test Limit Type): If TLT is 0, the component is malfunctioning when the test value is higher than the test limit. If TLT is 1, the component is malfunctioning when the test value is lower than the test limit.
CID (Component Identification Data) is assigned to each test value.
Unit Conversion is used to calculate the test value indicated on generic OBD ll scan tools. TID $07: A/F sensor heater TLT CID Unit Conversion Description of Test Data Description of Test Limit 1 $01 Multiply by 0.00017 (A) Maximum heater current (Bank 1) Malfunction criterion for A/F sensor heater 1 $10 Multiply by 0.00017 (A) Maximum heater current (Bank 2) Malfunction criterion for A/F sensor heater WIRING DIAGRAM Refer to DTC P2195 on page 05-629 . INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) (b) AF- Disconnect the A6 or A7 A/F sensor connector. Check the resistance between the terminals of the A/F sensor. Resistance: Tester Connection Condition Specified Condition 1 (HT) - 2 (+B) 20C (68F) 1.8 to 3.4 Ω 1 (HT) - 4 (AF-) - 10 kΩ or higher AF+ A52607 NG REPLACE AIR FUEL RATIO SENSOR OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 630 05-441 DIAGNOSTICS 2 (a) (b) 2 5 5 2 SFI SYSTEM (3MZ-FE) INSPECT RELAY (A/F) 1 3 - Remove the A/F relay from the engine room R/B No. 2. Check the resistance of the A/F relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1Ω (When battery voltage is applied to terminals 1 and 2) 1 3 B60778 NG REPLACE RELAY OK 3 CHECK ECM (HA1H, HA2A VOLTAGE) HA1H (+) HA2A (+) E1 (-) (a) (b) Turn the ignition switch ON. Check the voltage of the ECM connectors. Standard: Tester Connection Specified Condition E8-5 (HA1H) - E9-1 (E1) E8-4 (HA2A) - E9-1 (E1) 9 to 14 V HINT: E8 ECM E9 ECM A76903

The HA1H stands for the A/F sensor bank 1 sensor 1. The HA2A stands for the A/F sensor bank 2 sensor 1. OK REPLACE ECM (See page 10-24 ) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 631 05-442 DIAGNOSTICS 4 SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS (A/F SENSOR - ECM, A/F SENSOR - A/F RELAY) (a) Wire Harness Side E8 ECM HA1H Check the wire harness between the ECM and A/F sensors. (1) Disconnect the E8 ECM connector. (2) Disconnect the A6 or A7 A/F sensor connector. (3) Check the resistance of the wire harness side connectors. Standard: HA2A HT A6 (Bank 1) A7 (Bank 2) A/F Sensor Tester Connection Specified Condition A6-1 (HT) - E8-5 (HA1H) A7-1 (HT) - E8-4 (HA2A) Below 1 Ω A6-1 (HT) or E8-5 (HA1H) - Body ground A7-1 (HT) or E8-4 (HA2A) - Body ground 10 kΩ or higher +B 1 3 2 4 Y A81695 A76787 A85836 (b) Wire Harness Side +B HT A6 (Bank 1) A7 (Bank 2) A/F Sensor 1 3 2 4 Check the wire harness between the A/F sensor and A/F relay. (1) Disconnect the A6 or A7 A/F sensor connector. (2) Remove the A/F relay from the engine room R/B No. 2. (3) Check the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition A6-2 (+B) - R/B No. 2 A/F relay terminal 3 A7-2 (+B) - R/B No. 2 A/F relay terminal 3 Below 1 Ω A6-2 (+B) or R/B No. 2 A/F relay terminal 3 - Body ground A7-2 (+B) or R/B No. 2 A/F relay terminal 3 - Body ground 10 kΩ or higher Engine Room R/B No. 2 A/F Relay A76787 A76787 A87845 A87845 - A92546 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE ECM (See page 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 632 05-443 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EXM-05 DTC P0037 OXYGEN SENSOR HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2) DTC P0038 OXYGEN SENSOR HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2) DTC P0057 OXYGEN SENSOR HEATER CONTROL CIRCUIT LOW (BANK 2 SENSOR 2) DTC P0058 OXYGEN SENSOR HEATER CONTROL CIRCUIT HIGH (BANK 2 SENSOR 2) CIRCUIT DESCRIPTION Refer to DTC P0136 on page 05-485 . HINT: The ECM provides a pulse width modulated control circuit to adjust current through the heater. The heated oxygen sensor heater circuit uses a relay on the +B side of the circuit. Reference (Bank 1 Sensor 2 System Drawing) Heated Oxygen Sensor EFI Relay From Battery EFI NO. 1 Heater EFI NO. 2 +B ECM HT1B HT Sensor E1 OX1B OX E2 MREL A90346 DTC No. DTC Detection Condition Trouble Area P0037 P0057 Heated current is 0.25 A or less when the heater operates with +B greater than 11.5 V (1 trip detection logic)
Open or short in heater circuit of the heated oxygen sensor
Heated oxygen sensor heater
EFI relay
ECM P0038 P0058 Heated current exceeds 2 A when the heater operates (1 trip detection logic)
Open or short in heater circuit of the heated oxygen sensor
Heated oxygen sensor heater
EFI relay
ECM HINT:



Bank 1 is the bank that includes cylinder No.1. Bank 2 is the bank that does not include cylinder No.1. Sensor 1 is the sensor closest to the engine assembly. Sensor 2 is the sensor farthest away from the engine assembly. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 633 05-444 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) MONITOR DESCRIPTION The sensing portion of the heated oxygen sensor has a zirconia element that is used to detect oxygen concentration in the exhaust. If the zirconia element is at the proper temperature and the difference of the oxygen concentration between the inside and outside surface of the sensor is large, the zirconia element will generate voltage signals. In order to increase the oxygen concentration detecting capacity in the zirconia element, the ECM supplements the heat from the exhaust with heat from a heating element inside the sensor. When current in the sensor is out of the standard operating range, the ECM interprets this as a fault in the heated oxygen sensor and sets a DTC. Example: The ECM will set a high current DTC if the current in the sensor is more than 2 A when the heater is OFF. Similarly, the ECM will set a low current DTC if the current is less than 0.25 A when the heater is ON. MONITOR STRATEGY Related DTCs P0037: HO2S Heater (Bank 1) Range Check (Low current) P0038: HO2S Heater (Bank 1) Range Check (High current) P0057: HO2S Heater (Bank 2) Range Check (Low current) P0058: HO2S Heater (Bank 2) Range Check (High current) Required sensors / components (Main) HO2S heater Required sensors / components (Related) Vehicle Speed Sensor (VSS) Frequency of operation Continuous Duration 0.3 seconds MIL operation Immediate Sequence operation None TYPICAL ENABLING CONDITIONS P0037 and P0057: The monitor will run whenever these DTCs are not present See page 05-377 Either of the following conditions A and B is met: - Conditions A - Time after engine start 250 to 500 seconds Vehicle speed Within 55.9 mph (90 km/h) Battery voltage Less than 10.5 V Pass or Fail detection in this driving cycle None Conditions B - Time after engine start 500 seconds or more Vehicle speed 24.8 mph (40 km/h) or more Battery voltage Less than 10.5 V Pass or Fail detection in this driving cycle None P0038 and P0058: None TYPICAL MALFUNCTION THRESHOLDS P0037 and P0057: HO2S heater current when HO2S heater OFF Less than 0.25 A (when battery voltage is 11.5 V or more) P0038 and P0058: HO2S heater current when HO2S heater ON More than 2 A COMPONENT OPERATING RANGE HO2S heater current 0.4 to 1 A (at idle, warmed-up engine and +B: 11 to 14 V) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 634 05-445 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) MONITOR RESULT Refer to page 05-385 for detailed information. The test value and test limit information are described as shown in the following table. Check the monitor result and test values after performing the monitor drive pattern (see page 05-387 ).
TID (Test Identification Data) is assigned to each emissions-related component.
TLT (Test Limit Type): If TLT is 0, the component is malfunctioning when the test value is higher than the test limit. If TLT is 1, the component is malfunctioning when the test value is lower than the test limit.
CID (Component Identification Data) is assigned to each test value.
Unit Conversion is used to calculate the test value indicated on generic OBD ll scan tools. TID $04: HO2S heater TLT CID Unit Conversion 1 $02 Multiply by 0.000076 (A) 1 $20 Multiply by 0.000076 (A) Description of Test Data Description of Test Limit Maximum HO2S heater current (Bank 1 Sensor 2) Malfunction threshold for HO2S heater Maximum HO2S heater current (Bank 2 Sensor 2) Malfunction threshold for HO2S heater WIRING DIAGRAM Refer to DTC P0136 on page 05-485 . INSPECTION PROCEDURE HINT:
If DTCs related to different systems that have terminal E2 as the ground terminal are output simultaneously, terminal E2 may have an open circuit. Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred.
1 INSPECT HEATED OXYGEN SENSOR (HEATER RESISTANCE) (a) +B HT +B 2 1 4 3 E1 (b) HT 2 1 4 3 OX E1 OX Bank 1 Bank 2 A87828 Disconnect the H10 or H6 heated oxygen sensor connector. Check the resistance of the heated oxygen sensor terminals. Standard (bank 1, 2 sensor 2): Tester Connection Condition Specified Condition H10-1 (HT) - H10-2 (+B) H6-1 (HT) - H6-2 (+B) 20C (68F) 11 to 16 Ω H10-1 (HT) - H10-4 (E1) H6-1 (HT) - H6-4 (E1) 800C (1,472F) 23 to 32 Ω NG REPLACE HEATED OXYGEN SENSOR OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 635 05-446 DIAGNOSTICS 2 - SFI SYSTEM (3MZ-FE) INSPECT RELAY (EFI) 1 3 (a) (b) 2 5 5 2 Remove the EFI relay from the engine room J/B. Check the resistance of the EFI relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1Ω (When battery voltage is applied to terminals 1 and 2) 1 3 NG B60778 REPLACE RELAY OK 3 CHECK ECM (HT1B OR HT2B VOLTAGE) E2 (-) (a) (b) HT1B (+) HT2B (+) Turn the ignition switch ON. Check the voltage of the ECM connectors. Standard: Tester Connection Specified Condition E8-25 (HT1B) - E7-28 (E2) E8-33 (HT2B) - E7-28 (E2) 9 to 14 V HINT: E7 ECM E8 ECM
A76903
The HT1B stands for the heated oxygen sensor bank 1 sensor 2. The HT2B stands for the heated oxygen sensor bank 2 sensor 2. OK REPLACE ECM (See page 10-24 ) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 636 05-447 DIAGNOSTICS 4 SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS (HEATED OXYGEN SENSOR - ECM, HEATED OXYGEN SENSOR - EFI RELAY) (a) Wire Harness Side E8 ECM HT1B Check the wire harness between the ECM and heated oxygen sensor. (1) Disconnect the E8 ECM connector. (2) Disconnect the H10 or H6 heated oxygen sensor connector. (3) Check the resistance of the wire harness side connectors. Standard: HT2B Heated Oxygen Sensor HT +B 1 3 HT +B 1 3 2 4 E1 OX Specified Condition Below 1 Ω H10-1 (HT) or E8-25 (HT1B) - Body ground H6-1 (HT) or E8-33 (HT2B) - Body ground 10 kΩ or higher E1 OX H10 (Bank 1) Tester Connection H10-1 (HT) - E8-25 (HT1B) H6-1 (HT) - E8-33 (HT2B) 2 4 H6 (Bank 2) A81695 A81921 A92547 (b) Wire Harness Side Heated Oxygen Sensor HT +B 1 3 OX - HT +B 1 3 2 4 E1 H10 (Bank 1) OX 2 4 E1 H6 (Bank 2) Check the wire harness between the heated oxygen sensor and EFI relay. (1) Disconnect the H10 or H6 heated oxygen sensor connector. (2) Remove the EFI relay from the engine room J/B. (3) Check the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition H10-2 (+B) - J/B EFI relay terminal 3 H6-2 (+B) - J/B EFI relay terminal 3 Below 1 Ω H10-2 (+B) or J/B EFI relay terminal 3 - Body ground H6-2 (+B) or J/B EFI relay terminal 3 - Body ground 10 kΩ or higher Engine Room J/B EFI Relay A81921 A90291 A92548 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE ECM (See page 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 637 05-448 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EXN-05 DTC P0100 MASS OR VOLUME AIR FLOW CIRCUIT DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT CIRCUIT DESCRIPTION The Mass Air Flow (MAF) meter measures the amount of air flowing through the throttle valve. The ECM uses this information to determine the fuel injection time and provide a proper air fuel ratio. Inside the MAF meter, there is a heated platinum wire exposed to the flow of intake air. By applying a specific current to the wire, the ECM heats this wire to a given temperature. The flow of incoming air cools the wire and an internal thermistor, changing their resistance. To maintain a constant current value, the ECM varies the voltage applied to these components in the MAF meter. The voltage level is proportional to the air flow through the sensor. The ECM interprets this voltage as the intake air amount. The circuit is constructed so that the platinum hot wire and temperature sensor provide a bridge circuit, with the power transistor controlled so that the potential of A and B remains equal to maintain the set temperature. B+ Temperature sensor Power Transistor Platinum Hot Wire (Heater) A B Output Voltage Temperature Sensor Platinum Hot Wire (Heater) A80089 DTC No. DTC Detection Condition Trouble Area P0100 When MAF meter circuit has an open or a short for more than 3 seconds
Open or short in MAF meter circuit
MAF meter
ECM P0102 When MAF meter circuit has an open for more than 3 seconds
Open or short in MAF meter circuit
MAF meter
ECM P0103 When MAF meter circuit has a short for more than 3 seconds
Open or short in MAF meter circuit
MAF meter
ECM 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 638 05-449 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) HINT: After confirming DTC P0100, P0102 or P0103, use the hand-held tester or the OBD II scan tool to confirm the MAF ratio from the ALL menu (to reach the ALL menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL). Air Flow Value (gm/s) Approx. 0.0 271.0 or more Malfunction
Open in MAF meter power source circuit
Open or short in VG circuit
Open in E2G circuit MONITOR DESCRIPTION If there is a defect in the sensor, or an open or short circuit, the voltage level will deviate from the normal operating range. The ECM interprets this deviation as a defect in the MAF meter and sets a DTC. Example: The sensor voltage output is less than 0.2 V or more than 4.9 V and either condition continues for more than 3 seconds. MONITOR STRATEGY Related DTCs P0100: MAF Meter Range Check (Chattering) P0102: MAF Meter Range Check (Low voltage) P0103: MAF Meter Range Check (High voltage) Required sensors / components (Main) MAF meter Required sensors / components (Related) CKP sensor Frequency of operation Continuous Duration 3 seconds MIL operation Immediate: Engine RPM is less than 4,000 rpm 2 driving cycles: Engine RPM if 4,000 rpm or more Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-377 TYPICAL MALFUNCTION THRESHOLDS P0100: MAF meter voltage Less than 0.2 V, or more than 4.9 V P0102: MAF meter voltage Less than 0.2 V P0103: MAF meter voltage More than 4.9 V COMPONENT OPERATING RANGE MAF meter voltage Between 0.4 and 2.2 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 639 05-450 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) WIRING DIAGRAM M1 MAF Meter Engine Room R/B No. 2 EFI NO. 2 2 B-W 2 1 1 EB1 2 +B B-R ECM VG 1 R 3 30 VG E7 29 E2G L-W E2G E7 2 Y Engine Room J/B 3 2D 3 EFI Relay 5 5 2B P-L 13 IK3 B 8 MREL E5 1 2 EFI NO. 1 1 4 2F 2I W 3 W-B F7 FL Block Assy 1 A J2 J/C W FL Main Battery EH A88691 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 640 05-451 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 (a) (b) (c) (d) READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (MAF RATE) Connect the hand-held tester or the OBD II scan tool to the DLC3. Start the engine. Push the hand-held tester or the OBD II scan tool main switch ON. On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / MAF. Read the values. Result: Air Flow Rate (gm/s) Proceed to 0.0 A 271.0 or more B MAF rate greater than 1 but less than 270.0 C HINT: The value must change when the throttle valve is opened or closed. B Go to step 6 C CHECK FOR INTERMITTENT PROBLEMS (See page 05-370 ) A 2 CHECK MASS AIR FLOW METER (POWER SOURCE) (a) (b) (c) Wire Harness Side Turn the ignition switch ON. Disconnect the M1 MAF meter connector. Check the voltage of the wire harness side connector. Standard: M1 MAF Meter Tester Connection Specified Condition M1-1 (+B) - Body ground 9 to 14 V +B (+) A54396 NG Go to step 5 OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 641 05-452 DIAGNOSTICS 3 - SFI SYSTEM (3MZ-FE) CHECK ECM (VG VOLTAGE) VG (+) (a) Start the engine. (b) Check the voltage of the ECM connector. HINT: The shift position should be P or N and the A/C switch should be turned OFF. Standard: E2G (-) E7 ECM A76903 Tester Connection Condition Specified Condition E7-30 (VG) - E7-29 (E2G) Engine is idling 0.5 to 3.0 V OK REPLACE ECM (See page 10-24 ) NG 4 CHECK WIRE HARNESS (MAF METER - ECM) (a) (b) (c) Wire Harness Side M1 MAF Meter E2G Disconnect the M1 MAF meter connector. Disconnect the E7 ECM connector. Check the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition M1-3 (VG) - E7-30 (VG) M1-2 (E2G) - E7-29 (E2G) Below 1 Ω M1-3 (VG) or E7-30 (VG) - Body ground 10 kΩ or higher VG E7 ECM E2G Y A54396 A81699 VG A85482 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE MASS AIR FLOW METER 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 642 05-453 DIAGNOSTICS 5 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS (MAF METER - EFI RELAY) (a) (b) (c) Wire Harness Side M1 MAF Meter Disconnect the M1 MAF meter connector. Remove the EFI relay from the engine room J/B. Check the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition M1-1 (+B) - J/B EFI relay terminal 3 Below 1 Ω M1-1 (+B) or J/B EFI relay terminal 3 - Body ground 10 kΩ or higher +B Engine Room J/B EFI Relay A54396 A90291 A92539 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK INSPECT ECM POWER SOURCE CIRCUIT (See page 05-674 ) 6 INSPECT ECM (SENSOR GROUND) (a) E2G E7 ECM A76903 Check the resistance of the ECM connector. Standard: Tester Connection Specified Condition E7-29 (E2G) - Body ground Below 1 Ω NG REPLACE ECM (See page 10-24 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 643 05-454 DIAGNOSTICS 7 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS (MAF METER - ECM) (a) (b) (c) Wire Harness Side M1 MAF Meter E2G Disconnect the M1 MAF meter connector. Disconnect the E7 ECM connector. Check the resistance of between the wire harness side connectors. Standard: VG Tester Connection Specified Condition M1-3 (VG) - E7-30 (VG) M1-2 (E2G) - E7-29 (E2G) Below 1 Ω M1-3 (VG) or E7-30 (VG) - Body ground 10 kΩ or higher E7 ECM E2G Y A54396 A81699 VG A85482 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE MASS AIR FLOW METER 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 644 05-455 DIAGNOSTICS DTC P0101 - SFI SYSTEM (3MZ-FE) 052N9-44 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE PROBLEM CIRCUIT DESCRIPTION Refer to DTC P0100 on page 05-448 . DTC No. DTC Detection Condition P0101
High voltage: Conditions (a), (b) and (c) continue for more than 10 seconds (2 trip detection logic): (a) Engine speed less than 2,000 rpm (b) Engine coolant temperature 70C (158F) or higher (c) Voltage output of Mass Air Flow (MAF) meter more than 2.2 V (varies with Throttle Position [TP] sensor voltage)
Low voltage: Conditions (a) and (b) continue for more than 10 seconds (2 trip detection logic): (a) Engine speed more than 300 rpm (b) Voltage output of MAF meter less than 0.83 V (varies with TP sensor voltage) Trouble Area
MAF meter MONITOR DESCRIPTION The MAF meter is a sensor that measures the amount of air flowing through the throttle valve. The ECM uses this information to determine the fuel injection time and to provide an appropriate air-fuel ratio. Inside the MAF meter, there is a heated platinum wire which is exposed to the flow of intake air. By applying a specific electrical current to the wire, the ECM heats it to a specific temperature. The flow of incoming air cools both the wire and an internal thermistor, changing their resistance. To maintain a constant current value, the ECM varies the voltage applied to these components of the MAF meter. The voltage level is proportional to the air flow through the sensor, and the ECM uses it to calculate the intake air volume. If there is a defect in the sensor, or an open or short in the circuit, the voltage level deviates from the normal operating range. The ECM interprets this deviation as a malfunction in the MAF meter and sets the DTC. Example: If the voltage is more than 2.2 V, or less than 0.83 V while idling, the ECM determines that there is a malfunction in the MAF meter and sets the DTC. MONITOR STRATEGY Related DTCs P0101: MAF Meter Rationality (Low voltage) P0101: MAF Meter Rationality (High voltage) Required sensors/ components (Main) MAF meter Required sensors/ components (Related) Crankshaft position sensor, ECT sensor, Throttle position sensor Frequency of operation Continuous Duration 10 seconds MIL operation 2 driving cycles Sequence operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present See page 05-377 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 645 05-456 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) MAF Meter Rationality (High Voltage): Engine RPM Less than 2,000 rpm ECT 70°C (158°F) or more MAF Meter Rationality (Low Voltage): Engine RPM More than 300 rpm Fuel cut OFF TYPICAL MALFUNCTION THRESHOLDS MAF Meter Rationality (High Voltage): MAF meter voltage More than 2.2 V (varies with throttle position sensor voltage) MAF Meter Rationality (Low Voltage): MAF meter voltage Less than 0.54 V (varies with throttle position sensor voltage) WIRING DIAGRAM Refer to DTC P0100 on page 05-448 . INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 (a) CHECK OTHER DTC OUTPUT(IN ADDITION TO DTC P0101) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display (DTC Output) Proceed to P0101 and other DTCs are output A Only P0101 is output B HINT: If any other codes besides P0101 are output, perform the troubleshooting for those codes first. B REPLACE MASS AIR FLOW METER A GO TO RELEVANT DTC CHART (See page 05-412 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 646 05-457 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EXO-05 DTC P0110 INTAKE AIR TEMPERATURE CIRCUIT DTC P0112 INTAKE AIR TEMPERATURE CIRCUIT LOW INPUT DTC P0113 INTAKE AIR TEMPERATURE CIRCUIT HIGH INPUT CIRCUIT DESCRIPTION Fig. 1 30 20 Resistance KΩ 10 Acceptable 5 3 2 1 0.5 0.3 0.2 0.1 - 20 (- 4) 0 32 20 68 40 104 60 140 80 176 100 212 The Intake Air Temperature (IAT) sensor, mounted on the Mass Air Flow (MAF) meter, monitors the intake air temperature. The IAT sensor has a thermistor that varies its resistance depending on the temperature of the intake air. When the air temperature is low, the resistance in the thermistor increases. When the temperature is high, the resistance drops. The variations in resistance are reflected as changes in voltage applied to the ECM terminal (See Fig. 1). The IAT sensor is connected to the ECM (see below). The 5 V power source voltage in the ECM is applied to the IAT sensor from terminal THA via resistor R. That is, the resistor R and the IAT sensor are connected in series. When the resistance value of the IAT sensor changes in accordance with changes in the IAT, the voltage at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve the driveability during cold engine operation. Temp. C (F) A67628 DTC No. Proceed to DTC Detection Condition Trouble Area P0110 Step 1 Open or short in IAT (Intake air temperature) sensor circuit for 0.5 seconds (1 trip detection logic) P0112 Step 4 Short in IAT sensor circuit for 0.5 seconds (1 trip detection logic)
Open or short in IAT sensor circuit
IAT sensor (built in MAF meter)
ECM P0113 Step 2 Open in IAT sensor circuit for 0.5 seconds (1 trip detection logic)
Open or short in IAT sensor circuit
IAT sensor (built in MAF meter)
ECM
Open or short in IAT sensor circuit
IAT sensor (built in MAF meter)
ECM HINT: After confirming DTC P0110, P0112 or P0113, use the hand-held tester or the OBD II scan tool to confirm the IAT from the ALL menu (to reach the ALL menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL). Temperature Displayed Malfunction -40 °C (-40°F) Open circuit 140°C (284°F) or more Short circuit 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 647 05-458 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) MONITOR DESCRIPTION The ECM monitors the sensor voltage and uses this value to calculate the intake air temperature. When the sensor output voltage deviates from the normal operating range, the ECM interprets this as a fault in the IAT sensor and sets a DTC. Example: The sensor voltage output equals to -40C (-40F), or more than 140C (284F), and either condition continue for 0.5 seconds or more. MONITOR STRATEGY Related DTCs P0110: IAT Sensor Range Check (Chattering) P0112: IAT Sensor Range Check (Low Resistance) P0113: IAT Sensor Range Check (High Resistance) Required sensors / components (Main) IAT sensor Required sensors / components (Related) - Frequency of operation Continuous Duration 0.5 seconds MIL operation Immediate Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-377 TYPICAL MALFUNCTION THRESHOLDS P0110: Less than 98.5 Ω, or more than 156 kΩ IAT sensor resistance P0112: Less than 98.5 Ω [More than 140C (284F)] IAT sensor resistance [IAT] P0113: IAT sensor resistance [IAT] More than 156 kΩ [-40C (-40F)] COMPONENT OPERATING RANGE 98.5 Ω to 156 kΩ [-39 to 140C (-40 to 284F)] IAT sensor resistance [IAT] WIRING DIAGRAM M1 MAF Meter (IAT Sensor) ECM 5V THA 20 THA E7 L-B 4 E2 W-B 5 BR 5 S28 5 S29 BR 28 E2 E7 Short Connector A88688 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 648 05-459 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) INSPECTION PROCEDURE HINT:
If DTCs related to different systems that have terminal E2 as the ground terminal are output simultaneously, terminal E2 may have an open circuit. Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred.
1 (a) (b) (c) READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (INTAKE AIR TEMPERATURE) Connect the hand-held tester or the OBD II scan tool to the DLC3. Turn the ignition switch ON. Push the hand-held tester or the OBD II scan tool main switch ON. On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / INTAKE AIR. Read the values. Temperature: Same value as the actual intake air temperature. Result: Temperature Displayed Proceed to -40 °C (-40°F) A 140°C (284°F) or more B OK (Same as present temperature) C HINT:

If there is an open circuit, the hand-held tester or the OBD II scan tool indicates -40°C (-40°F). If there is a short circuit, the hand-held tester or the OBD II scan tool indicates 140°C (284°F) or more. B Go to step 4 C CHECK FOR INTERMITTENT PROBLEMS (See page 05-370 ) A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 649 05-460 DIAGNOSTICS 2 - SFI SYSTEM (3MZ-FE) READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (CHECK FOR OPEN IN WIRE HARNESS) M1 MAF Meter (a) (b) ECM (c) (d) THA E2 Disconnect the M1 MAF meter connector. Connect terminals THA and E2 of the M1 MAF meter wire harness side connector. Turn the ignition switch ON. On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / INTAKE AIR. Read the values. OK: Temperature value: 140°C (284°F) or more Wire Harness Side M1 MAF Meter THA E2 OK Y A75743 A76903 A85506 CONFIRM GOOD CONNECTION AT SENSOR. IF OK, REPLACE MASS AIR FLOW METER NG 3 READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (CHECK FOR OPEN IN ECM) M1 MAF Meter (a) Disconnect the M1 MAF meter connector. (b) Connect terminals THA and E2 of the E7 ECM connector. HINT: Before checking, do a visual and contact pressure check for the ECM connector. (c) Turn the ignition switch ON. (d) On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / INTAKE AIR. Read the values. OK: Temperature value: 140°C (284°F) or more ECM THA E2 THA Y A75742 A76903 E2 E7 ECM OK A85507 REPAIR OR CONNECTOR REPLACE HARNESS AND NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 650 05-461 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) CONFIRM GOOD CONNECTION AT ECM. IF OK, REPLACE ECM (See page 10-24 ) 4 READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (CHECK FOR SHORT IN WIRE HARNESS) M1 MAF Meter (a) (b) (c) ECM THA E2 A75766 Disconnect the M1 MAF meter connector. Turn the ignition switch ON. Select the item ”DIAGNOSIS/ENHANCED OBD II/DATA LIST/ALL/INTAKE AIR” and read its value displayed on the hand-held tester or the OBD II scan tool. OK: Temperature value: -40°C (-40°F) OK REPLACE MASS AIR FLOW METER NG 5 READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (CHECK FOR SHORT IN ECM) (a) (b) (c) E7 ECM M1 MAF Meter Disconnect the E7 ECM connector. Turn the ignition switch ON. Select the item ”DIAGNOSIS/ENHANCED OBD II/DATA LIST/ALL/INTAKE AIR” and read its value displayed on the hand-held tester or the OBD II scan tool. OK: Temperature value: -40°C (-40°F) ECM THA E2 Y A81699 A75744 A85841 OK REPAIR OR CONNECTOR REPLACE HARNESS AND NG REPLACE ECM (See page 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 651 05-462 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EXP-05 DTC P0115 ENGINE COOLANT TEMPERATURE CIRCUIT DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW INPUT DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH INPUT CIRCUIT DESCRIPTION A thermistor is built into the Engine Coolant Temperature (ECT) sensor and changes the resistance value according to the engine coolant temperature. The structure of the sensor and connection to the ECM are the same as the Intake Air Temperature (IAT) sensor. HINT: If the ECM detects the DTC P0115, P0117 or P0118, it operates the fail-safe function in which the ECT is assumed to be 80C (176F). DTC No. Proceed to DTC Detection Condition Trouble Area P0115 Step 1 Open or short in ECT sensor circuit for 0.5 seconds
Open or short in ECT sensor circuit
ECT sensor
ECM P0117 Step 4 Short in ECT sensor circuit for 0.5 seconds
Open or short in ECT sensor circuit
ECT sensor
ECM P0118 Step 2 Open in ECT sensor circuit for 0.5 seconds
Open or short in ECT sensor circuit
ECT sensor
ECM HINT: After confirming DTC P0115, P0117 or P0118, use the hand-held tester or the OBD II scan tool to confirm the ECT from the ALL menu (to reach the ALL menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL). Temperature Displayed Malfunction -40 °C (-40°F) Open circuit 140°C (284°F) or more Short circuit MONITOR DESCRIPTION The ECT sensor is used to monitor the engine coolant temperature. The ECT sensor has a thermistor that varies its resistance depending on the temperature of the engine coolant. When the coolant temperature is low, the resistance in the thermistor increases. When the temperature is high, the resistance drops. The variations in resistance are reflected in the voltage output from the sensor. The ECM monitors the sensor voltage and uses this value to calculate the engine coolant temperature. When the sensor output voltage deviates from the normal operating range, the ECM interprets this as a fault in the ECT sensor and sets a DTC. Example: When the ECM calculates that the ECT is -40C (-40F) or more than 140C (284F) and if either condition continues for 0.5 seconds or more, the ECM will set a DTC. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 652 05-463 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) MONITOR STRATEGY Related DTCs P0115: ECT Sensor Range Check (Chattering) P0117: ECT Sensor Range Check (Low Resistance) P0118: ECT Sensor Range Check (High Resistance) Required sensors / components (Main) ECT sensor Required sensors / components (Related) - Frequency of operation Continuous Duration 0.5 seconds MIL operation Immediate Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-377 TYPICAL MALFUNCTION THRESHOLDS P0115: Less than 79 Ω, or more than 156 kΩ ECT sensor resistance P0117: Less than 79 Ω [More than 140C (284F)] ECT sensor resistance [ECT] P0118: ECT sensor resistance [ECT] More than 156 kΩ [-40C (-40F)] COMPONENT OPERATING RANGE 79 Ω to 156 kΩ [-39 to 140C (-40 to 284F)] ECT sensor resistance [ECT] WIRING DIAGRAM ECM E2 ECT Sensor 5V THW 19 THW E7 G-B 2 E2 W-B 1 BR 5 S28 5 S29 BR 28 E2 E7 Short Connector A88688 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 653 05-464 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) INSPECTION PROCEDURE HINT:
If DTCs related to different system that have terminal E2 as the ground terminal are output simultaneously, terminal E2 may have an open circuit. Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred.
1 (a) (b) (c) READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (ENGINE COOLANT TEMPERATURE) Connect the hand-held tester or the OBD II scan tool to the DLC3. Turn the ignition switch ON. Push the hand-held tester or the OBD II scan tool main switch ON. On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / COOLANT TEMP. Read the values. Temperature: Same value as the actual engine coolant temperature. Result: Temperature Displayed Proceed to -40 °C (-40°F) A 140°C (284°F) or more B OK (same as present temperature) C HINT:

If there is an open circuit, the hand-held tester or the OBD II scan tool indicates -40°C (-40°F). If there is a short circuit, the hand-held tester or the OBD II scan tool indicates 140°C (284°F) or more. B Go to step 4 C CHECK FOR INTERMITTENT PROBLEMS (See page 05-370 ) A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 654 05-465 DIAGNOSTICS 2 - SFI SYSTEM (3MZ-FE) READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (CHECK FOR OPEN IN WIRE HARNESS) E2 ECT Sensor (a) (b) ECM (c) (d) THW E2 Disconnect the E2 ECT sensor connector. Connect terminals 1 and 2 of the E2 ECT sensor wire harness side connector. Turn the ignition switch ON. On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / COOLANT TEMP. Read the values. OK: Temperature value: 140°C (284°F) or more Wire Harness Side E2 ECT Sensor OK Y 75743 A66104 A85509 CONFIRM GOOD CONNECTION AT SENSOR. IF OK, REPLACE ENGINE COOLANT TEMPERATURE SENSOR NG 3 READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (CHECK FOR OPEN IN ECM) E2 ECT Sensor (a) Disconnect the E2 ECT sensor connector. (b) Connect terminals THW and E2 of the E7 ECM connector. HINT: Before checking, do a visual and contact pressure check for the ECM connector. (c) Turn the ignition switch ON. (d) On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / COOLANT TEMP. Read the values. OK: Temperature value: 140°C (284°F) or more ECM THW E2 THW Y A75742 A76903 E2 E7 ECM A85507 OK REPAIR OR CONNECTOR REPLACE HARNESS AND NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 655 05-466 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) CONFIRM GOOD CONNECTION AT ECM. IF OK, REPLACE ECM (See page 10-24 ) 4 READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (CHECK FOR SHORT IN WIRE HARNESS) E2 ECT Sensor (a) (b) (c) ECM THW E2 A75766 Disconnect the E2 ECT sensor connector. Turn the ignition switch ON. On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / COOLANT TEMP. Read the values. OK: Temperature value: -40°C (-40°F) OK REPLACE ENGINE COOLANT TEMPERATURE SENSOR NG 5 READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (CHECK FOR SHORT IN ECM) (a) (b) (c) E7 ECM E2 ECT Sensor Disconnect the E7 ECM connector. Turn the ignition switch ON. On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / COOLANT TEMP. Read the values. OK: Temperature value: -40°C (-40°F) ECM THW E2 Y A75744 A81699 A85842 OK REPAIR OR CONNECTOR REPLACE HARNESS AND NG REPLACE ECM (See page 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 656 05-467 DIAGNOSTICS DTC P0116 - SFI SYSTEM (3MZ-FE) 05BNS-11 ENGINE COOLANT TEMPERATURE CIRCUIT RANGE/PERFORMANCE PROBLEM CIRCUIT DESCRIPTION Refer to DTC P0115 on page 05-462 . DTC No. DTC Detection Condition P0116 ECT is between 35C (95F) and 60C (140F) when engine is started, and conditions (a) and (b) are met: (a) Vehicle has accelerated and decelerated. (b) ECT remains within 3°C (5.4°F) of the initial engine coolant temperature (2 trip detection logic) Trouble Area ECT P0116
ECT is more than 60°C (140°F) when engine is started and vehicle has accelerated and decelerated
ECT sensor records a temperature variation is within 1°C (1.8°F) successively 6 times (6 trip detection logic) ECT MONITOR DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to monitor the engine coolant temperature. The ECT sensor has a thermistor that varies its resistance depending on the temperature of the engine coolant. When the coolant temperature is low, the resistance in the thermistor increases. When the temperature is high, the resistance drops. The variations in resistance are reflected in the voltage output from the sensor. The ECM monitors the sensor voltage and uses this value to calculate the engine coolant temperature. When the sensor output voltage deviates from the normal operating range, the ECM interprets this as a fault in the ECT sensor and sets a DTC. Examples: 1) Upon starting the engine, the ECT is between 35C (95F) and 60C (140F). If, after driving for 250 seconds, the ECT still remains within 3C (5.4F) of the starting temperature, a DTC will be set (2 trip detection logic). 2) Upon starting the engine, the ECT is over 60C (140F). If, after driving for 250 seconds, the ECT still remains within 1C (1.8F) of the starting temperature, a DTC will be set (6 trip detection logic). MONITOR STRATEGY Related DTCs P0116: ECT Sensor Stuck at Low ECT P0116: ECT Sensor Stuck at High ECT Required sensors / components (Main) ECT sensor Required sensors / components (Related) CKP sensor, IAT sensor, MAF meter Frequency of operation Continuous Duration 250 seconds or more MIL operation 2 driving cycles: ECT Sensor Stuck at Low ECT 6 driving cycles: ECT Sensor Stuck at High ECT Sequence operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever this DTC is not present See page 05-377 ECT Sensor Stuck at Low ECT: Cumulative idle off period 250 seconds or more Speed increase by 30 km/h (18.6 mph) or more 10 times or more ECT 35 to 60C (95 to 140F) IAT -6.7 C (20F) or more 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 657 05-468 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) ECT Sensor Stuck at High ECT: ECT 60C (140F) or more -6.7 C (20F) or more IAT ”Stop and go”*1 ”Steady driving and stop ”*2 Once or more Once or more HINT: *1: Vehicle is stopped for 20 seconds or more and accelerated to more than 70 km/h (43.5 mph) within 40 seconds. *2: Vehicle is driven by 65 km/h (40.4 mph) or more for 30 seconds or more and the vehicle speed reaches 43.5 mph (70 km/h). The vehicle is decelerated from 65 km/h (40.4 mph) to 3 km/h (1.86 mph) or less within 35 seconds and stopped for 10 seconds. TYPICAL MALFUNCTION THRESHOLDS ECT Sensor Stuck at Low ECT: ECT change Less than 3C (5.4F) ECT Sensor Stuck at High ECT: ECT change 1C (1.8F) or less COMPONENT OPERATING RANGE ECT Varies with actual ECT (Engine coolant temperature) INSPECTION PROCEDURE HINT:

If DTC P0115, P0116, P0117, P0118 and P0125 are output simultaneously, the ECT sensor circuit may be open or shorted. Perform the troubleshooting of DTC P0115, P0117 or P0118 first. Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. REPLACE ENGINE COOLANT TEMPERATURE SENSOR 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 658 05-469 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EXQ-05 DTC P0120 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”A” CIRCUIT DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”A” CIRCUIT LOW INPUT DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”A” CIRCUIT HIGH INPUT DTC P0220 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”B” CIRCUIT DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”B” CIRCUIT LOW INPUT DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”B” CIRCUIT HIGH INPUT DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”A”/”B” VOLTAGE CORRELATION 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 659 05-470 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) CIRCUIT DESCRIPTION HINT:

Throttle Position Sensor Magnet ECM IC No. 1 VC VTA1 Throttle Position Sensor Output Voltage (V) This Electronic Throttle Control System (ECTS) does not use a throttle cable. This throttle position sensor is a non-contact type. The throttle position sensor is mounted on the throttle body and it detects the opening angle of the throttle valve. This sensor is electronically controlled and uses Hall-effect elements, so that accurate control and reliability can be obtained. The throttle position sensor has 2 sensor elements/signal outputs: VTA1 and VTA2. VTA1 is used to detect the throttle opening angle and VTA2 is used to detect malfunctions in VTA1. Voltage applied to VTA1 and VTA2 changes between 0V and 5V in proportion to the opening angle of the throttle valve. There are several checks that the ECM performs to confirm proper operation of the throttle position sensor and VTA1. The ECM judges the current opening angle of the throttle valve from these signals input from terminals VTA1 and VTA2, and the ECM controls the throttle motor to make the throttle valve angle properly in response to driver inputs. Fail Safe Angle *1 5 VTA2 VTA1 2.55 2.25 0.93 0.69 6 0 Usable Range 84 Throttle Valve Opening Angle (deg.) VTA2 E2 IC No. 2 Magnet Throttle Valve Fully Closed (Throttle Position expressed as percentage (VTA1) 10 to 24 %) Throttle Valve Fully Opened (Throttle Position expressed as percentage (VTA1) 64 to 96 %) *1: Fail Safe Angle 6° (Throttle Position expressed as percentage (VTA1) about 16 %) A19755 A19802 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 660 05-471 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) DTC Detection Condition DTC No. Condition (a) of DTC P0120, P0122, P0123, P0220, P0222 or P0223 continues for 2 seconds (open or short in the throttle position sensor circuit) P0120 Detection conditions for DTCs P0122 and P0123 are not satisfied but condition (a) is satisfied (a) VTA1 is 0.2 V or less or VTA1 is 4.8 V or more
Throttle position sensor
ECM (a) VTA1 is 0.2 V or less
Throttle position sensor
Short in VTA1 circuit
Open in VC circuit
ECM P0123 (a) VTA1 is 4.8 V or more
Throttle position sensor
Open in VTA1 circuit
Open in E2 circuit
Short in VC and VTA1 circuits
ECM P0220 Detection conditions for DTCs P0222 and P0223 are not satisfied but condition (a) is satisfied (a) VTA2 is 0.5 V or less or VTA2 is 4.8 V or more and VTA1 is 0.2 V or more and VTA1 is 1.8 V or less
Throttle position sensor
ECM (a) VTA2 is 0.5 V or less
Throttle position sensor
Short in VTA2 circuit
Open in VC circuit
ECM P0223 (a) VTA2 is 4.8 V or more and VTA1 is 0.2 V or more and VTA1 is 1.8 V or less
Throttle position sensor
Open in VTA2 circuit
Open in E2 circuit
Short in VC and VTA2 circuits
ECM P2135 Condition (a) continues for 0.5 seconds or more, or condition (b) continues for 0.4 seconds or more: (a) Difference between VTA1 and VTA2 is 0.02 V or less (b) VTA1 is 0.2 V or less and VTA2 is 0.5 V or less
Short in VTA1 and VTA2 circuit
Throttle position sensor
ECM P0122 P0222 Trouble Area HINT:

After confirming DTCs, use the hand-held tester or the OBD II scan tool to confirm the throttle valve opening percentage and closed throttle position switch condition. ”THROTTLE POS” is the VTA1 signal. ”THROTTLE POS #2” is the VTA2 signal. Reference (Normal condition): Tester display Accelerator pedal released Accelerator pedal fully depressed THROTTLE POS 10 to 24 % 64 to 96 % THROTTLE POS #2 2.1 to 3.1 V 4.5 to 5.5 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 661 05-472 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) MONITOR DESCRIPTION The ECM uses the throttle position sensor to monitor the throttle valve opening angle. (a) There is a specific voltage difference between VTA1 and VTA2 for each throttle opening angle.
If the difference between VTA1 and VTA2 deviates from the specified range, the ECM interprets this as a default and will set a DTC. (b) VTA1 and VTA2 have each specific voltage operating range.
If VTA1 or VTA2 is out of the normal operating range, the ECM interprets this as a fault and will set a DTC. (c) VTA1 and VTA2 should never be close to the same voltage levels.
If the difference between VTA1 and VTA2 is within 0.02 V, the ECM interprets this as a short circuit in the throttle position sensor system and will set a DTC. FAIL SAFE If the ETCS has a malfunction, the ECM cuts off current to the throttle control motor. The throttle control valve returns to a predetermined opening angle (approximately 16) by the force of the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue at a minimal speed. If the accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly. If a ”pass” condition is detected and then the ignition switch is turned OFF, the fail-safe operation will stop and the system will return to normal condition. MONITOR STRATEGY Related DTCs P0120: TP Sensor 1 Range Check (Chattering) P0122: TP Sensor 1 Range Check (Low voltage) P0123: TP Sensor 1 Range Check (High voltage) P0220: TP Sensor 2 Range Check (Chattering) P0222: TP Sensor 2 Range Check (Low voltage) P0223: TP Sensor 2 Range Check (High voltage) P2135: TP Sensor Range Check (Correlation) Required sensors / components (Main) TP (Throttle position) sensor Required sensors / components (Related) - Frequency of operation Continuous Duration Accelerator pedal ON: 2 seconds Accelerator pedal OFF: 10 seconds 0.5 seconds or 0.4 seconds (P2135) MIL operation Immediate Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-377 TYPICAL MALFUNCTION THRESHOLDS P0120: VTA1 voltage 0.2 V or less, or 4.8 V or more P0122: VTA1 voltage 0.2 V or less P0123: VTA1 voltage 4.8 V or more P0220: VTA2 voltage 0.5 V or less, or 4.8 V or more 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 662 05-473 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) P0222: VTA2 voltage 0.5 V or less P0223: VTA2 voltage when the VTA is 0.2 to 1.8 V 4.8 V or more P2135: Either of the following condition(s) is met: Condition 1 or 2 Condition 1 - Difference between VTA1 and VTA2 voltages 0.02 V or less Condition 2 - VTA1 voltage 0.2 V or less VTA2 voltage 0.5 V or less COMPONENT OPERATING RANGE VTA1 voltage 0.6 to 3.96 V VTA2 voltage 2.25 to 4.8 V WIRING DIAGRAM T13 Throttle Position Sensor VC VTA1 VTA2 E2 ECM 18 VC E7 Y 5 R-W 21 VTA1 E7 B-R 31 VTA2 E7 6 4 W-B 3 BR 5 S28 5 BR S29 5V 28 E7 E2 Short Connector A88690 INSPECTION PROCEDURE HINT:

If DTCs related to different systems that have terminal E2 as the ground terminal are output simultaneously, terminal E2 may have an open circuit. Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 663 05-474 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) Hand-held tester: 1 READ VALUE OF HAND-HELD TESTER (THROTTLE POS AND THROTTLE POS #2) (a) On the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / THROTTLE POS and THROTTLE POS #2. Read the values. Result: Throttle position expressed as percentage and voltage Throttle position expressed as percentage and voltage Throttle position expressed as percentage and voltage Throttle position expressed as percentage and voltage Accelerator pedal released Accelerator pedal released Accelerator pedal repressed Accelerator pedal repressed THROTTLE POS (VTA1) THROTTLE POS #2 (VTA2) THROTTLE POS (VTA1) THROTTLE POS #2 (VTA2) Trouble Area Proceed to 0% 0 to 0.2 V 0% 0 to 0.2 V VC circuit open A 100 % 4.5 to 5.5 V 100 % 4.5 to 5.5 V E2 circuit open A 0 % or 100 % 2.1 to 3.1 V (fail safe) 0 % or 100 % 2.1 to 3.1 V (fail safe) VTA1 circuit open or ground short A about 16 % (fail safe) 0 to 0.2 or 4.5 to 5.5 V about 16 % (fail safe) 0 to 0.2 or 4.5 to 5.5 V VTA2 circuit open or ground short A 10 to 24 % 2.1 to 3.1 V 64 to 96 % (does not fail safe) 4.5 to 5.5 V (does not fail safe) Throttle position sensor circuit is normal B B Go to step 5 A 2 CHECK WIRE HARNESS (THROTTLE POSITION SENSOR - ECM) (a) (b) (c) Wire Harness Side T13 Throttle Position Sensor Disconnect the T13 throttle position sensor connector. Disconnect the E7 ECM connector. Check the resistance of the wire harness side connectors. Standard: Tester Connection E2 VTA2 VC T13-5 (VC) T13-6 (VTA1) T13-4 (VTA2) T13-3 (E2) - VTA1 E7-18 E7-21 E7-31 E7-28 Specified Condition (VC) (VTA1) (VTA2) (E2) Below 1 Ω T13-5 (VC) or E7-18 (VC) - Body ground T13-6 (VTA1) or E7-21 (VTA1) - Body ground T13-4 (VTA2) or E7-31 (VTA2) - Body ground 10 kΩ or higher E7 ECM VC E2 Y B53781 A81699 VTA1 VTA2 A85510 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 664 05-475 DIAGNOSTICS 3 - SFI SYSTEM (3MZ-FE) INSPECT ECM (VC VOLTAGE) (a) (b) (c) VC (+) E7 E2 (-) ECM A76903 Disconnect the T13 throttle position sensor connector. Turn the ignition switch ON. Check the voltage of the ECM connector. Standard: Tester Connection Specified Condition E7-18 (VC) - E7-28 (E2) 4.5 to 5.5 V NG REPLACE ECM (See page 10-24 ) OK 4 REPLACE THROTTLE BODY ASSY (See page 10-18 ) GO 5 (a) (b) (c) (d) READ OUTPUT DTC (THROTTLE POSITION SENSOR DTCS ARE OUTPUT AGAIN) Clear the DTC (see page 05-400 ). Start the engine. Run the engine at idle for 15 seconds or more. Read the DTC (see page 05-400 ). Result: Display (DTC Output) Proceed to P0120, P0122, P0123, P0220, P0222, P0223 and/or P2135 are output again A No DTC output B B SYSTEM OK A REPLACE ECM (See page 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 665 05-476 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) OBD II scan tool (excluding hand-held tester): 1 CHECK WIRE HARNESS (THROTTLE POSITION SENSOR - ECM) (a) (b) (c) Wire Harness Side T13 Throttle Position Sensor Disconnect the T13 throttle position sensor connector. Disconnect the E7 ECM connector. Check the resistance of the wire harness side connectors. Standard: Tester Connection E2 VTA2 VC T13-5 (VC) T13-6 (VTA1) T13-4 (VTA2) T13-3 (E2) - VTA1 E7-18 E7-21 E7-31 E7-28 Specified Condition (VC) (VTA1) (VTA2) (E2) Below 1 Ω T13-5 (VC) or E7-18 (VC) - Body ground T13-6 (VTA1) or E7-21 (VTA1) - Body ground T13-4 (VTA2) or E7-31 (VTA2) - Body ground 10 kΩ or higher E7 ECM VC E2 Y B53781 A81699 VTA1 VTA2 NG A85510 REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2 INSPECT ECM (VC VOLTAGE) (a) (b) (c) VC (+) E2 (-) E7 ECM A76903 Disconnect the T13 throttle position sensor connector. Turn the ignition switch ON. Measure the voltage of the ECM connector. Standard: NG Tester Connection Specified Condition E7-18 (VC) - E7-28 (E2) 4.5 to 5.5 V REPLACE ECM (See page 10-24 ) OK 3 REPLACE THROTTLE BODY ASSY (See page 10-18 ) GO 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 666 05-477 DIAGNOSTICS 4 (a) (b) (c) (d) - SFI SYSTEM (3MZ-FE) READ OUTPUT DTC (THROTTLE POSITION SENSOR DTCS ARE OUTPUT AGAIN) Clear the DTC (see page 05-400 ). Start the engine. Run the engine at idle for 15 seconds or more. Read the DTC (see page 05-400 ). Result: Display (DTC Output) Proceed to P0120, P0122, P0123, P0220, P0222, P0223 and/or P2135 are output again A No DTC output B B SYSTEM OK A REPLACE ECM (See page 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 667 05-478 DIAGNOSTICS DTC P0121 - SFI SYSTEM (3MZ-FE) 052NE-54 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”A” CIRCUIT RANGE/PERFORMANCE PROBLEM CIRCUIT DESCRIPTION Refer to DTC P0120 on page 05-469 . DTC No. P0121 DTC Detection Condition Trouble Area Condition (a) continues for 2.0 sec.: (a) Difference between VTA1 and VTA2 deviates from threshold Throttle position sensor MONITOR DESCRIPTION The ECM uses the throttle position sensor to monitor the throttle valve opening angle. This sensor includes 2 signals: VTA1 and VTA2. VTA1 is used to detect the throttle opening angle and VTA2 is used to detect malfunctions in VTA1. There are several checks that the ECM performs to confirm proper operation of the throttle position sensor and VTA1. The VTA1 and VTA2 voltage output difference should be less than 0.1V and more than 0.4V. If the voltage output difference deviates from this range, the ECM concludes the throttle position sensor has a malfunction.The ECM will turn on the MIL and a DTC will be set. FAIL SAFE If the Electronic Throttle Control System (ETCS) has a malfunction, the ECM cuts off current to the throttle control motor. The throttle control valve returns to a predetermined opening angle (approximately 16
) by the force of the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue at a minimal speed. If the accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly. If a ”pass” condition is detected and then the ignition switch is turned OFF, the fail-safe operation will stop and the system will return to normal condition. MONITOR STRATEGY Related DTCs P0121: TP (Throttle position) Sensor Rationality Required sensors / components (Main) TP sensor Required sensors / components (Related) - Frequency of operation Continuous Duration 2 seconds MIL operation Immediate Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-377 TYPICAL MALFUNCTION THRESHOLDS Either of the following condition is met: - TP sensor 1 - (TP sensor 2 x 0.8) Below 0.8 V or 1.6 V or more 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 668 05-479 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. REPLACE THROTTLE BODY ASSY (See page 10-18 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 669 05-480 DIAGNOSTICS DTC P0125 - SFI SYSTEM (3MZ-FE) 052NC-43 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL CIRCUIT DESCRIPTION Refer to DTC P0115 on page 05-462 . DTC No. DTC Detection Condition P0125 When ECT or IAT is less than -19.45°C (-3°F) at engine start and 20 minutes or more after starting engine, ECT sensor value is 20°C (68°F) or less (2 trip detection logic)
Cooling system
ECT sensor
Thermostat Trouble Area P0125 When ECT and IAT are between -19.45°C (-3°F) and -8.34 °C (17°F) at engine start, 5 minutes or more after starting engine and ECT sensor value is 20°C (68°F) or less (2 trip detection logic)
Cooling system
ECT sensor
Thermostat P0125 When ECT and IAT greater than -8.34°C (17°F) at engine start and 2 minutes or more after starting engine, ECT sensor value is 20°C (68°F) or less (2 trip detection logic)
Cooling system
ECT sensor
Thermostat MONITOR DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to monitor the temperature of the engine coolant. The resistance of the sensor varies with the actual coolant temperature. The ECM applies a voltage to the sensor and the varying resistance of the sensor causes the signal voltage to vary. The ECM monitors the ECT signal voltage after engine start-up. If, after sufficient time has passed, the sensor still reports that the engine is not warm enough for closed-loop fuel control, the ECM interprets this as a fault in the sensor or cooling system and sets a DTC. Example: The ECT is 0C (32F) at engine start. After 5 minutes running time, the ECT sensor still indicates that the engine is not warm enough to begin air fuel ratio feedback control of the air-fuel ratio. The ECM interprets this as a fault in the sensor or cooling system and sets a DTC. MONITOR STRATEGY Related DTCs P0125: Insufficient ECT for Closed Loop Required sensors / components (Main) Thermostat, Cooling system Required sensors / components (Related) ECT sensor, MAF meter Frequency of operation Continuous Duration 2 minutes: Engine start ECT is -8.34C (17F) or more 5 minutes: Engine start ECT is -19.45 to -8.34C (-3 to 17F) 20 minutes: Engine start ECT is less than -19.45C (-3F) MIL operation 2 driving cycles Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present See page 05-377 Fuel cut OFF Engine Running Idle OFF TYPICAL MALFUNCTION THRESHOLDS Time until ”actual ECT” reaches ”Closed Loop ECT” 2 minutes: Engine start ECT is -8.34C (17F) or more 5 minutes: Engine start ECT is -19.45 to -8.34C (-3 to 17F) 20 minutes: Engine start ECT is less than -19.45C (-3F) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 670 05-481 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) INSPECTION PROCEDURE HINT:
If DTC P0115, P0116, P0117, P0118 and P0125 are output simultaneously, ECT sensor circuit may be open or short. Perform the troubleshooting of DTC P0115, P0117 or P0118 first. Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred.
1 (a) CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0125) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display (DTC Output) Proceed to Only P0125 are output A P0125 and other DTCs are output B HINT: If any other codes besides P0125 is output, perform the troubleshooting for those codes first. B GO TO RELEVANT DTC CHART (See page 05-412 ) A 2 (a) INSPECT THERMOSTAT (See page 16-21 ) Check the valve opening temperature of the thermostat. OK: Valve opening temperature: 80 to 84C (176 to 183F). HINT: Also check the valve is completely closed under opening temperature as above. NG REPLACE THERMOSTAT (See page 16-31 ) OK 3 (a) CHECK COOLING SYSTEM Check the cooling system for excessive cooling, such as abnormal radiator fan operation, modified cooling system and other defects. OK: There is no modification of cooling system. NG REPAIR OR REPLACE COOLING SYSTEM OK REPLACE ENGINE COOLANT TEMPERATURE SENSOR 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 671 05-482 DIAGNOSTICS DTC P0128 - SFI SYSTEM (3MZ-FE) 05C1M-10 COOLANT THERMOSTAT (COOLANT TEMPERATURE BELOW THERMOSTAT REGULATING TEMPERATURE) CIRCUIT DESCRIPTION This DTC is output when the Engine Coolant Temperature (ECT) does not reach 75°C (167°F) despite sufficient engine warm-up time. DTC No. P0128 DTC Detection Condition Trouble Area
Thermostat
Cooling system
ECT sensor
ECM Conditions (a), (b) and (c) are met: (a) Cold start (b) Sufficient warm-up time has elapsed (c) ECT is less than 75°C (167°F) MONITOR DESCRIPTION 5 seconds Estimated ECT Threshold (75C (167F)) Indicated coolant temp. reading ECT Time DTC set (after 2 driving cycle) A82385 The ECM estimates the coolant temperature based on starting temperature, engine loads, and engine speeds. The ECM then compares the estimated temperature with the actual ECT. When the estimated coolant temperature reaches 75C (167F), the ECM checks the actual ECT. If the actual ECT is less than 75C (167F), the ECM will interpret this as a fault in the thermostat or engine cooling system and set a DTC. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 672 05-483 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) MONITOR STRATEGY Related DTCs P0128: Coolant Thermostat Required sensors / components (Main) Thermostat Required sensors / components (Related) ECT sensor, IAT sensor, VSS Frequency of operation Once per driving cycle Duration 900 seconds MIL operation 2 driving cycles Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present See page 05-377 Battery voltage 11 V or more Throttle position learning Completed Either of the following conditions is met: Condition 1 or 2 1. All of the following conditions are met: Condition (a), (b) and (c) (a) ECT at engine start - IAT at engine start -15 to 7C (-27 to 12.6F) (b) ECT at engine start -10 to 56C (14 to 132.8F) (c) IAT at engine start -10 to 56C (14 to 132.8F) 2. All of the following conditions are met: Condition (a), (b) and (c) (a) ECT at engine start - IAT at engine start More than 7C (12.6F) (b) ECT at engine start 56C (132.8F) or less (c) IAT at engine start -10 C (14 F) or more Accumulated time that vehicle speed is 80 mph (128 km/h) or more Less than 20 seconds TYPICAL MALFUNCTION THRESHOLDS Duration that both of the following conditions are met: 5 seconds or more Estimated ECT 75C (167F) or more Actual ECT Less than 75C (167F) MONITOR RESULT Refer to page 05-385 for detailed information. The test value and test limit information are described as shown in the following table. Check the monitor result and test values after performing the monitor drive pattern (see page 05-387 ).
TID (Test Identification Data) is assigned to each emissions-related component.
TLT (Test Limit Type): If TLT is 0, the component is malfunctioning when the test value is higher than the test limit. If TLT is 1, the component is malfunctioning when the test value is lower than the test limit.
CID (Component Identification Data) is assigned to each test value.
Unit Conversion is used to calculate the test value indicated on generic OBD ll scan tools. TID $08: Thermostat TLT 1 CID $01 Unit Conversion Multiply by 0.625 and subtract 40 (C) Description of Test Data ECT sensor output when estimated ECT has reached to malfunction criterion Description of Test Limit Malfunction criteria for thermostat INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 673 05-484 DIAGNOSTICS 1 (a) - SFI SYSTEM (3MZ-FE) CHECK COOLING SYSTEM Check the cooling system for excessive cooling, such as abnormal radiator fan operation, modified cooling system and other defects. OK: There is no modification of cooling system. NG REPAIR OR REPLACE COOLING SYSTEM OK 2 (a) INSPECT THERMOSTAT (See page 16-21 ) Check the valve opening temperature of the thermostat. OK: Valve opening temperature: 80 to 84C (176 to 183F). HINT: Also check the valve is completely closed under opening temperature as above. NG REPLACE THERMOSTAT (See page 16-31 ) OK REPLACE ECM (See page 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 674 05-485 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05MON-01 DTC P0136 OXYGEN SENSOR CIRCUIT MALFUNCTION (BANK 1 SENSOR 2) DTC P0137 OXYGEN SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2) DTC P0138 OXYGEN SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2) DTC P0156 OXYGEN SENSOR CIRCUIT MALFUNCTION (BANK 2 SENSOR 2) DTC P0157 OXYGEN SENSOR CICRCUIT LOW VOLTAGE (BANK 2 SENSOR 2) DTC P0158 OXYGEN SENSOR CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 2) CIRCUIT DESCRIPTION The heated oxygen sensor (HO2S) is used to monitor oxygen in the exhaust gas. For optimum catalyst operation, the air fuel mixture (air-fuel ratio) must be maintained near the ideal stoichiometric ratio. The HO2S output voltage changes suddenly in the vicinity of the stoichiometric ratio. The ECM adjusts the fuel injection time so that the air-fuel ratio is nearly stoichiometirc. The HO2S generates a voltage between 0.1 and 0.9 V in response to oxygen in the exhaust gas. If the oxygen in the exhaust gas increases, the air-fuel ratio becomes Lean. The ECM interprets Lean when the HO2S voltage is below 0.45 V. If the oxygen in the exhaust gas decreases, the air-fuel ratio becomes Rich. The ECM interprets Rich when the HO2S voltage is above 0.45 V. Atmosphere Ideal Air-fuel Mixture Platinum Electrode Solid Electrolyte (Zirconia Element) Platinum Electrode Heater Coating (Ceramic) Output Voltage Housing Richer - Air Fuel Ratio - Leaner Cover Exhaust Gas A00798 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 675 05-486 DIAGNOSTICS DTC No. - SFI SYSTEM (3MZ-FE) DTC Detection Condition Trouble Area P0136
Either of the following condition is met: (a) Heated oxygen sensor voltage was less than 0.05 V for a certain period (2-trip detection logic) (b) Heated oxygen sensor did not switch for a certain period (2-trip detection logic)
Heated oxygen sensor circuit (bank 1)
Heated oxygen sensor (bank 1)
Oxygen sensor heater (bank 1)
A/F sensor (bank 1)
A/F sensor heater (bank 1) P0137 Heated oxygen sensor voltage was less than 0.03 V for 90 seconds
Heated oxygen sensor circuit (bank 1)
Heated oxygen sensor (bank 1)
Oxygen sensor heater (bank 1) P0138 Either of the following condition is met: (a) Heated oxygen sensor voltage did not drop during fuel-cut (2-trip detection logic) (b) Heated oxygen sensor voltage was 1.2 V or higher for 10 seconds
Heated oxygen sensor circuit (bank 1)
Heated oxygen sensor (bank 1)
Oxygen sensor heater (bank 1) P0156
Either of the following condition is met: (a) Heated oxygen sensor voltage was less than 0.05 V for a certain period (2-trip detection logic) (b) Heated oxygen sensor did not switch for a certain period (2-trip detection logic)
Heated oxygen sensor circuit (bank 2)
Heated oxygen sensor (bank 2)
Oxygen sensor heater (bank 2)
A/F sensor (bank 2)
A/F sensor heater (bank 2) P0157 Heated oxygen sensor voltage was less than 0.03 V for 90 seconds
Heated oxygen sensor circuit (bank 2)
Heated oxygen sensor (bank 2)
Oxygen sensor heater (bank 2) P0158 Either of the following condition is met: (a) Heated oxygen sensor voltage did not drop during fuel-cut (2-trip detection logic) (b) Heated oxygen sensor voltage was 1.2 V or higher for 10 seconds
Heated oxygen sensor circuit (bank 2)
Heated oxygen sensor (bank 2)
Oxygen sensor heater (bank 2) MONITOR DESCRIPTION The ECM monitors the rear heated oxygen sensor (HO2S) in the following 3 items:
1. The HO2S voltage changes between Rich (more than 0.45 V) and Lean (less than 0.45 V) while the vehicle is running (repeating acceleration and deceleration) for 8 minutes. If not, the ECM interprets this as a malfunction, illuminates the MIL, and then sets a DTC.
2. The HO2S voltage does not remain at less than 0.05 V for a long time while the vehicle is running (60% of the time in the 220 seconds monitor, the sensor output is less than 0.05 V). If it does, the ECM interprets this as a malfunction, illuminates the MIL, and then sets a DTC.
3. The sensor’s voltage drops to below 0.2 V (extremely Lean status) immediately when the vehicle decelerates and the fuel cut is working for 6 seconds. If not, the ECM interprets this to mean the sensor’s response feature has deteriorated, illuminates the MIL, and then sets a DTC. MONITOR STRATEGY Related DTCs P0136, P0156: Heated oxygen sensor output voltage (Output voltage) P0136, P0156: Heated oxygen sensor impedance (Low impedance) P0137, P0157: Heated oxygen sensor low voltage P0138, P0158: Heated oxygen sensor high voltage P0138, P0158: Heated oxygen sensor output voltage (Extremely high) Required sensors/components (Main) HO2S Required sensors/components (Related) ECT sensor, MAF meter, VSS Frequency of operation Once per driving cycle Duration Within 480 seconds MIL operation Immediate: Heated oxygen sensor low/high voltage 2 driving cycles: Others Sequence operation None 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 676 05-487 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present See page 05-377 P0136, P0156 (Rear HO2S output voltage - case 1): All of the following conditions are met: Conditions 1, 2, 3 and 4 1. Malfunction determination in this driving cycle Not detected 2. Engine Running 3. Time after engine start 0 second or more 4. Either of the following conditions is met: Conditions (a) or (b) (a) Cumulative time while HO2S heater is operating 22 seconds or more (b) HO2S voltage Has reached to 0.2 V or more P0136, P0156 (Rear HO2S output voltage - case 2): Engine Running P0137, P0157 (Rear HO2S low voltage): Battery voltage 11 V or more Estimated heated oxygen sensor temperature 450C (842F) or more Time after fuel-cut ended 30 seconds or more P0138, P0158 (Rear HO2S high voltage): Engine Running Battery voltage 11 V or more P0138, P0158 (Rear HO2S output voltage during fuel-cut): Engine coolant temperature 70C (158F) or more Catalyst temperature 500C (932F) or more Fuel-cut Excuting TYPICAL MALFUNCTION THRESHOLDS P0136, P0156 (Rear HO2S output voltage - case 1): Both of the following conditions are met: Conditions 1 and 2 1. Frequency that HO2S voltage changes between (a) and (b) 0 time (a) Maximum voltage 0.6 V or more (b) Minimum voltage Less than 0.45 V 2. Cumulative monitor time *1 of rear HO2S 320 seconds or more *1: Monitor time is counted when all of the following conditions are met: Conditions (a) and (b) (a) Fuel system status Closed-loop (b) Idle OFF P0136, P0156 (Rear HO2S output voltage - case 2): All of the following conditions are met: 1. Cumulative monitor time *2 of HO2S Conditions 1, 2, 3, 4 and 5 160 seconds or more 2. Duration while HO2S voltage is below 0.05 V 96 seconds or more 3. Duration while HO2S voltage is higher than 0.7 V Less than 32 seconds 4. Duration while HO2S voltage is 0.45 V to 0.7 V Less than 48 seconds 5. Duration while HO2S voltage is 0.45 V or more Less than 20 seconds *2: Monitor time is counted when all of the following conditions are met: Conditions 1, 2, 3 and 4 1. Intake air amount per revolution 7 g/rev or more 2. Vehicle speed 3 km/h (1.875 mph) or more 3. Idle OFF 4. Fuel-cut OFF 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 677 05-488 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) P0137, P0157 (Rear HO2S low voltage): Sensor voltage Lower than 0.03 V P0138, P0158 (Rear HO2S high voltage): Sensor voltage 1.2 V or more P0138, P0158 (Rear HO2S output voltage during fuel-cut): Either of the following conditions is met: Conditions 1 or 2 1. Duration until rear HO2S voltage drops to 0.2 V after fuelcut start 6 seconds or more 2. Both of the following conditions are met: Conditions (a) and (b) (a) Rear HO2S voltage when fuel-cut starts 0.5 V or more (b) Duration that HO2S voltage is 0.2 to 0.35 V 1 second or more COMPONENT OPERATING RANGE HO2S voltage Varies between 0.1 and 0.9 V O2S TEST RESULT (MODE 05) Refer to page 05-383 for detailed information. TEST ID/COMP ID Description of TEST VALUE Conversion Factor Unit Standard Value $07 Minimum HO2S voltage N/A V Less than TEST LIMIT $08 Maximum HO2S voltage N/A V More than TEST LIMIT $31 Average time per one-cycle of HO2S frequency that HO2S switches Rich to Lean N/A Second Less than TEST LIMIT $32 Average time per one-cycle of HO2S frequency that HO2S switches Lean to Rich N/A Second Less than TEST LIMIT $37 Time until HO2S voltage drops to 0.2 V during fuel-cut N/A Second Less than TEST LIMIT $81 Percentage in monitoring time while HO2S voltage is lower than 0.05 V Multiply by 0.39 % Less than TEST LIMIT $84 Percentage in monitoring time while HO2S voltage is higher than 0.7 V Multiply by 0.39 % Less than TEST LIMIT $85 Continuous time while HO2S voltage is higher than 0.45 V Multiply by 0.262 Second Less than TEST LIMIT $87 Percentage in monitoring time while HO2S voltage is higher than 0.45 V Multiply by 0.39 % More than TEST LIMIT 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 678 05-489 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) WIRING DIAGRAM Engine Room R/B No. 2 ECM EFI NO. 2 2 1 25 HT1B E8 R-Y 2 2 B-W 1 EB1 Y B-R H10 Heated Oxygen Sensor (Bank 1 Sensor 1) 5 IM1 B-R GR 1 HT IM1 6 BR 21 OX1B E8 W +B 2 IM1 3 *1 Engine Room J/B 3 2D W 5 2B 3 EFI Relay 1 B 3 OX 2 IM1 E1 4 H6 Heated Oxygen Sensor (Bank 2 Sensor 2) B-R BR 5 33 HT2B E8 W-L 2 +B HT 1 2 *1 B EFI NO. 1 4 E1 OX 3 5 S28 5 S29 29 OX2B E8 BR 1 4 2F 2I Short Connector W 3 W-B F7 FL Block Assy 1 28 E7 E2 BR P-L 13 IK3 8 E5 B MREL A R J2 J/C W 4 IM1 FL Main A BR A J7 J/C A BR Battery EH ED *1: Shielded A88692 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 679 05-490 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) CONFIRMATION DRIVING PATTERN (a), (b) Vehicle speed Once 40 sec. or more Twice 40 sec. or more (d) (d) 60 km/h (38 mph) Idling (c) (e) 12 times 40 sec. or more (d) (e) (f) IG SW OFF Warm up 10 sec. (engine coolant or more temperature is more than 75C) 10 sec. or more 10 sec. or more A58686 (a) Connect the hand-held tester to the DLC3. (b) Switch the hand-held tester from the normal mode to the check (test) mode (see page 05-402 ). (c) Start the engine and warm up the engine untill engine coolant temperature is more than 75C. (d) Drive the vehicle at 60 km/h (38 mph) or more for 40 seconds or more. (e) Let the engine idle for 10 seconds or more. (f) Perform steps (d) to (e) 12 times. HINT: If a malfunction exists, the MIL will illuminate during step (f). NOTICE: If the conditions in this test are not strictly followed, detection of a malfunction will not occur. If you do not have a hand-held tester, turn the ignition switch OFF after performing steps from (c) to (f), then perform steps from (c) to (f) again. CONFIRMATION DRIVING PATTERN (P0137 and/or P0157) Warm up the engine and run the engine at 60 km/h (38 mph) for 7 minutes. CONFIRMATION DRIVING PATTERN (P0138 and/or P0158) Warm up the engine and run the engine at idle for 30 seconds. INSPECTION PROCEDURE HINT: Hand-held tester only: It is possible the malfunctioning area can be found using the ACTIVE TEST A/F CONTROL operation. The A/F CONTROL operation can determine if the A/F sensor, heated oxygen sensor or other potential trouble areas are malfunctioning or not. (a) Perform the ACTIVE TEST A/F CONTROL operation. HINT: The A/F CONTROL operation lowers the injection volume by 12.5 % or increases the injection volume by 25 %. (1) Connect the hand-held tester to the DLC3 on the vehicle. (2) Turn the ignition switch ON. (3) Warm up the engine by running the engine at 2,500 rpm for approximately 90 seconds. (4) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (5) Perform the A/F CONTROL operation with the engine idle (press the right or left button). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 680 05-491 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) Result: A/F sensor reacts in accordance with increase and decrease of injection volume: +25 % → rich output: Less than 3.0 V -12.5 % → lean output: More than 3.35 V Heated oxygen sensor reacts in accordance with increase and decrease of injection volume: +25 % → rich output: More than 0.55 V -12.5 % → lean output: Less than 0.4 V NOTICE: The A/F sensor output has a few seconds of delay and the heated oxygen sensor output has about 20 seconds of delay at maximum. Output voltage of A/F sensor (sensor 1) Output voltage of heated oxygen sensor (sensor 2) Injection volume Injection volume +25 % +25 % -12.5 % -12.5 % Case 1 Output voltage More than 3.35 V Less than 3.0 V OK More than 0.55 V Injection volume +25 % -12.5 % -12.5 % Case 2 Output voltage A/F sensor (A/F sensor, heater, A/F sensor circuit) Output voltage NG Injection volume More than 0.55 V OK Less than 0.4V Injection volume +25 % +25 % -12.5 % -12.5 % Case 3 Output voltage NG Heated oxygen sensor (heated oxygen sensor, heater, heated oxygen sensor circuit) NG Extremely rich or lean actual air-fuel ratio (Injector, fuel pressure, gas leakage in exhaust system, etc.) Output voltage More than 3.35 V OK Injection volume Almost No reaction Injection volume +25 % +25 % -12.5 % -12.5 % Case 4 Output voltage Almost No reaction OK Less than 0.4V +25 % Less than 3.0V  Output voltage Injection volume Almost No reaction Mainly suspected Trouble Area Output voltage NG Almost No reaction The following A/F CONTROL procedure enables the technician to check the graph of the voltage output from both the A/F sensor and the heated oxygen sensor. To display the graph, enter ”ACTIVE TEST / A/F CONTROL / USER DATA”, select ”AFS B1S1 and O2S B1S2” by pressing ”YES”, and then ”ENTER”. Then press ”F4”. HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 681 05-492 DIAGNOSTICS 1 - SFI SYSTEM (3MZ-FE) CHECK OTHER DTC OUTPUT (a) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display (DTC Output) Proceed to P0138 and/or P0158 are output A P0137 and/or P0157 are output B P0136 and/or P0156 are output C HINT: If any other codes besides P0136, P0137, P0138, P0156, P0157 and/or P0158 are output, perform the troubleshooting for those codes first. B Go to step 9 C Go to step 6 A 2 READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (OUTPUT VOLTAGE OF HEATED OXYGEN SENSOR) (a) (b) (c) (d) (e) Connect the hand-held tester or the OBD II scan tool to the DLC3. Turn ON the ignition switch. Push the hand-held tester or the OBD II scan tool main switch ON. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / O2S B1S2. Run the engine at idle. Read the output voltage of the heated oxygen sensor during idling. Heated oxygen sensor output voltage Proceed to More than 1.2 V A Less than 1.0 V B B Go to step 5 A 3 CHECK WIRE HARNESS (a) (b) (c) E8 ECM HT1B HT2B Turn the ignition switch OFF and wait for 5 minutes. Disconnect the E8 ECM connector. Measure the resistance of the wire harness side connectors. Standard: OX1B OX2B A81695 OK Tester Connection Specified Condition E8-25 (HT1B) - E8-21 (OX1B) 10 kΩ or higher E8-33 (HT2B) - E8-29 (OX2B) 10 kΩ or higher E8-25 (HT1B) - Body ground 10 kΩ or higher E8-33 (HT2B) - Body ground 10 kΩ or higher REPLACE ECM NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 682 05-493 DIAGNOSTICS 4 - SFI SYSTEM (3MZ-FE) INSPECT HEATED OXYGEN SENSOR (CHECK FOR SHORT) (a) (b) Heated Oxygen Sensor HT +B +B 1 2 3 4 E1 Disconnect the H10 heated oxygen sensor connector. Measure the resistance of the sensor side connectors. Standard: HT 2 1 4 3 OX E1 H10 (Bank 1) OX H6 (Bank 2) A87828 OK Tester Connection Specified Condition H10-1 (+B) - H10-3 (E1) 10 kΩ or higher H10-1 (+B) - H10-4 (OX) 10 kΩ or higher H6-2 (+B) - H6-4 (E1) 10 kΩ or higher H6-2 (+B) - H6-3 (OX) 10 kΩ or higher REPAIR OR CONNECTOR REPLACE HARNESS AND NG REPLACE HEATED OXYGEN SENSOR 5 (a) READ OUTPUT DTC (CHECK MODE) Change the ECM to check mode with the hand-held tester. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / CHECK MODE. Warm up the engine and drive the vehicle at over 25 mph (40 km/h) for an accumulated total of 10 minutes. (b) HINT: Driving should be continued for 10 minutes consecutively, but it is not necessary to maintain a speed of 25 mph (40 km/h) during this time. (c) Read the DTC. Result: Display (DTC output) Proceed to P0138 and/or P0158 are output A No DTC B B CHECK FOR INTERMITTENT PROBLEMS (See page 05-370 ) A REPLACE HEATED OXYGEN SENSOR 6 READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (OUTPUT VOLTAGE OF HEATED OXYGEN SENSOR) (a) After warming up the engine, run the engine at 2,500 rpm for 3 minutes. (b) Read the output voltage of the heated oxygen sensor when the engine rpm is suddenly increased. HINT: Quickly accelerate the engine to 4,000 rpm 3 times by using the accelerator pedal. Heated oxygen sensor output voltage: Alternates 0.4 V or less and 0.5 V or more. OK Go to step 10 NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 683 05-494 DIAGNOSTICS 7 - SFI SYSTEM (3MZ-FE) INSPECT HEATED OXYGEN SENSOR (HEATER RESISITANCE) (a) (b) Heated Oxygen Sensor HT +B +B 1 2 3 4 HT 2 1 4 3 OX E1 E1 OX H6 (Bank 2) H10 (Bank 1) A87828 Disconnect the H10 heated oxygen sensor connector. Measure the resistance of the heated oxygen sensor terminals. Standard: Tester Connection Condition Specified Condition H10-2 (HT) - H10-1 (+B) 20C (68F) 11 to 16 Ω H6-1 (HT) - H6-2 (+B) 20C (68F) 11 to 16 Ω H10-2 (HT) - H10-1 (+B) 800C (1,472F) 23 to 32 Ω H6-1 (HT) - H6-2 (+B) 800C (1,472F) 23 to 32 Ω NG REPLACE HEATED OXYGEN SENSOR OK 8 INSPECT RELAY (EFI) 1 3 2 5 1 2 5 (a) (b) Remove the EFI relay from the engine room J/B. Measure the resistance of the EFI relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 3 B60778 NG REPLACE RELAY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 684 05-495 DIAGNOSTICS 9 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS (a) Check the wire harness between the ECM and heated oxygen sensor. (1) Disconnect the H10 heated oxygen sensor connector. (2) Disconnect the E8 ECM connector. (3) Measure the resistance of the wire harness side connectors. Standard: Heated Oxygen Sensor +B HT 1 2 3 4 2 1 4 3 OX +B HT E1 H10 (Bank 1) E1 OX H6 (Bank 2) E8 ECM OX1B HT1B Tester Connection Specified Condition H10-4 (OX) - E8-21 (OX1B) Below 1 Ω H10-2 (HT) - E8-25 (HT1B) Below 1 Ω H6-3 (OX) - E8-29 (OX2B) Below 1 Ω H6-1 (HT) - E8-33 (HT2B) Below 1 Ω H10-4 (OX) or E8-21 (OX1B) - Body ground 10 kΩ or higher H10-2 (HT) or E8-25 (HT1B) - Body ground 10 kΩ or higher H6-3 (OX) or E8-29 (OX2B) - Body ground 10 kΩ or higher H6-1 (HT) or E8-33 (HT2B) - Body ground 10 kΩ or higher OX2B HT2B A81921 A81695 A92549 Reference (Bank 1 Sensor 2 System Drawing) EFI Relay From Battery EFI NO. 1 Heated Oxygen Sensor Heater EFI NO. 2 +B HT1B HT Sensor E1 ECM OX1B OX E2 MREL A90346 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 685 05-496 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) REPLACE HEATED OXYGEN SENSOR 10 PERFORM CONFIRMATION DRIVING PATTERN HINT: Clear all DTCs prior to performing the confirmation driving pattern. GO 11 (a) READ OUTPUT DTC (DTC P0136 AND/OR P0156 ARE OUTPUT AGAIN) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display (DTC Output) Proceed to P0136 and/or P0156 are not output again A P0136 and/or P0156 are output again B A CHECK FOR INTERMITTENT PROBLEMS (See page 05-370 ) B 12 REPLACE HEATED OXYGEN SENSOR GO 13 PERFORM CONFIRMATION DRIVING PATTERN HINT: Clear all DTCs prior to performing the confirmation driving pattern. GO 14 (a) READ OUTPUT DTC (DTC P0136 AND/OR P0156 ARE OUTPUT AGAIN) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display (DTC Output) Proceed to P0136 and/or P0156 are not output again A P0136 and/or P0156 are output again B A REPAIR COMPLETED B 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 686 05-497 DIAGNOSTICS 15 (a) (b) (c) (d) (e) - SFI SYSTEM (3MZ-FE) PERFORM ACTIVE TEST USING HAND-HELD TESTER Start the engine and warm it up. Connect the hand-held tester to the DLC3. Turn ON the ignition switch and the hand-held tester main switch. Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / INJ VOL. Using the hand-held tester, change the injection volume to check the A/F sensor output and heated oxygen sensor output values below. HINT: Change the injection volume from -12.5 % to +12.5 %. Result: A/F sensor output remains more than 3.3 V or A/F sensor output remains less than 3.3 V (Heated oxygen sensor reacts in accordance with increase and decrease of injection volume) Injection Volume +12.5 % -12.5 % Malfunction A/F Sensor Output Normal 3.3 V Heated Oxygen Sensor Output Malfunction 1V 0 A87979 OK REPLACE AIR FUEL RATIO SENSOR NG CHECK AND REPLACE EXTREMLY RICH OR LEAN ACTUAL AIR FUEL RATIO(INJECTOR, FUEL PRESSURE, GAS LEAKAGE IN EXHAUST SYSTEM, ETC.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 687 05-498 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EXR-06 DTC P0171 SYSTEM TOO LEAN (BANK 1) DTC P0172 SYSTEM TOO RICH (BANK 1) DTC P0174 SYSTEM TOO LEAN (BANK 2) DTC P0175 SYSTEM TOO RICH (BANK 2) CIRCUIT DESCRIPTION The fuel trim is related to the feedback compensation value, not to the basic injection time. The fuel trim includes the short-term fuel trim and the long-term fuel trim. The short-term fuel trim is the short-term fuel compensation used to maintain the air-fuel ratio at the stoichiometric air-fuel ratio. The signal from the A/F sensor indicates whether the air-fuel ratio is RICH or LEAN compared to the stoichiometric air-fuel ratio. This variance triggers a reduction in the fuel volume if the airfuel ratio is RICH, and an increase in the fuel volume if it is LEAN. The short-term fuel trim varies from the central value due to individual engine differences, wear over time and changes in the operating environment. The long-term fuel trim, which controls overall fuel compensation, steadies long-term deviations of the short-term fuel trim from the central value. If both the short-term fuel trim and the long-term fuel trim are LEAN or RICH beyond a certain value, it is detected as a malfunction and the MIL is illuminated and a DTC is set. DTC No. P0171 P0174 P0172 P0175 DTC Detection Condition Trouble Area When air-fuel ratio feedback is stable after warming up engine, fuel trim is considerably in error on LEAN side (2 trip detection logic)
Air induction system
Injector blockage
MAF meter
ECT sensor
Fuel pressure
Gas leakage in exhaust system
Open or short in A/F sensor (bank 1, 2 sensor 1) circuit
A/F sensor (bank 1, 2 sensor 1)
A/F sensor heater (bank 1, 2 sensor 1)
A/F relay
PCV valve and hose
PCV hose connection When air-fuel ratio feedback is stable after warming up engine, fuel trim is considerably in error on RICH side (2 trip detection logic)
Injector leak, blockage
MAF meter
ECT sensor
Ignition system
Fuel pressure
Gas leakage in exhaust system
Open or short in A/F sensor (bank 1, 2 sensor 1) circuit
A/F sensor (bank 1, 2 sensor 1)
A/F sensor heater
A/F relay HINT:

When DTC P0171 or P0174 is recorded, the actual air-fuel ratio is on the LEAN side. When DTC P0172 or P0175 is recorded, the actual air-fuel ratio is on the RICH side. If the vehicle runs out of fuel, the air-fuel ratio is LEAN and DTC P0171 or P0174 may be recorded. The MIL then illuminates. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 688 05-499 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) MONITOR DESCRIPTION +35 (%): Threshold at LEAN 1.35 Fuel Compensation Amount 1.0 -35 (%): Threshold at RICH 0.65 A82386 Under closed-loop fuel control, fuel injection amounts that deviate from the ECM’s estimated fuel amount will cause a change in the long-term fuel trim compensation value. This long-term fuel trim is adjusted when there are persistent deviations in the short-term fuel trim values. And the deviation from the simulated fuel injection amount by the ECM affects a smoothed fuel trim learning value. The smoothed fuel trim learning value is the combination of smoothed short-term fuel trim (fuel feedback compensation value) and smoothed long-term fuel trim (learning value of the air-fuel ratio). When the smoothed fuel trim learning value exceeds the DTC threshold, the ECM interprets this as a fault in the fuel system and sets a DTC. Example: The smoothed fuel trim learning value is more than +35 % or less than -35 %. The ECM interprets this as a failure in the fuel system. MONITOR STRATEGY Related DTCs P0171: Fuel System Lean (Bank 1) P0172: Fuel System Rich (Bank 1) P0174: Fuel System Lean (Bank 2) P0175: Fuel System Rich (Bank 2) Required sensors / components (Main) Fuel system Required sensors / components (Related) A/F sensor, MAF meter, CKP sensor Frequency of operation Continuous Duration 10 seconds MIL operation 2 driving cycles Sequence operation None 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 689 05-500 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-377 Battery voltage 11 V or more Fuel system Closed Loop Throttle position learning Completed Either of the following conditions is met: - Engine RPM Less than 1,100 rpm Intake air amount 0.22 g/rev or more TYPICAL MALFUNCTION THRESHOLDS Fuel Trim Lean: Smoothed fuel trim learning value 35 %* or more Fuel Trim Rich: Smoothed fuel trim learning value -35 %* or more HINT: *: The threshold value varies with the ECT. WIRING DIAGRAM Refer to DTC P2195 on page 05-629 . INSPECTION PROCEDURE HINT: Hand-held tester only: It is possible the malfunctioning area can be found using the ACTIVE TEST A/F CONTROL operation. The A/F CONTROL operation can determine if the A/F sensor, heated oxygen sensor or other potential trouble areas are malfunctioning or not. (a) Perform the ACTIVE TEST A/F CONTROL operation. HINT: The A/F CONTROL operation lowers the injection volume by 12.5 % or increases the injection volume by 25 %. (1) Connect the hand-held tester to the DLC3 on the vehicle. (2) Turn the ignition switch ON. (3) Warm up the engine by running the engine at 2,500 rpm for approximately 90 seconds. (4) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (5) Perform the A/F CONTROL operation with the engine idling (press the right or left button). Result: A/F sensor reacts in accordance with increase and decrease of injection volume: +25 % → RICH output: Less than 3.0 V -12.5 % → LEAN output: More than 3.35 V Heated oxygen sensor reacts in accordance with increase and decrease of injection volume: +25 % → RICH output: More than 0.55 V -12.5 % → LEAN output: Less than 0.4 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 690 05-501 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) NOTICE: The A/F sensor output has a few seconds of delay and the heated oxygen sensor output has about 20 seconds of delay. Output voltage of A/F sensor (sensor 1) Output voltage of heated oxygen sensor (sensor 2) Injection volume Injection volume +25 % +25 % -12.5 % -12.5 % Case 1 Output voltage More than 3.35 V Less than 3.0 V OK More than 0.55 V Injection volume +25 % -12.5 % -12.5 % Case 2 Output voltage A/F sensor (A/F sensor, heater, A/F sensor circuit) Output voltage NG Injection volume More than 0.55 V OK Less than 0.4V Injection volume +25 % +25 % -12.5 % -12.5 % Case 3 Output voltage Output voltage More than 3.35 V OK Injection volume Almost No reaction NG Injection volume +25 % +25 % -12.5 % -12.5 % Case 4 Output voltage Almost No reaction OK Less than 0.4V +25 % Less than 3.0V  Output voltage Injection volume Almost No reaction Mainly suspected Trouble Area Output voltage NG Almost No reaction NG Heated oxygen sensor (heated oxygen sensor, heater, heated oxygen sensor circuit) Extremely rich or lean actual air-fuel ratio (Injector, fuel pressure, gas leakage in exhaust system, etc.) The following A/F CONTROL procedure enables the technician to check and graph the voltage outputs of both the A/F sensor and the heated oxygen sensor. For displaying the graph, enter ”ACTIVE TEST / A/F CONTROL / USER DATA”, select ”AFS B1S1 and O2S B1S2” by pressing ”YES” and push ”ENTER”. Then press ”F4”. HINT:
Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred.
A high A/F sensor voltage could be caused by a RICH air-fuel mixture. Check the conditions that would cause the engine to run with a RICH air-fuel mixture.
A low A/F sensor voltage could be caused by a LEAN air-fuel mixture. Check the conditions that would cause the engine to run with a LEAN air-fuel mixture. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 691 05-502 DIAGNOSTICS 1 (a) - SFI SYSTEM (3MZ-FE) CHECK AIR INDUCTION SYSTEM Check for vacuum leaks in air induction system. OK: No vacuum leak. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK 2 CHECK CONNECTION OF PCV HOSE OK: PCV hose is connected correctly, and PCV hose is not damaged. NG REPAIR OR REPLACE PCV HOSE OK 3 INSPECT FUEL INJECTOR ASSY (INJECTION AND VOLUME) (See page 11-38 ) Standard: Injection volume Difference between each injector 60 to 73 cm3 (3.7 to 4.5 cu in.) per 15 seconds 13 cm3 (0.8 cu in.) or less NG REPLACE FUEL INJECTOR ASSY (See page 11-46 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 692 05-503 DIAGNOSTICS 4 - SFI SYSTEM (3MZ-FE) INSPECT MASS AIR FLOW METER (a) (b) Air E2 THA 5 VG +B E2G 4 3 2 1 (c) 30 20 10 Remove the MAF meter. Check the output voltage. (1) Apply battery voltage across terminals +B and E2G. (2) Connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. (3) Blow air into the MAF meter, and check that the voltage fluctuates. Check the resistance of the IAT sensor terminals. Standard: Tester Connection Condition Specified Condition THA (4) - E2 (5) -20 C (-4F) 13.6 to 18.4 kΩ THA (4) - E2 (5) 20C (68F) 2.21 to 2.69 kΩ THA (4) - E2 (5) 60C (140F) 0.49 to 0.67 kΩ Resistance kΩ 5 3 2 1 0.5 0.3 0.2 Acceptable 0.1 -20 (-4) 0 20 40 60 80 100 (32) (80) (104) (140)(176) (212) TemperatureC(F) A60548 NG REPLACE MASS AIR FLOW METER OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 693 05-504 DIAGNOSTICS 5 - SFI SYSTEM (3MZ-FE) INSPECT ENGINE COOLANT TEMPERATURE SENSOR (RESISTANCE) (a) (b) Ohmmeter Remove the ECT sensor. Check the resistance of the ECT sensor terminals. Standard: Tester Connection Condition Specified Condition 1-2 20C (68F) 2.32 to 2.59 kΩ 1-2 80C (176F) 0.310 to 0.326 kΩ 30 20 10 5 Resistance KΩ Acceptable 3 2 1 0.5 0.3 0.2 0.1 -20 S01196 S01699 (-4) 0 20 40 60 80 100 NOTICE: When checking the ECT sensor in the water, be careful not to allow water to go into the terminals. After the check, dry the sensor. HINT: Alternate procedure: Connect an ohmmeter to the installed ECT sensor and read the resistance. Use an infrared thermometer to measure the engine temperature in the immediate vicinity of the sensor. Compare these values to the resistance/temperature graph. Change the engine temperature (warm up or allow to cool down) and repeat the test. (32) (68) (104) (140) (176) (212) Temperature C (F) A81700 NG REPLACE ENGINE COOLANT TEMPERATURE SENSOR OK 6 CHECK FOR SPARK AND IGNITION (See page 18-7 ) OK: Spark occurs. NG REPAIR OR REPLACE OK 7 (a) CHECK FUEL PRESSURE (See page 11-38 ) Check the fuel pressure (high or low pressure). Standard: Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi) NG REPLACE FUEL SYSTEM OK 8 CHECK FOR EXHAUST GAS LEAKAGE OK: No gas leak. NG REPAIR OR REPLACE EXHAUST LEAKAGE POINT (See page 15-5 ) GAS OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 694 05-505 DIAGNOSTICS 9 (a) (b) - SFI SYSTEM (3MZ-FE) READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (OUTPUT VOLTAGE OF AIR FUEL RATIO SENSOR (BANK 1, 2 SENSOR 1)) Connect the hand-held tester or the OBD II scan tool to the DLC 3. Warm up the A/F sensors (bank 1, 2 sensor 1) by running the engine at 2,500 rpm for approximately 90 seconds. Read A/F sensor voltage output on the hand-held tester or the OBD II scan tool. Hand-held tester only: Enter the following menus: ENHANCED OBD II / SNAPSHOT / MANUAL SNAPSHOT / USER DATA. Select ”AFS B1 S1 or AFS B2 S1/ENGINE SPD” and press YES. Monitor the A/F sensor voltage carefully. Check the A/F sensor voltage output under the following conditions: (1) Allow engine to idle for 30 seconds. (2) Running the engine at approximately 2,500 rpm (where engine RPM is not suddenly changed). (3) Raise the engine speed to 4,000 rpm and quickly release the accelerator pedal so that the throttle is fully closed. Standard: Condition (1) and (2) Voltage change of 3.3 V (0.66 V)* (between approximately 3.1 to 3.5 V) as shown in the illustration. Condition (3) A/F sensor voltage increases to 3.8 V (0.76 V)* or more when fuel is cut during engine deceleration, as shown in the illustration. (c) (d) (e) (f) (g) HINT: *: Voltage when using the OBD II scan tool. Normal Condition Malfunction Condition (3) Approximately 4,000 rpm (3) Approximately 4,000 rpm (2) Approximately 2,500 rpm (1) Idle (2) Approximately 2,500 rpm A/F Sensor Voltage (1) Idle (1) Idle (1) Idle Engine RPM Engine RPM ”Condition (3)” 3.8 V or More A/F Sensor Voltage Fuel Cut ”Condition (1), (2)” Change approximately 3.3 V Fuel Cut When A/F sensor circuit is malfunctioning, voltage output does not change A72304 HINT:
Whenever the output voltage of the A/F sensor remains at approximately 3.3 V (0.660 V)* (see ”Malfunction Condition” graphic) under any condition as well as the above conditions, the A/F sensor may have an open circuit (this will happen also when the A/F sensor heater has an open circuit). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 695 05-506 DIAGNOSTICS - SFI SYSTEM (3MZ-FE)
Whenever the output voltage of the A/F sensor remains at a certain value of approximately 3.8 V (0.76 V)* or more, or 2.8 V (0.56 V)* or less (see ”Malfunction Condition” graphic) under any condition as well as the above conditions, the A/F sensor may have a short circuit.
The ECM will stop fuel injection (fuel cut) during engine deceleration. This will cause a LEAN condition and should result in a momentary increase in A/F sensor voltage output.
The ECM must establish a closed throttle position learned value to perform fuel cut. If the battery terminal has been disconnected, the vehicle must be driven over 10 mph to allow the ECM to learn the closed throttle position.
When the vehicle is driven: The output voltage of the A/F sensor may be below 2.8 V (0.76 V)* during fuel enrichment. For the vehicle, this translates to a sudden increase in speed with the accelerator pedal fully depressed when trying to overtake another vehicle. The A/F sensor is functioning normally.
The A/F sensor is a current output element, and therefore the current is converted into voltage inside the ECM. If measuring voltage at connectors of A/F sensor or ECM, you will observe a constant voltage. *: Voltage when using the OBD II scan tool. OK Go to step 17 NG 10 INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) (b) AF- Disconnect the A6 or A7 A/F sensor connector. Check the resistance of the A/F sensor terminals. Standard: Tester Connection Condition Specified Condition 1 (HT) - 2 (+B) 20C (68F) 1.8 to 3.4 Ω 1 (HT) - 4 (AF-) - 10 kΩ or higher AF+ A52607 NG REPLACE AIR FUEL RATIO SENSOR OK 11 INSPECT RELAY (A/F) 1 3 (a) (b) 2 5 5 2 Remove the A/F relay from the engine room R/B No. 2. Check the resistance of the A/F relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 1 3 B60778 NG REPLACE RELAY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 696 05-507 DIAGNOSTICS 12 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS (A/F SENSOR - ECM) (a) (b) (c) Wire Harness Side HT A6 (Bank 1) A7 (Bank 2) A/F Sensor AF+ +B Disconnect the A6 or A7 A/F sensor connector. Disconnect the E8 ECM connector. Check the resistance of the wire harness side connectors. Standard: Tester Connection 1 2 3 4 A6-3 (AF+) A6-4 (AF-) A6-1 (HT) A7-3 (AF+) A7-4 (AF-) A7-1 (HT) - AF- E8-22 (A1A+) E8-30 (A1A-) E8-5 (HA1H) E8-23 (A2A+) E8-31 (A2A-) E8-4 (HA2A) Below 1 Ω A6-3 (AF+) or E8-22 (A1A+) - Body ground A6-4 (AF-) or E8-30 (A1A-) - Body ground A6-1 (HT) or E8-5 (HA1H) - Body ground A7-3 (AF+) or E8-23 (A2A+) - Body ground A7-4 (AF-) or E8-31 (A2A-) - Body ground A7-1 (HT) or E8-4 (HA2A) - Body ground E8 ECM HA2A HA1H A2A+ Specified Condition 10 kΩ or higher A1A+ A1AA2A- Y A76787 A81695 A85512 Reference (Bank 1 Sensor 1 System Drawing) A/F Relay From Battery A/F ECM A/F Sensor +B Heater HT HA1H AF- Sensor AF+ A1A+ Duty Control A1AMREL A87980 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 13 REPLACE AIR FUEL RATIO SENSOR GO 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 697 05-508 DIAGNOSTICS 14 - SFI SYSTEM (3MZ-FE) PERFORM CONFIRMATION DRIVING PATTERN Vehicle Speed (e) 60 to 120 km/h (38 to 75 mph) Idling IG SW OFF (d) 2 min. 3 to 5 min. Time (a), (b), (c) A79199 (a) Clear the DTCs. (1) Disconnect the battery cable or remove the EFI NO. 1 and ETCS fuses for 60 seconds or more. Connect the hand-held tester to the DLC3. Switch the hand-held tester from the normal mode to the check mode (see page 05-402 ). Start the engine and warm it up with all the accessory switches OFF. Drive the vehicle at 60 to 120 km/h (38 to 75 mph) and engine speed at 1,400 to 3,200 rpm for 3 to 5 minutes. (b) (c) (d) (e) HINT: If a malfunction exists, the MIL will be illuminated during step (e). NOTICE: If the conditions in this test are not strictly followed, detection of a malfunction will not occur. If you do not have a hand-held tester, turn the ignition switch OFF after performing steps (d) and (e), then perform step (e) again. GO 15 (a) READ OUTPUT DTC (DTC P0171, P0172, P0174 AND/OR P0175 ARE OUTPUT AGAIN) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display (DTC Output) Proceed to DTC P0171, P0172, P0174 and/or P0175 are not output again A DTC P0171, P0172, P0174 and/or P0175 are output again B B REPLACE ECM (See page 10-24 ) AND PERFORM CONFIRMATION DRIVING PATTERN (Refer to step 14) A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 698 05-509 DIAGNOSTICS 16 - SFI SYSTEM (3MZ-FE) CONFIRM IF VEHICLE HAS RUN OUT OF FUEL IN PAST NO CHECK FOR INTERMITTENT PROBLEMS (See page 05-370 ) YES DTC IS CAUSED BY RUNNING OUT OF FUEL (DTCS P0171, P0172, P0174 AND/OR P0175) 17 PERFORM CONFIRMATION DRIVING PATTERN HINT: Clear all DTCs prior to performing the confirmation driving pattern (refer to step 14). GO 18 (a) READ OUTPUT DTC (DTC P0171, P0172, P0174 AND/OR P0175 ARE OUTPUT AGAIN) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display (DTC Output) Proceed to DTC P0171, P0172, P0174 and/or P0175 are not output again A DTC P0171, P0172, P0174 and/or P0175 are output again B B Go to step 22 A 19 REPLACE AIR FUEL RATIO SENSOR GO 20 PERFORM CONFIRMATION DRIVING PATTERN GO 21 (a) READ OUTPUT DTC (DTC P0171, P0172, P0174 AND/OR P0175 ARE OUTPUT AGAIN) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display (DTC Output) Proceed to DTC ”P0171, P0172, P0174 and/or P0175” are output again A DTC ”P0171, P0172, P0174 and/or P0175” are not output again B B REPLACE ECM (See page 10-24 ) AND PERFORM CONFIRMATION DRIVING PATTER (Refer to step 14) A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 699 05-510 DIAGNOSTICS 22 - SFI SYSTEM (3MZ-FE) CONFIRM IF VEHICLE HAS RUN OUT OF FUEL IN PAST NO CHECK FOR INTERMITTENT PROBLEMS (See page 05-370 ) YES DTC IS CAUSED BY RUNNING OUT OF FUEL (DTCS P0171, P0172, P0174 AND/OR P0175) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 700 05-51 1 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EXS-05 DTC P0300 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED DTC P0301 CYLINDER 1 MISFIRE DETECTED DTC P0302 CYLINDER 2 MISFIRE DETECTED DTC P0303 CYLINDER 3 MISFIRE DETECTED DTC P0304 CYLINDER 4 MISFIRE DETECTED DTC P0305 CYLINDER 5 MISFIRE DETECTED DTC P0306 CYLINDER 6 MISFIRE DETECTED CIRCUIT DESCRIPTION When a misfire occurs in the engine, hydrocarbons (HC) are output in high concentrations. If this HC concentration is high enough, there could be an increase in exhaust emission levels. High concentrations of HC can also cause the temperature of the catalyst to increase, possibly damaging the catalyst. To prevent this increase in emissions and limit the possibility of thermal damage, the ECM monitors the misfire rate. When the temperature of the catalyst reaches a point of thermal degradation, the ECM will blink the MIL. For monitoring misfires, the ECM uses both the camshaft position sensor and the crankshaft position sensor. The camshaft position sensor is used to identify misfiring cylinders and the crankshaft position sensor is used to measure variations in the crankshaft rotation speed. A misfire is counted when crankshaft rotation speed variations exceed threshold values. If the misfiring rate exceeds the threshold value and could cause emission deterioration, the ECM illuminates the MIL. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 701 05-512 DIAGNOSTICS DTC No. P0300 P0301 P0302 P0303 P0304 P0305 P0306 - SFI SYSTEM (3MZ-FE) DTC Detection Condition Trouble Area Misfiring of random cylinders is detected
Open or short in engine wire
Connector connection
Vacuum hose connection
Ignition system
Injector
Fuel pressure
MAF meter
ECT sensor
Compression pressure
Valve clearance
Valve timing
PCV hose connection
PCV hose
ECM Misfiring of each cylinder is detected
Open or short in engine wire
Connector connection
Vacuum hose connection
Ignition system
Injector
Fuel pressure
MAF meter
ECT sensor
Compression pressure
Valve clearance
Valve timing
PCV hose connection
PCV hose
ECM HINT: When several codes for a misfiring cylinder are recorded repeatedly but no random misfire code is recorded, the misfires have been detected and recorded at different times. MONITOR DESCRIPTION ECM Camshaft Position Sensor Crankshaft Position Sensor (36-2 teeth or 12 teeth) A87798 The ECM illuminates the MIL (2 trip detection logic) if:
The misfiring rate exceeds a threshold value and could cause emission deterioration.
During the first 1,000 engine revolutions after the engine starts, an excessive misfire rate (approximately 20 to 50 misfires per 1,000 engine revolutions) occurs 1 time.
After the first 1,000 engine revolutions after the engine starts, an excessive misfire rate (approximately 20 to 50 misfires per 1,000 engine revolutions) occurs 4 times. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 702 05-513 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) The ECM blinks the MIL (MIL blinks immediately) if:
Within 200 engine revolutions at a high rpm, the threshold for ”percentage of misfire causing catalyst damage” is reached 1 time.
Within 200 engine revolutions at a normal rpm, the threshold for ”percentage of misfire causing catalyst damage” is reached 3 times (for the 2nd trip, reaching the threshold once will cause the MIL to flash). MONITOR STRATEGY Related DTCs P0300: Multiple Cylinder Misfire P0301: Cylinder 1 Misfire P0302: Cylinder 2 Misfire P0303: Cylinder 3 Misfire P0304: Cylinder 4 Misfire P0305: Cylinder 5 Misfire P0306: Cylinder 6 Misfire Required sensors / components (Main) Injector, Ignition coil, Spark plug Required sensors / components (Related) CKP, CMP, ECT, IAT and MAF meter Frequency of operation Continuous Duration 1,000 revolutions x 4: Emission-related-misfire 200 revolutions x 3: Catalyst-damaged-misfire MIL operation 2 driving cycles: emission-related misfire MIL flashes immediately: catalyst-damage misfire Sequence operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present See page 05-377 Battery voltage 8 V or more Throttle position learning Completed VVT system Not operated by scan tool Engine RPM 450 to 5,900 rpm All of the following conditions are met: Condition 1, 2 and 3 1. Engine Coolant Temperature (ECT) -10 C (14F) or more 2. Either of the following conditions is met Condition (a) or (b) (a) IAT -10 C (14F) or more (b) ECT 75C (167F) or more 3. Either of the following conditions is met: Condition (a) or (b) (a) ECT at engine start More than -7C (19.4F) (b) ECT More than 20C (68F) Fuel-cut OFF Monitor Period of Emission-related-misfire: First 1,000 revolutions after engine start, or check mode Crankshaft 1,000 revolutions Except above Crankshaft 1,000 revolutions × 4 Monitor Period of Catalyst-damage-misfire (MIL blinks): All of the following conditions 1, 2 and 3 met: Crankshaft 200 revolutions 1. Driving cycles 1st 2. Check Mode OFF 3. Engine RPM Less than 3,000 rpm Except above Crankshaft 200 revolutions x 3 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 703 05-514 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) TYPICAL MALFUNCTION THRESHOLDS Monitor Period of Emission-related-misfire: Misfire rate 1.0 % or more Monitor Period of Catalyst-damage-misfire (MIL blinks): Number of misfire per 200 revolutions 77 or more (varies with intake air amount and engine RPM) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 704 05-515 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) WIRING DIAGRAM Refer to DTC P0351 on page 05-541 for the wiring diagram of the ignition system. I15 Ignition Switch 7 6 AM2 Y ECM I8 Injector No. 1 IG2 R 2 GR L 1 #10 E7 Y 2 #20 E7 B 3 #30 E7 W 4 #40 E7 B-W 5 #50 E7 G 3 #60 E8 1 1 IC1 I9 Injector No. 2 Instrument Panel J/B Assy R 1 1C 2 1 9 1G R L-Y I10 Injector No. 3 IG2 R 4 1C 1 1G 2 LG 1 B R I11 Injector No. 4 AM2 10 F7 FL Block Assy 1 R 6 IC3 R 2 1 R I12 Injector No. 5 W 5 EB1 R 2 FL Main R 1 R I13 Injector No. 6 R 2 1 Battery A88693 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 705 05-516 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) CONFIRMATION DRIVING PATTERN (a) (b) (c) (d) Connect the hand-held tester to the DLC3. Record DTC and the freeze frame data. Set the hand-held tester to check mode (see page 05-400 ). Read the value on the misfire counter for each cylinder when idling. If the value is displayed on the misfire counter, skip the following procedure of confirmation driving. (e) Drive the vehicle several times with the engine speed, load and its surrounding range shown with ENGINE SPD, CALC LOAD in the freeze frame data or MISFIRE RPM, MISFIRE LOAD in the DATA LIST. If you have no hand-held tester, turn the ignition switch OFF after the symptom is simulated once. Then repeat the simulation process again. HINT: In order to memorize the misfire DTC, it is necessary to drive with MISFIRE RPM, MISFIRE LOAD in the DATA LIST for the period of time in the chart below. Take care not to turn the ignition switch OFF. Turning the ignition switch OFF switches the diagnosis system from check mode to normal mode and all DTCs, freeze frame data and other data are erased. (f) (g) Engine Speed Time Idling 3 minutes 30 seconds or more 1,000 rpm 3 minutes or more 2,000 rpm 1 minute 30 seconds or more 3,000 rpm 1 minute or more Check if there is misfire and DTC and the freeze frame data. Record the DTC’s, freeze frame date and misfire counter data. Turn the ignition switch OFF and wait for at least 5 seconds. INSPECTION PROCEDURE HINT:




If DTCs besides misfire DTCs are memorized simultaneously, troubleshoot the non-misfire DTCs first. Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air-fuel ratio was lean or rich, etc. at the time of the malfunction. If the misfire does not occur when the vehicle is brought to the workshop, the misfire can be confirmed by reproducing the condition of the freeze frame data. Also, after finishing the repair, confirm that there is no misfire (see confirmation driving pattern). On 6 and 8 cylinder engines, cylinder specific misfire fault codes are disabled at high engine speeds.If the misfire starts in a high engine speed area or the misfire occurs only in a high engine speed area, only the general fault code P0300 will be stored. When only a general misfire fault code like P0300 is stored: (1) Erase the general misfire fault code from the ECM using the hand-held tester or OBD II scan tool. (2) Start the engine and drive the confirmation patten. (3) Read the value of the misfire ratio for each cylinder. Or read the DTC. (4) Perform repairs on the cylinder that has a high misfire ratio. Or repair the cylinder indicated by the DTC. (5) After finishing repairs, drive the confirmation pattern again and confirm that no misfire occurs. When either of SHORT FT #1, LONG FT #1, SHORT FT #2 or LONG FT #2 in the freeze frame data is over the range of ±20 %, there is a possibility that the air-fuel ratio is becoming RICH (-20 % or less) or LEAN (+20 % or more). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 706 05-517 DIAGNOSTICS
- SFI SYSTEM (3MZ-FE) When COOLANT TEMP in the freeze frame data is less than 80°C (176°F), there is a possibility of misfire only during engine warm-up. If the misfire cannot be reproduced, the following reasons may apply: 1) the vehicle has low fuel, 2) improper fuel is being used, and 3) the ignition plug is contaminated. Be sure to check the value on the misfire counter after the repair.

1 (a) CHECK OTHER DTC OUTPUT (IN ADDITION TO MISFIRE DTCS) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display (DTC Output) Proceed to Only P0300, P0301, P0302, P0303, P0304, P0305 and/or P0306 are output A P0300, P0301, P0302, P0303, P0304, P0305 or P0306 and other DTCs are output B HINT: If any other codes besides P0300, P0301, P0302, P0303, P0304, P0305 or P0306 are output, perform the troubleshooting for those codes first. B GO TO RELEVANT DTC CHART (See page 05-412 ) A 2 (a) (b) CHECK WIRE HARNESS, CONNECTOR AND VACUUM HOSE IN ENGINE ROOM Check the connection conditions of the wire harness and connector. Check for the disconnection, piping and break of the vacuum hose. OK: Connected correctly and no damage ON wire harness. NG REPAIR OR REPLACE, THEN CONFIRM THAT THERE IS NO MISFIRE OK 3 CHECK CONNECTION OF PCV HOSE OK: PCV hose is connected correctly. And PCV hose has no damage. NG REPAIR OR REPLACE PCV HOSE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 707 05-518 DIAGNOSTICS 4 - SFI SYSTEM (3MZ-FE) READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (NUMBER OF MISFIRE) (a) Connect the hand-held tester or the OBD II scan tool to the DLC3. (b) Turn the ignition switch ON and push the hand-held tester or the OBD II scan tool main switch ON. (c) Start the engine. (d) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / CYL#1 to CYL#6. (e) Read the number of misfires on the hand-held tester or the OBD II scan tool. HINT: When a misfire is not reproduced, be sure to branch below based on the stored DTC. Result: High Misfire Rate Cylinder Proceed to 1 or 2 cylinders A More than 3 cylinders B B Go to step 15 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 708 05-519 DIAGNOSTICS 5 - SFI SYSTEM (3MZ-FE) CHECK SPARK PLUG AND SPARK OF MISFIRING CYLINDER Base of the Ground Electrode (a) (b) (c) Remove the ignition coil. Remove the spark plug. Check the spark plug type. Recommended spark plug: DENSO made SK20R11 NGK made IFR6A11 (d) 1.0 to 1.1 mm (0.039 to 0.043 in.) B02101 B04941 A74353 Check the spark plug electrode gap. Standard: 1.0 to 1.1 mm (0.039 to 0.043 in.) Maximum: 1.3 mm (0.051 in.) NOTICE: If adjusting the gap of a new spark plug, bend only the base of the ground electrode. Do not touch the tip. Never attempt to adjust the gap on a used plug. (e) Check the electrode for carbon deposits. (f) Perform a spark test. CAUTION: Always disconnect each injector connector. NOTICE: Do not crank the engine for more than 2 seconds. (1) Install the spark plug to the ignition coil and connect the ignition coil connector. (2) Disconnect the injector connector. (3) Ground the spark plug. (4) Check if spark occurs while the engine is being cranked. OK: Spark jumps across electrode gap. OK Go to step 8 NG 6 CHANGE NORMAL SPARK PLUG AND CHECK SPARK OF MISFIRING CYLINDER (a) Change to a normal spark plug. (b) Perform a spark test. CAUTION: Always disconnect each injector connector. NOTICE: Do not crank the engine for more than 2 seconds. (1) Install the spark plug to the ignition coil and connect the ignition coil connector. (2) Disconnect the injector connector. (3) Ground the spark plug. (4) Check if spark occurs while the engine is being cranked. OK: Spark jumps across electrode gap. OK REPLACE SPARK PLUG NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 709 05-520 DIAGNOSTICS 7 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS OF MISFIRING CYLINDER (IGNITION COIL - ECM) (a) Wire Harness Side I2 I3 I4 I5 I6 I7 Ignition Coil Check the wire harness between the ignition coil and ECM. (1) Disconnect the I2, I3, I4, I5, I6 and I7 ignition coil connector. (2) Disconnect the E7 ECM connector. (3) Check the resistance of the wire harness side connectors. Standard: Tester Connection I2-2 I3-2 I4-2 I5-2 I6-2 I7-2 E7 ECM A85513 (b) Wire Harness Side I2 I3 I4 I5 I6 I7 Ignition Coil IGT5 Y A54393 A81699 Specified Condition (IGF1) (IGF1) (IGF1) (IGF1) (IGF1) (IGF1) Below 1 Ω 10 kΩ or higher Check the wire harness between the ignition coil and ECM. (1) Disconnect the I2, I3, I4, I5, I6 and I7 ignition coil connector. (2) Disconnect the E7 ECM connector. (3) Check the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition I2-3 - E7-8 (IGT1) I3-3 - E7-9 (IGT2) I4-3 - E7-10 (IGT3) I5-3 - E7-11 (IGT4) I6-3 - E7-12 (IGT5) I7-3 - E7-13 (IGT6) Below 1 Ω I2-3 or E7-8 (IGT1) - Body ground I3-3 or E7-9 (IGT2) - Body ground I4-3 or E7-10 (IGT3) - Body ground I5-3 or E7-11 (IGT4) - Body ground I6-3 or E7-12 (IGT5) - Body ground I7-3 or E7-13 (IGT6) - Body ground 10 kΩ or higher E7 ECM IGT6 E7-24 E7-24 E7-24 E7-24 E7-24 E7-24 I2-2 or E7-24 (IGF1) - Body ground I3-2 or E7-24 (IGF1) - Body ground I4-2 or E7-24 (IGF1) - Body ground I5-2 or E7-24 (IGF1) - Body ground I6-2 or E7-24 (IGF1) - Body ground I7-2 or E7-24 (IGF1) - Body ground IGF1 Y A54393 A81699 - IGT1 IGT2 IGT3 IGT4 A85513 OK REPLACE IGNITION COIL ASSY (THEN CONFIRM THAT THERE IS NO MISFIRE) NG REPAIR OR REPLACE HARNESS AND CONNECTOR 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 710 05-521 DIAGNOSTICS 8 - SFI SYSTEM (3MZ-FE) INSPECT ECM TERMINAL OF MISFIRING CYLINDER (#10, #20, #30, #40, #50, #60 VOLTAGE) #40 (+) #50 (+) #30 (+) #10 (+) #20 (+) #60 (+) (a) (b) Turn the ignition switch ON. Check the voltage of the ECM connectors. Standard: Tester Connection E01 (-) E7 ECM E8 ECM E7-1 E7-2 E7-3 E7-4 E7-5 E8-3 A76903 (#10) (#20) (#30) (#40) (#50) (#60) - E7-7 E7-7 E7-7 E7-7 E7-7 E7-7 Specified Condition (E01) (E01) (E01) (E01) (E01) (E01) 9 to 14 V HINT: Reference: Inspection using the oscilloscope. During cranking or idling, check the waveform between the terminals of the ECM connector. Tester Connection Condition Specified Condition #1 to #6 - E01 Engine idling Connect waveform is as shown Injector Signal Waveform (Magnification) 20 V /Division 20 V /Division GND GND Injection duration 1 msec./Division (Idling) 100 msec./Division (Idling) A78423 OK Go to step 11 NG 9 INSPECT FUEL INJECTOR RESISTANCE OF MISFIRING CYLINDER (See page 11-41 ) NG REPLACE FUEL INJECTOR ASSY (See page 11-46 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 711 05-522 DIAGNOSTICS 10 SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS OF MISFIRING CYLINDER (INJECTOR - ECM, INJECTOR - IGNITION SWITCH) (a) Wire Harness Side I8 I9 I10 I11 I12 I13 Injector E7 ECM #40 - E8 ECM #30 #20 #10 #60 #50 Y A72872 A76789 Check the wire harness between the injector and ECM. (1) Disconnect the I8, I9, I10, I11, I12 and I13 injector connectors. (2) Disconnect the E7 or E8 ECM connector. (3) Check the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition I8-1 - E7-1 (#10) I9-1 - E7-2 (#20) I10-1 - E7-3 (#30) I11-1 - E7-4 (#40) I12-1 - E7-5 (#50) I13-1 - E8-3 (#60) Below 1 Ω I8-1 or E7-1 (#10) - Body ground I9-1 or E7-2 (#20) - Body ground I10-1 or E7-3 (#30) - Body ground I11-1 or E7-4 (#40) - Body ground I12-1 or E7-5 (#50) - Body ground I13-1 or E8-3 (#60) - Body ground 10 kΩ or higher A85844 (b) Instrument Panel J/B Assy Check the IG2 fuse. (1) Remove the IG2 fuse from the instrument panel J/B. (2) Check the resistance of the IG2 fuse. OK: Below 1 Ω IG2 Fuse A90345 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 712 05-523 DIAGNOSTICS (c) Wire Harness Side I7 I8 I10 I11 I12 I13 Injector 2 6 3 7 4 8 IG2 Y A72872 A85676 SFI SYSTEM (3MZ-FE) Check the wire harness between the injector and ignition switch. (1) Disconnect the I8, I9, I10, I11, I12 and I13 injector connector. (2) Disconnect the I15 ignition switch connector. (3) Check the resistance of the wire harness side connectors. Standard: I15 Ignition Switch 1 5 - A88566 NG Tester Connection Specified Condition I8-2 - I15-6 (IG2) I9-2 - I15-6 (IG2) I10-2 - I15-6 (IG2) I11-2 - I15-6 (IG2) I12-2 - I15-6 (IG2) I13-2 - I15-6 (IG2) Below 1 Ω I8-2 or I15-6 (IG2) - Body ground I9-2 or I15-6 (IG2) - Body ground I10-2 or I15-6 (IG2) - Body ground I11-2 or I15-6 (IG2) - Body ground I12-2 or I15-6 (IG2) - Body ground I13-2 or I15-6 (IG2) - Body ground 10 kΩ or higher REPAIR OR CONNECTOR REPLACE HARNESS AND OK 11 INSPECT FUEL INJECTOR INJECTION AND VOLUME OF MISFIRING CYLINDER (See page 11-41 ) Standard: Injection volume Difference between each injector 60 to 73 cm3 (3.7 to 4.5 cu in.) per 15 seconds 13 cm3 (0.8 cu in.) or less NG REPLACE FUEL INJECTOR ASSY OK 12 CHECK CYLINDER COMPRESSION PRESSURE OF MISFIRING CYLINDER (See page 14-121 ) Standard: Compression pressure: 1.5 MPa (15.3 kgf/cm2, 218 psi) Minimum pressure: 1.0 MPa (10.2 kgf/cm2, 145 psi) Difference between each cylinder: 100 kPa (1.0 kgf/cm2, 15 psi) NG REPAIR OR REPLACE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 713 05-524 DIAGNOSTICS 13 - SFI SYSTEM (3MZ-FE) CHECK VALVE CLEARANCE OF MISFIRING CYLINDER (See page 14-127 ) Standard (cold): Item Specified Condition Intake 0.15 to 0.25 mm (0.059 to 0.0098 in.) Exhaust 0.25 to 0.35 mm (0.098 to 0.00138 in.) NG ADJUST VALVE CLEARANCE (See page 14-127 ) OK 14 SWITCH STEP BY NUMBER OF MISFIRE CYLINDER (REFER TO RESULTS OF STEP 4) HINT:

If the result of step 4 is ”1 or 2 cylinders”, proceed to A. If the result of step 4 is ”more than 3 cylinders”, proceed to B. B CHECK FOR INTERMITTENT PROBLEMS (See page 05-370 ) A 15 CHECK VALVE TIMING (CHECK FOR LOOSENESS OR A JUMPED TOOTH OF THE TIMING BELT) (See page 14-206 ) OK: The matchmarks of crankshaft pulley and camshaft pulley are aligning. NG ADJUST VALVE TIMING (See page 14-206 ) (REPAIR OR REPLACE TIMING BELT) OK 16 CHECK FUEL PRESSURE (See page 11-38 ) Standard: Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 55 psi). NG CHECK AND REPLACE FUEL PUMP, PRESSURE REGULATOR, FUEL PIPE LINE AND FILTER OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 714 05-525 DIAGNOSTICS 17 (a) (b) (c) - SFI SYSTEM (3MZ-FE) READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (INTAKE AIR TEMPERATURE AND MASS AIR FLOW RATE) Connect the hand-held tester or the OBD II scan tool to the DLC3. Turn the ignition switch ON. Check the intake air temperature. (1) On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / INTAKE AIR. Read the values. Temperature: Equivalent to ambient temperature. Check the air flow rate. (1) On the hand-held tester or the OBD II scan tool, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / MAF. Read the values. Standard: (d) Condition Air Flow Rate (gm/s) Ignition switch ON (do not start engine) 0 Idling 4 to 6 Running without load (2,500 rpm) 13 to 20 Idling to quickly accelerating Air flow rate fluctuates NG REPLACE MASS AIR FLOW METER OK 18 INSPECT ENGINE COOLANT TEMPERATURE SENSOR (RESISTANCE) (a) (b) Ohmmeter 30 20 Resistance KΩ 10 5 Acceptable 3 2 1 0.5 0.3 0.2 0.1 -20 S01196 S01699 (-4) 0 20 40 60 80 100 (32) (68) (104) (140) (176) (212) Temperature C (F) A81700 Remove the ECT sensor. Measure the resistance between the terminals of the sensor. Standard: Tester Connection Condition Specified Condition 1-2 20C (68F) 2.32 to 2.59 kΩ 1-2 80C (176F) 0.310 to 0.326 kΩ NOTICE: If of checking the ECT sensor in the water, be careful not to allow water to contact the terminals. After the check, dry the sensor. HINT: Alternate procedure: Connect an ohmmeter to the installed ECT sensor and read the resistance. Use an infrared thermometer to measure the engine temperature in the immediate vicinity of the sensor. Compare these values to the resistance/temperature graph. Change the engine temperature (warm up or allow to cool down) and repeat the test. NG REPLACE ENGINE COOLANT TEMPERATURE SENSOR OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 715 05-526 DIAGNOSTICS 19 - SFI SYSTEM (3MZ-FE) SWITCH STEP BY NUMBER OF MISFIRE CYLINDER (REFER TO RESULTS OF STEP 4) HINT:

If the result of step 4 is ”1 or 2 cylinders”, proceed to A. If the result of step 4 is ”more than 3 cylinders”, proceed to B. B AGAIN GO TO STEP 5 A CHECK FOR INTERMITTENT PROBLEMS (See page 05-370 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 716 05-527 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05MOO-01 DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW INPUT (BANK 1 OR SINGLE SENSOR) DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH INPUT (BANK 1 OR SINGLE SENSOR) DTC P0332 KNOCK SENSOR 2 CIRCUIT LOW INPUT (BANK 2) DTC P0333 KNOCK SENSOR 2 CIRCUIT HIGH INPUT (BANK 2) CIRCUIT DESCRIPTION A flat type knock sensor (non-resonant type) can detect vibrations in a wide band of frequency (about 6 kHz to 15 kHz) and has the following features:
Knock sensors are fitted on the cylinder block to detect the engine knocking.
The sensor contains a piezoelectric element which generates a voltage, when the cylinder block vibrates due to knocking. If engine knocking occurs, the ignition timing is retarded to suppress it. DTC No. DTC Detection Condition Trouble Area P0327 P0332 Output voltage of the knock sensor 1 or 2 is 0.5 V or less (1 trip detection logic)
Short in knock sensor 1 or 2 circuit
Knock sensor 1 or 2
ECM P0328 P0333 Output voltage of the knock sensor 1 or 2 is 4.5 V or more (1 trip detection logic)
Open in knock sensor 1 or 2 circuit
Knock sensor 1 or 2
ECM MONITOR DESCRIPTION The knock sensor, located on the cylinder block, detects spark knock. When spark knock occurs, the sensor picks up vibrations in a specific frequency range. When the ECM detects the voltage in this frequency range, it retards the ignition timing to suppress the spark knock. The ECM also senses background engine noise with the knock sensor and uses this noise to check for faults in the sensor. If the knock sensor signal level is too low for more than 10 seconds, and if the knock sensor output voltage is out of normal range, the ECM interprets this as a fault in the knock sensor and sets a DTC. MONITOR STRATEGY Related DTCs P0327: Knock Sensor (Bank 1) Range Check (Low voltage) P0328: Knock Sensor (Bank 1) Range Check (High voltage) P0332: Knock Sensor (Bank 2) Range Check (Low voltage) P0333: Knock Sensor (Bank 2) Range Check (High voltage) Required sensors / components (Main) Knock Sensor Required sensors / components (Related) MAF meter, CKP sensor, ECT sensor Frequency of operation Continuous Duration 1 second MIL operation Immediate Sequence operation None 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 717 05-528 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present See page 05-377 Knock Sensor Range Check P0327, P0328, P0332, P0330: Battery voltage 10.5 V or more Time after engine start 5 seconds or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Knock Sensor Range Check (Low voltage) P0327, P0332: Knock sensor Voltage Less than 0.5 V Knock Sensor Range Check (High voltage) P0328, P0333: Knock sensor voltage More than 4.5 V WIRING DIAGRAM ECM K2 Knock Sensor 1 1 Shielded B KNK1 1 EA1 W 28 E8 EKNK 4 EA1 R 2 E8 KNK2 3 EA1 G 20 E8 EKN2 2 B W K3 Knock Sensor 2 1 2 R G 5V 1 E8 2 EA1 Shielded 5V A BR ED A A J7 J/C A87844 INSPECTION PROCEDURE HINT:


DTC P0327 and P0328 are for the bank 1 knock sensor circuit. DTC P0332 and P0333 are for the bank 2 knock sensor circuit. Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 718 05-529 DIAGNOSTICS 1 - SFI SYSTEM (3MZ-FE) READ OUTPUT DTC (CHECK KNOCK SENSOR CIRCUIT) EA1 Knock Sensor 1 2 1 2 ECM 2 2 1 1 4 4 3 3 Male Connector EA1 1 E8 28 E8 2 E8 20 E8 (a) (b) Disconnect the EA1 connector. Using lead wires, connect the EA1 terminals as follows. Male Connector - Female Connector KNK1 Terminal 2 - Terminal 4 EKNK Terminal 1 - Terminal 3 KNK2 Terminal 4 - Terminal 2 EKN2 Terminal 3 - Terminal 1 Female Connector (c) (d) (e) Warm up the engine. Run the engine at 3,000 rpm for 10 seconds or more. Check the DTC. Result: A87795 B Display Proceed to DTC same as when vehicle brought in P0327, P0328 → P0327, P0328 or P0332, P0333 → P0332, P0333 A DTC different from when vehicle brought in P0327, P0328 → P0332, P0333 or P0332, P0333 → P0327, P0328 B Go to step 4 A 2 CHECK WIRE HARNESS (EA1 CONNECTOR - ECM) (a) (b) (c) Wire Harness Side EA1 Female Connector E8 ECM KNK2 Disconnect the EA1 connector. Disconnect the E8 ECM connector. Check the resistance of the wire harness side connector. Standard: Tester Connection Specified Condition 2 of EA1 female connector - E8-1 (KNK1) 1 of EA1 female connector - E8-28 (EKNK) 4 of EA1 female connector 4 - E8-2 (KNK2) 3 of EA1 female connector - E8-20 (EKN2) Below 1 Ω 2 of EA1 female connector or E8-1 (KNK1) - Body ground 1 of EA1 female connector or E8-28 (EKNK) - Body ground 4 of EA1 female connector or E8-2 (KNK2) - Body ground 3 of EA1 female connector or E8-20 (EKN2) - Body ground 10 kΩ or higher KNK1 EKN2 EKNK A88585 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 719 05-530 DIAGNOSTICS 3 - SFI SYSTEM (3MZ-FE) INSPECT ECM KNK2 (a) (b) (c) KNK1 Disconnect the E8 ECM connector. Turn the ignition switch ON. Check the voltage of the ECM terminals. Voltage: EKN2 EKNK E8 ECM Specified Condition E8-1 (KNK1) - E8-28 (EKNK) E8-2 (KNK2) - E8-20 (EKN2) 4.5 to 5.5 V A76969 KNK1 and KNK2 Signal Waveform 1V / DIV GND 1 msec./ Division Tester Connection A85286 HINT: Reference: Inspection using the oscilloscope. After warming up, run the engine at 4,000 rpm, and check the waveform of the ECM connector. Standard: Tester Connection Specified Condition E8-1 (KNK1) - E8-28 (EKNK) E8-2 (KNK2) - E8-20 (EKN2) Correct waveform is as shown NG REPLACE ECM (See page 10-24 ) OK CHECK FOR INTERMITTENT PROBLEMS (See page 05-370 ) NOTICE: Fault may be intermittent. Check harness and connectors carefully and retest. 4 INSPECT KNOCK SENSOR (a) (b) Wire Harness Side EA1 Male Connector A73938 Disconnect the EA1 connector. Check the resistance between the terminals of the EA1 male connector. Standard: OK Tester Connection Specified Condition 2 - 1 of EA1 male connector 4 - 3 of EA1 male connector 120 to 280 kΩ CHECK FOR INTERMITTENT PROBLEMS (See page 05-370 ) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 720 05-531 DIAGNOSTICS 5 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS HINT: Wire Harness Side

(a) (b) (c) EA1 Male Connector If DTC P0327 has changed to P0328, or if DTC P0332 has changed to P0333, check the knock sensor circuit on the bank 1 side. If DTC P0332 has changed to P0327, or if DTC P0333 has changed to P0338, check the knock sensor circuit on the bank 2 side. Disconnect the EA1 connector. Disconnect the K2 or K3 knock sensor connector. Check the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition 2 of EA1 male connector - K2-2 1 of EA1 male connector - K2-1 4 of EA1 male connector - K3-2 3 of EA1 male connector - K3-1 Below 1 Ω 2 of EA1 male connector or K2-2 - Body ground 1 of EA1 male connector or K2-1 - Body ground 4 of EA1 male connector or K3-2 - Body ground 3 of EA1 male connector or K3-1 - Body ground 10 kΩ or higher 1 2 Y A73938 A610.31 K2 (Bank 1) K3 (Bank 2) Knock Sensor A85847 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE KNOCK SENSOR (See page 10-20 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 721 05-532 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EXT-05 DTC P0335 CRANKSHAFT POSITION SENSOR ”A” CIRCUIT DTC P0339 CRANKSHAFT POSITION SENSOR ”A” CIRCUIT INTERMITTENT CIRCUIT DESCRIPTION The crankshaft position (CKP) sensor system consists of a crankshaft position sensor plate and a pickup coil. The sensor plate has 34 teeth and is installed on the crankshaft. The pickup coil is made of an iron core and magnet. The sensor plate rotates and as each tooth passes through the pickup coil, a pulse signal is generated. The pickup coil generates 34 signals for each engine revolution. Based on these signals, the ECM calculates the crankshaft position and engine RPM. Using these calculations, the fuel injection time and ignition timing are controlled. DTC No. DTC Detection Condition Trouble Area P0335 No crankshaft position sensor signal to ECM during cranking (2 trip detection logic)
Open or short in crankshaft position sensor circuit
Crankshaft position sensor
Crankshaft timing pulley
ECM P0335 No crankshaft position sensor signal to ECM with engine speed 600 rpm or more (2 trip detection logic)
Open or short in crankshaft position sensor circuit
Crankshaft position sensor
Crankshaft timing pulley
ECM P0339 No crankshaft position sensor signal is input to ECM for 0.05 seconds. or more, and conditions (a), (b) and (c) are met: (a) Engine is at 1,000 rpm or more (b) STA signal is OFF (c) 3 seconds or more have elapsed after STA signal is switched from ON to OFF
Open or short in crankshaft position sensor circuit
Crankshaft position sensor
Crankshaft timing pulley
ECM MONITOR DESCRIPTION If there is no signal from the crankshaft sensor even though the engine is cranking, the ECM interprets this as a malfunction of the sensor. MONITOR STRATEGY Related DTCs P0335: CKP Sensor Range Check during Cranking P0335: CKP Sensor Range Check during Engine Running Required sensors / components (Main) CKP (Crankshaft position) sensor Required sensors / components (Related) - Frequency of operation Continuous Duration 4.7 seconds: CKP Sensor Range Check during Cranking 0.016 seconds: CKP Sensor Range Check during Engine Running MIL operation 2 driving cycles Sequence operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present See page 05-377 CKP Sensor Range Check during Cranking P0335: Starter ON Minimum battery voltage while starter is ON Below 11 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 722 05-533 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) CKP Sensor Check during Engine Running P0335: Engine RPM 600 rpm or more Starter OFF Time after starter turns from ON to OFF 3 seconds or more TYPICAL MALFUNCTION THRESHOLDS CKP signal No signal COMPONENT OPERATING RANGE CKP sensor voltage fluctuates when the crankshaft rotates 34 CKP signals per 1 revolution crankshaft CKP signal WIRING DIAGRAM V7 VVT Sensor RH (Bank 1) ECM Shielded B-W 1 27 E9 VV1+ 26 E9 VV2+ 25 E9 NE+ 24 E9 NE- L 2 V6 VVT Sensor LH (Bank 2) Shielded L 1 R 2 C7 Crankshaft Position Sensor Shielded R 1 G G 2 A A G J7 J/C A BR A ED A88687 INSPECTION PROCEDURE HINT:

Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. Read values on the hand-held tester or OBD II scan tool. (a) Connect the hand-held tester or the OBD II scan tool to the DLC3. (b) Start the engine and push the hand-held tester or the OBD II scan tool main switch ON. (c) Select the item ”DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / ENGINE SPD”. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 723 05-534 DIAGNOSTICS
- SFI SYSTEM (3MZ-FE) The engine speed can be confirmed in DATA LIST using the hand-held tester or OBD II scan tool. If there are no NE signals from the crankshaft position sensor despite the engine revolving, the engine speed will be indicated as zero. If voltage output of the crankshaft position sensor is insufficient, the engine speed will be indicated as lower than the actual rpm. 1 INSPECT CRANKSHAFT POSITION SENSOR (RESISTANCE) (a) (b) A64984 E9 ECM NEVV1+ VV2+ Disconnect the C7 sensor connector. Measure the resistance between the terminals of the sensor. Standard: Tester Connection Condition Specified Condition 1-2 Cold 1,630 to 2,740 Ω 1-2 Hot 2,065 to 3,225 Ω NOTICE: In the above section, the terms ”cold” and ”hot” refer to the temperature of the coils. ”Cold” means approximately -10 C to 50C (14F to 122F). ”Hot” means approximately 50C to 100C (122F to 212F). HINT: Reference: Inspection using the oscilloscope. During cranking or idling, check the waveform of the ECM connector. Tester Connection Specified Condition E9-27 (VV1+) - E9-24 (NE-) E9-26 (VV2+) - E9-24 (NE-) E9-25 (NE+) - E9-24 (NE-) Correct waveform is as shown NE+ VV1, VV2 and NE Signal Waveforms 2 V/ Division VV1 GND VV2 GND NE GND 20 msec./Division (Idling) A88569 NG REPLACE CRANKSHAFT POSITION SENSOR (See page 18-9 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 724 05-535 DIAGNOSTICS 2 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS (CRANKSHAFT POSITION SENSOR - ECM) (a) (b) (c) Wire Harness Side Disconnect the C7 sensor connector. Disconnect the E9 ECM connector. Check the resistance of the wire harness side connectors. Standard: C7 Crankshaft Position Sensor Tester Connection Specified Condition C7-1 - E9-25 (NE+) C7-2 - E9-24 (NE-) Below 1 Ω C7-1 or E9-25 (NE+) - Body ground C7-2 or E9-24 (NE-) - Body ground 10 kΩ or higher E9 ECM NENE+ Y A54385 A81699 A85533 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 3 (a) CHECK SENSOR INSTALLATION (CRANKSHAFT POSITION SENSOR) Check the crankshaft position sensor installation. OK: Sensor is installed correctly. NG TIGHTEN SENSOR OK 4 (a) CHECK CRANKSHAFT TIMING PULLEY Check the teeth of the crankshaft timing pulley. OK: The pulley does not have any cracks or deformation. NG REPLACE CRANKSHAFT TIMING PULLEY OK REPLACE ECM (See page 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 725 05-536 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EXU-05 DTC P0340 CAMSHAFT POSITION SENSOR ”A” CIRCUIT (BANK 1 OR SINGLE SENSOR) DTC P0341 CAMSHAFT POSITION SENSOR ”A” CIRCUIT RANGE/PERFORMANCE (BANK 1 OR SINGLE SENSOR) DTC P0345 CAMSHAFT POSITION SENSOR ”A” CIRCUIT (BANK 2) DTC P0346 CAMSHAFT POSITION SENSOR ”A” CIRCUIT RANGE/PERFORMANCE (BANK 2) CIRCUIT DESCRIPTION The Variable Valve Timing (VVT) sensor (VV signal) consists of a magnet, iron core and pickup coil. The VV signal plate has 3 teeth on its outer circumference and is installed on the camshaft timing pulley. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pickup coil change, causing fluctuations in the magnetic field and generating a voltage in the pickup coil. This sensor monitors a timing rotor located on the camshaft and is used to detect camshaft angle by the ECM. The camshaft rotation synchronizes with the crankshaft rotation, and this sensor communicates the rotation of the camshaft timing rotor as a pulse signal to the ECM. Based on the signal, the ECM controls fuel injection time and ignition timing. DTC No. DTC Detection Condition Trouble Area P0340 P0345
No VVT sensor signal to ECM during cranking (2 trip detection logic)
No VVT sensor signal to ECM with engine speed 600 rpm or more (1 trip detection logic)
Open or short in VVT sensor circuit
VVT sensor
Camshaft timing pulley
Timing belt has a jumped tooth
ECM P0341 While crankshaft rotates twice, VVT sensor signal is input to ECM 12 times or more (1 trip detection logic) HINT: Under normal condition, the camshaft position sensor signal is input into the ECM 3 times per 2 engine revolutions.
Open or short in VVT sensor circuit
VVT sensor
Camshaft timing pulley
Timing belt has a jumped tooth
ECM P0346 While crankshaft rotates twice, VVT sensor signal is input to EMC 5 times or more. (1 trip detection logic) HINT: Under normal condition, the camshaft position sensor signal is input into the ECM 3 times per 2 engine revolutions.
Open or short in VVT sensor circuit
VVT sensor
Camshaft timing pulley
Timing belt has a jumped tooth
ECM HINT:

DTC P0340 and P0345 indicate a malfunction related to the VVT sensor (+) circuit (Wire harness (ECM - VVT sensor) and VVT sensor). DTC P0341 and P0346 indicate a malfunction related to the VVT sensor (-) circuit (Wire harness (ECM - VVT sensor) and VVT sensor). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 726 05-537 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) MONITOR DESCRIPTION If there is no signal from the VVT sensor even though the engine is cranking, or if the rotations of the camshaft and the crankshaft are not synchronized, the ECM interprets this as a malfunction of the sensor. MONITOR STRATEGY Related DTCs P0340: CMP Sensor (Bank 1) Range Check P0340: CMP/CKP Misalignment (Bank 1) P0341: CMP Sensor (Bank 1) Malfunction P0345: VVT Sensor (Bank 2) Range Check (Case 1) P0345: VVT Sensor (Bank 2) Range Check (Case 2) P0346: VVT Sensor (Bank 2) Malfunction Required sensors / components (Main) CMP (Crankshaft position) sensor VVT sensor Required sensors / components (Related) CKP sensor Frequency of operation Continuous Duration 5 seconds MIL operation 2 driving cycles: CMP Sensor Range Check VVT Sensor Range Check (Case 1) Immediate: Others Sequence operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present See page 05-377 CMP Sensor Range Check P0340: Starter ON Minimum battery voltage while starter is ON Less than 11V CMP/CKP Misalignment P0340: Engine RPM 600 rpm or more Starter OFF VVT Sensor Range Check P0345 (Case 1): Starter ON Minimum battery voltage while starter is ON Less than 11V VVT Sensor Range Check P0345 (Case 2): Engine RPM 600 rpm or more Starter OFF Battery voltage 8 V or more Ignition switch ON TYPICAL MALFUNCTION THRESHOLDS CMP Sensor Range Check P0340: CMP signal No signal CMP/CKP Misalignment P0340: Alignment is judged using CMP-CKP input timing CMP sensor signal input in appropriate timing No signal CMP Sensor (Bank 1) Malfunction P0341: CMP and CKP phase Misaligned CMP signal per 2 revolutions crankshaft 12 CMP signals or more VVT Sensor Range Check P0345 (Case 1): VVT sensor signal No signal VVT Sensor Range Check P0345 (Case 2): VVT sensor signal No signal 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 727 05-538 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) VVT Sensor (Bank 2) Malfunction P0346: VVT sensor signal count 12 signals or more COMPONENT OPERATING RANGE CMP sensor signal CMP sensor voltage fluctuates when the crankshaft rotates 3 CMP signals per 2 revolutions of crankshaft WIRING DIAGRAM Refer to DTC P0335 on page 05-532 . 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 728 05-539 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 INSPECT VVT SENSOR (RESISTANCE) (a) (b) A64984 E9 ECM NEVV1+ VV2+ Disconnect the V7 or V6 VVT sensor connector. Measure the resistance between the terminals of the VVT sensor. Standard: Tester Connection Condition Specified Condition 1-2 Cold 835 to 1,400 Ω 1-2 Hot 1,060 to 1,645 Ω NOTICE: In the above section, the terms ”cold” and ”hot” refer to the temperature of the coils. ”Cold” means approximately -10 C to 50C (14F to 122F). ”Hot” means approximately 50C to 100C (122F to 212F). HINT: Reference: Inspection using the oscilloscope. During cranking or idling, check the waveform of the ECM connector. Tester Connection Specified Condition E9-27 (VV1+) - E9-24 (NE-) E9-26 (VV2+) - E9-24 (NE-) E9-25 (NE+) - E9-24 (NE-) Correct waveform is as shown NE+ VV1, VV2 and NE Signal Waveforms 2 V/ Division VV1 GND VV2 GND NE GND 20 msec./Division (Idling) A88569 NG REPLACE VVT SENSOR (See page 18-1 1) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 729 05-540 DIAGNOSTICS 2 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS (VVT SENSOR - ECM) (a) (b) (c) Wire Harness Side V7 (Bank 1) V6 (Bank 2) VVT Sensor Disconnect the V7 or V6 VVT sensor connector. Disconnect the E9 ECM connector. Check the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition V7-1 - E9-27 (VV1+) V6-1 - E9-26 (VV2+) V6 or V7-2 - E9-24 (NE-) Below 1 Ω V7-1 or E9-27 (VV1+) - Body ground V6 -1 or E9-26 (VV2+) - Body ground 2 of V6 or V7 or E9-24 (NE-) - Body ground 10 kΩ or higher E9 ECM NEVV1+ VV2+ Y A54385 A81699 A85533 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 3 (a) CHECK SENSOR INSTALLATION (VVT SENSOR) Check the sensor installation. OK: Sensor is installed correctly. NG TIGHTEN SENSOR OK 4 (a) CHECK CAMSHAFT TIMING PULLEY Check the teeth of the camshaft timing pulley. OK: The pulley does not have any cracks or deformation. NG REPLACE CAMSHAFT TIMING PULLEY OK REPLACE ECM (See page 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 730 05-541 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EXE-05 DTC P0351 IGNITION COIL ”A” PRIMARY/SECONDARY CIRCUIT DTC P0352 IGNITION COIL ”B” PRIMARY/SECONDARY CIRCUIT DTC P0353 IGNITION COIL ”C” PRIMARY/SECONDARY CIRCUIT DTC P0354 IGNITION COIL ”D” PRIMARY/SECONDARY CIRCUIT DTC P0355 IGNITION COIL ”E” PRIMARY/SECONDARY CIRCUIT DTC P0356 IGNITION COIL ”F” PRIMARY/SECONDARY CIRCUIT HINT:        These DTCs indicate a malfunction related to primary circuit. If DTC P0351 is displayed, check No. 1 ignition coil with igniter If DTC P0352 is displayed, check No. 2 ignition coil with igniter If DTC P0353 is displayed, check No. 3 ignition coil with igniter If DTC P0354 is displayed, check No. 4 ignition coil with igniter If DTC P0355 is displayed, check No. 5 ignition coil with igniter If DTC P0356 is displayed, check No. 6 ignition coil with igniter circuit. circuit. circuit. circuit. circuit. circuit. CIRCUIT DESCRIPTION A Direct Ignition System (DIS) is used on this vehicle. The DIS is a 1-cylinder ignition system which ignites one cylinder with one ignition coil. In the 1-cylinder ignition system, the one spark plug is connected to the end of the secondary winding. High voltage generated in the secondary winding is applied directly to the spark plug. The spark of the spark plug passes from the center electrode to the ground electrode. The ECM determines the ignition timing and outputs the ignition signals (IGTs) for each cylinder. Using the IGT, the ECM turns on and off the power transistor inside the igniter, which switches on and off current to the primary coil. When current to the primary coil is cut off, high-voltage is generated in the secondary coil and this voltage is applied to the spark plugs to create sparks inside the cylinders. As the ECM cuts the current to the primary coil, the igniter sends back the ignition confirmation signal (IGF) for each cylinder ignition to the ECM. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 731 05-542 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) From Battery ECM Igniter No.1 Ignition Coil with Igniter IGT1 No. 1 Cylinder IGF1 Crankshaft Position Sensor Ignition Coil IGT2 No. 2 Ignition Coil with Igniter No. 2 Cylinder IGT3 No. 3 Ignition Coil with Igniter No. 3 Cylinder IGT4 No. 4 Ignition Coil with Igniter No. 4 Cylinder IGT5 No. 5 Ignition Coil with Igniter No. 5 Cylinder IGT6 No. 6 Ignition Coil with Igniter No. 6 Cylinder VVT Sensor Other Sensors  ECT Sensor  MAF Meter  Throttle Position Sensor  Others Spark Plug TACH To Tachometer A82677 DTC No. P0351 P0352 P0353 P0354 P0355 P0356 DTC Detection Condition No IGF signal to ECM while engine is running (1 trip detection logic) Trouble Area  Ignition system  Open or short in IGF1 and IGT circuits (1 through 6) from ignition coil assy to ECM  Ignition coil assy (No. 1 through No. 6)  ECM 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 732 05-543 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) MONITOR DESCRIPTION Ignition Coil with Igniter IGT ECM Ignition Coil Igniter IGF Ignition Signal (IGT) Ignition Confirmation Signal (IGF) Normal Malfunction Circuit Open time A82388 If the ECM does not receive the IGF after sending the IGT, it interprets this as a fault in the igniter and sets a DTC. MONITOR STRATEGY Related DTCs P0351: Igniter (Cylinder 1) malfunction P0352: Igniter (Cylinder 2) malfunction P0353: Igniter (Cylinder 3) malfunction P0354: Igniter (Cylinder 4) malfunction P0355: Igniter (Cylinder 5) malfunction P0356: Igniter (Cylinder 6) malfunction Required sensors / components (Main) Igniter Required sensors / components (Related) CKP sensor Frequency of operation Continuous Duration 0.256 seconds + 6 sparks MIL operation Immediate Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-377 Either of the following conditions is met: Condition 1 or 2 1. Engine RPM 1,500 rpm or less 2. Starter OFF TYPICAL MALFUNCTION THRESHOLDS IGF signal ECM does not detect IGF signal from igniter when ECM sends IGT signal to igniter 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 733 05-544 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) COMPONENT OPERATING RANGE IGF signal Igniter outputs IGF signal when it receives IGT signal from ECM WIRING DIAGRAM ECM I15 Ignition Switch I2 Ignition Coil Assy No. 1 7 AM2 R IG2 6 1 Y W-B IC1 1 4 GR +B IGT GND IGF 3 W-R R 1 W-B 6 1F 4 R 1 W-B 4 R IGT GND IGF R 1 IC3 1 W-B 10 AM2 F7 FL Block Assy BR 4 R IGT2 W-R 2 +B IGT GND IGF +B IGT GND IGF 10 E7 Y-B 3 IGT3 W-R 2 W-R 11 E7 L-Y 3 IGT4 W-R 2 Ignition Coil Assy No. 5 R 1 W W-B BR 4 R +B IGT GND IGF FL Main W-B N1 Noise Filter R 1 R +B IGT 4 W-B EC GND IGF IGT5 W-R 2 W-R L-R 3 W-B 1 12 E7 3 Ignition Coil Assy No. 6 R W-R G-Y I7 Battery IGF1 I6 W-B 2 EB1 1 9 E7 3 Ignition Coil Assy No. 4 W-B IGT1 W-R P I5 L-Y W-R 24 E7 W-R R O 4 S29 Ignition Coil Assy No. 3 W-B 1 1G 4 1C B +B I4 IG2 4 S28 Short Connector Ignition Coil Assy No. 2 1 1C W-R 2 I3 Instrument Panel J/B Assy 8 E7 R-L BR A 2 13 E7 1 IGT6 E9 E1 J7 J/C A BR ED A88694 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 734 05-545 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK SPARK PLUG AND SPARK OF MISFIRING CYLINDER (See page 18-9 ) OK: Spark occurs. NG Go to step 4 OK 2 CHECK WIRE HARNESS (IGNITION COIL ASSY - ECM (IGF1 TERMINAL) (a) Wire Harness Side (b) (c) I2 I3 I4 I5 I6 I7 Ignition Coil Disconnect the I2, I3, I4, I5, I6 and I7 ignition coil connectors. Disconnect the E7 ECM connector. Check the resistance of the wire harness side connectors. Standard: Tester Connection I2-2 I3-2 I4-2 I5-2 I6-2 I7-2 E7 ECM I2-2 I3-2 I4-2 I5-2 I6-2 I7-2 or or or or or or - E7-24 E7-24 E7-24 E7-24 E7-24 E7-24 (IGF1) (IGF1) (IGF1) (IGF1) (IGF1) (IGF1) E7-24 E7-24 E7-24 E7-24 E7-24 E7-24 (IGF1) (IGF1) (IGF1) (IGF1) (IGF1) (IGF1) - Body Body Body Body Body Body Specified Condition Below 1 Ω ground ground ground ground ground ground 10 kΩ or higher IGF1 Y A54393 A81699 A85848 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 735 05-546 DIAGNOSTICS 3 - SFI SYSTEM (3MZ-FE) CHECK ECM (IGF VOLTAGE) (a) IGF1 (+) E1 (-) (b) (c) E7 ECM E9 ECM Disconnect the I2, I3, I4, I5, I6 and I7 ignition coil connectors. Turn the ignition switch ON. Measure the voltage between the terminals of the ECM connectors. Standard: Tester Connection Specified Condition E7-24 (IGF1) - E9-1 (E1) 4.5 to 5.5 V A76903 HINT: Reference: Inspection using the oscilloscope. During cranking or idling, check the waveform of the ECM connectors. IGF 1 Tester Connection Specified Condition E7-24 (IGF1) - E9-1 (E1) Correct waveform is as shown E1 (-) E7 ECM E9 ECM IGF Signal Waveform 2 V/ Division CH2 GND 20 msec./Division A88572 NG REPLACE ECM (See page 10-24 ) OK REPLACE IGNITION COIL ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 736 05-547 DIAGNOSTICS 4 SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS (IGNITION COIL ASSY - ECM (IGT TERMINAL)) (a) Wire Harness Side (b) (c) I2 I3 I4 I5 I6 I7 Ignition Coil Disconnect the I2, I3, I4, I5, I6 and I7 ignition coil connectors. Disconnect the E7 ECM connector. Check the resistance of the wire harness side connectors. Standard: E7 ECM IGT6 IGT5 Y A54393 A81699 - IGT1 IGT2 IGT3 IGT4 A85848 NG Tester Connection Specified Condition I2-3 - E7-8 (IGT1) I3-3 - E7-9 (IGT2) I4-3 - E7-10 (IGT3) I5-3 - E7-11 (IGT4) I6-3 - E7-12 (IGT5) I7-3 - E7-13 (IGT6) Below 1 Ω I2-3 or E7-8 (IGT1) - Body ground I3-3 or E7-9 (IGT2) - Body ground I4-3 or E7-10 (IGT3) - Body ground I5-3 or E7-1 (1IGT4) - Body ground I6-3 or E7-12 (IGT5) - Body ground I7-3 or E7-13 (IGT6) - Body ground 10 kΩ or higher REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 737 05-548 DIAGNOSTICS 5 - SFI SYSTEM (3MZ-FE) CHECK ECM (IGT1, IGT2, IGT3, IGT4, IGT5 OR IGT6 VOLTAGE) IGT5 (+) IGT3 (+) IGT 6 (+) IGT4 (+) IGT1 (+) IGT2 (+) (a) Check the voltage of the ECM connectors when the engine is cranked. Standard: E1 (-) E7 ECM IGT5 (+) E9 ECM A76903 (b) IGT3 (+) IGT 6 (+) IGT4 (+) IGT2 (+) IGT1 (+) (c) IGT5 (+) A76903 IGT3 (+) IGT 6 (+) IGT4 (+) IGT2 (+) IGT1 (+) More than 0.1 V or less than 4.5 V Tester Connection Specified Condition E7-8 (IGT1) - E9-1 (E1) E7-9 (IGT2) - E9-1 (E1) E7-10 (IGT3) - E9-1 (E1) E7-1 1 (IGT4) - E9-1 (E1) E7-12 (IGT5) - E9-1 (E1) E7-13 (IGT6) - E9-1 (E1) 4.5 V or more HINT: Reference: Inspection using the oscilloscope. During cranking or idling, check the waveform of the ECM connectors. E1 (-) E7 ECM Specified Condition Disconnect the I2, I3, I4, I5, I6 and I7 ignition coil connectors. Check the voltage of the ECM connectors when the engine is cranked. Standard: E1 (-) E9 ECM E7 ECM Tester Connection E7-8 (GT1) - E9-1 (E1) E7-9 (IGT2) - E9-1 (E1) E7-10 (IGT3) - E9-1 (E1) E7-1 1 (IGT4) - E9-1 (E1) E7-12 (IGT5) - E9-1 (E1) E7-13 (IGT6) - E9-1 (E1) E9 ECM Tester Connection Specified Condition E7-8 (GT1) - E9-1 (E1) E7-9 (IGT2) - E9-1 (E1) E7-10 (IGT3) - E9-1 (E1) E7-1 1 (IGT4) - E9-1 (E1) E7-12 (IGT5) - E9-1 (E1) E7-13 (IGT6) - E9-1 (E1) Correct waveform is as shown IGT Signal Waveform 2 V/ Division CH1 GND 20 msec./Division A88572 NG REPLACE ECM OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 738 05-549 DIAGNOSTICS 6 - SFI SYSTEM (3MZ-FE) INSPECT IGNITION COIL ASSY (POWER SOURCE) (a) Wire Harness Side (b) (c) I2 I3 I4 I5 I6 I7 Ignition Coil Disconnect the I2, I3, I4, I5, I6 and I7 ignition coil connectors. Turn the ignition switch ON. Check the voltage of the wire harness side connector. Standard: Tester Connection I2-1 I3-1 I4-1 I5-1 I6-1 I7-1 A54393 OK - Body Body Body Body Body Body Specified Condition ground ground ground ground ground ground 9 to 14 V REPLACE IGNITION COIL ASSY NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 739 05-550 DIAGNOSTICS 7 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS (IGNITION COIL ASSY - IGNITION SWITCH) (a) Wire Harness Side Instrument Panel J/B Assy IG2 Fuse (b) (c) (d) Check the IG2 fuse. (1) Remove the IG2 fuse from the instrument panel J/B assy. (2) Check for resistance of the IG2 fuse. Standard: Below 1 Ω Disconnect the I2, I3, I4, I5, I6 and I7 ignition coil connectors. Disconnect the II5 ignition switch connector. Check the resistance of the wire harness side connectors. Standard: Tester Connection I2 I3 I4 I5 I6 I7 Ignition Coil I2-1 I3-1 I4-1 I5-1 I6-1 I7-1 I15 Ignition Switch 1 5 2 6 3 7 or or or or or or I2-1 I3-1 I4-1 I5-1 I6-1 I7-1 - I15-6 I15-6 I15-6 I15-6 I15-6 I15-6 I15-6 I15-6 I15-6 I15-6 I15-6 I15-6 (IG2) (IG2) (IG2) (IG2) (IG2) (IG2) - Specified Condition (IG2) (IG2) (IG2) (IG2) (IG2) (IG2) Body Body Body Body Body Body Below 1 Ω ground ground ground ground ground ground 10 kΩ or higher 4 8 IG2 A92540 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE IGNITION COIL ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 740 05-551 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05BNU-11 DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1) DTC P0430 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 2) MONITOR DESCRIPTION The ECM uses sensors mounted before and after the Three-Way Catalyst (TWC) to monitor its efficiency. The first sensor, an Air-Fuel Ratio (A/F) sensor 1, sends pre-catalyst A/F ratio information to the ECM. The second sensor, a heated oxygen sensor (O2S) sends post-catalyst information to the ECM. The ECM compares these two signals to judge the efficiency of the catalyst and the catalyst’s ability to store oxygen. During normal operation, the TWC stores and releases oxygen as needed. The capacity to store oxygen results in a low variation in the post-TWC exhaust stream as shown below. If the catalyst is functioning normally, the waveform of the heated oxygen sensor slowly switches between RICH and LEAN. If the catalyst is deteriorated, the waveform will alternate frequently between RICH and LEAN. As the catalyst efficiency degrades, its ability to store oxygen is reduced and the catalyst output becomes more variable. When running the monitor, the ECM compares sensor 1 signals (A/F sensor) over a specific amount of time to determine catalyst efficiency. The ECM begins by calculating the signal length for both sensors (for the rear oxygen sensor, the ECM uses the output voltage signal length). If the oxygen sensor output voltage signal length is greater than the threshold (threshold is calculated based on the A/F sensor signal length), the ECM concludes that the catalyst is malfunctioning. The ECM will turn on the MIL and a DTC will be set. Normal Catalyst Waveform of A/F Sensor Before Catalyst 1.0 V 3.5 V Waveform of Heated Oxygen Sensor After Catalyst 3.0 V 0V 10 seconds Deteriorated Catalyst Waveform of A/F Sensor Before Catalyst 3.5 V 1.0 V Waveform of Heated Oxygen Sensor After Catalyst 3.0 V 0V 10 seconds A85838 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 741 05-552 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) Heated Oxygen Sensor Signal Length Signal Length Sensor Output Voltage Time A82718 DTC No. DTC Detecting Condition Trouble Area P0420 After engine and catalyst are warmed up, and while vehicle is driven within set vehicle and engine speed ranges: Waveform of heated oxygen sensor (bank 1 sensor 2) alternates frequently between RICH and LEAN (2 trip detection logic)
Gas leakage in exhaust system
A/F sensor (bank 1 sensor 1)
Heated oxygen sensor (bank 1 sensor 2)
Three-way catalytic converter (exhaust manifold) P0430 After engine and catalyst are warmed up, and while vehicle is driven within set vehicle and engine speed ranges: Waveform of heated oxygen sensor (bank 2 sensor 2) alternates frequently between RICH and LEAN (2 trip detection logic)
Gas leakage in exhaust system
A/F sensor (bank 2 sensor 1)
Heated oxygen sensor (bank 2 sensor 2)
Three-way catalytic converter (exhaust manifold) HINT:



Bank 1 is the bank that includes cylinder No. 1. Bank 2 is the bank that does not include cylinder No. 1. Sensor 1 is the sensor closest to the engine assembly. Sensor 2 is the sensor farthest away from the engine assembly. MONITOR STRATEGY Related DTCs P0420: Catalyst (Bank 1) Deterioration P0430: Catalyst (Bank 2) Deterioration Required sensors / components (Main) Catalyst Required sensors / components (Related) A/F sensor, Rear HO2S, IAT sensor, MAF meter, CKP sensor, ECT sensor Frequency of operation Once per driving cycle Duration 150 seconds (30 seconds x 5) MIL operation 2 driving cycles Sequence operation None 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 742 05-553 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present See page 05-377 Accumulated time that all of the following conditions are met: 30 seconds Battery voltage 11 V or more IAT -10 C (14F) or more Idle OFF MAF 6 to 45 g/second Engine RPM Less than 3,000 rpm ECT 75C (167F) or more Fuel system status Closed Loop Rich experience after fuel cut Yes A/F sensor Activated Estimated catalyst temperature Both of the following conditions 1 and 2 are met 1. Upstream catalyst temperature 500 to 800C (932 to 1472F) 2. Downstream catalyst temperature 500 to 800C (932 to 1472F) TYPICAL MALFUNCTION THRESHOLDS Rear HO2S locus length 15 V or more (Varies with A/F sensor locus length) Frequency of the monitor 3 times MONITOR RESULT Refer to page 05-385 for detailed information. The test value and test limit information are described as shown in the following table. Check the monitor result and test values after performing the monitor drive pattern (see page 05-387 ).
TID (Test Identification Data) is assigned to each emissions-related component.
TLT (Test Limit Type): If TLT is 0, the component is malfunctioning when the test value is higher than the test limit. If TLT is 1, the component is malfunctioning when the test value is lower than the test limit.
CID (Component Identification Data) is assigned to each test value.
Unit Conversion is used to calculate the test value indicated on generic OBD ll scan tools. TID $01: Catalyst - Sensor 1 A/F sensor, Sensor 2 HO2S TLT CID Unit Conversion Description of Test Data 0 $01 Multiply by 0.0078 (no dimension) Catalyst deterioration level (bank 1): Determined by waveforms of A/F sensor and HO2S 2 0 $02 Multiply by 0.0078 (no dimension) Catalyst deterioration level (bank 2): Determined by waveforms of A/F sensor and HO2S 2 Description of Test Limit Malfunction criteria for catalyst deterioration Malfunction criteria for catalyst deterioration 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 743 05-554 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) CONDITIONING A/F SENSOR AND HEATED OXYGEN SENSOR FOR TESTING Engine Speed (c) (d) 3,000 rpm 2,000 rpm Idling (a) IG SW OFF (b) Time Warmed up 3 min. or so 2 sec. 2 sec. Check A00479 (a) (b) (c) (d) Connect the the hand-held tester or the OBD II scan tool to the DLC3. Start the engine and warm it up with all the accessories switched OFF until the ECT is stable. Run the engine at 2,500 to 3,000 rpm for about 3 minutes. When alternating the engine between 3,000 rpm and 2,000 rpm for 2 seconds respectively, check the waveform of the oxygen sensor (bank 1 sensor 2). INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 (a) CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0420 AND/OR P0430) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display (DTC Output) Proceed to Only P0420 and/or P0430 are output A P0420 or P0430 and other DTCs are output B HINT: If any other codes besides P0420 and/or P0430 are output, perform the troubleshooting for those codes first. B GO TO RELEVANT DTC CHART (See page 05-412 ) A 2 CHECK FOR EXHAUST GAS LEAKAGE OK: No gas leakage. NG REPAIR OR REPLACE LEAKAGE POINT EXHAUST GAS OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 744 05-555 DIAGNOSTICS 3 - SFI SYSTEM (3MZ-FE) INSPECT AIR FUEL RATIO SENSOR (See page 12-23 ) NG REPLACE AIR FUEL RATIO SENSOR OK 4 INSPECT HEATED OXYGEN SENSOR (See page 05-485 ) OK: During air-fuel ratio feedback, the O2S’s output alternates between rich and lean. NG REPLACE HEATED OXYGEN SENSOR OK REPLACE THREE-WAY CATALYTIC CONVERTER (EXHAUST MANIFOLD LH OR RH AND FRONT EXHAUST PIPE) NOTICE: On the damaged bank, replace both the front catalyst and rear catalyst. HINT: Hand-held tester only:
The following procedure enables the technician to identify a trouble area if malfunction in A/F sensors front or rear heated oxygen sensors other than the catalyst converter, or the malfunction that indicates the actual air-fuel ratio extremely RICH or LEAN.
It is possible the malfunctioning area can be found using the ACTIVE TEST A/F CONTROL operation. The A/F CONTROL operation can determine if the A/F sensor, heated oxygen sensor or other potential trouble areas are malfunctioning or not. (a) Perform the ACTIVE TEST A/F CONTROL operation. HINT: The A/F CONTROL operation lowers the injection volume 12.5 % or increases the injection volume 25 %. (1) Connect the hand-held tester to the DLC3 on the vehicle. (2) Turn the ignition switch ON. (3) Warm up the engine by running the engine speed at 2,500 rpm for approximately 90 seconds. (4) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (5) Perform the A/F CONTROL operation with the engine idle (press the right or left button). Result: Heated oxygen sensor reacts in accordance with increase and decrease of injection volume +25 % → rich output: More than 0.5 V -12.5 % → lean output: Less than 0.4 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 745 05-556 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) NOTICE: The A/F sensor output has a few seconds of delay and the heated oxygen sensor output has about 20 seconds of delay at maximum. Output voltage of A/F sensor (sensor 1) Output voltage of heated oxygen sensor (sensor 2) Injection volume Injection volume +25 % +25 % -12.5 % -12.5 % Case 1 Output voltage More than 3.35 V Less than 3.0 V OK More than 0.55 V Injection volume +25 % -12.5 % -12.5 % Case 2 Output voltage A/F sensor (A/F sensor, heater, A/F sensor circuit) Output voltage NG Injection volume More than 0.55 V OK Less than 0.4V Injection volume +25 % +25 % -12.5 % -12.5 % Case 3 Output voltage Output voltage More than 3.35 V OK Injection volume Almost No reaction NG Injection volume +25 % +25 % -12.5 % -12.5 % Case 4 Output voltage Almost No reaction OK Less than 0.4V +25 % Less than 3.0V  Output voltage Injection volume Almost No reaction Mainly suspected Trouble Area Output voltage NG Almost No reaction NG Heated oxygen sensor (heated oxygen sensor, heater, heated oxygen sensor circuit) Extremely rich or lean actual air-fuel ratio (Injector, fuel pressure, gas leakage in exhaust system, etc.) The following of A/F CONTROL procedure enables the technician to check and graph the voltage outputs of both the heated oxygen sensors. For displaying the graph, enter ”ACTIVE TEST / A/F CONTROL / USER DATA”, select ”AFS B1S1 and O2S B1S2” by pressing ”YES” and push ”ENTER”. Then press ”F4”. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 746 05-557 DIAGNOSTICS DTC P0441 - SFI SYSTEM (3MZ-FE) 05MOP-01 EVAPORATIVE EMISSION CONTROL SYSTEM INCORRECT PURGE FLOW CIRCUIT DESCRIPTION The circuit description can be found in the EVAP INSPECTION PROCEDURE (see page 05-679 ). INSPECTION PROCEDURE Refer to the EVAP INSPECTION PROCEDURE (see page 05-679 ). MONITOR DESCRIPTION The ECM tests the Evaporative Emissions (EVAP) system using the fuel tank pressure sensor, Canister Close Valve (CCV), and EVAP VSV. The ECM closes the EVAP system and creates negative pressure (vacuum) into it. The ECM then monitors the internal pressure using the fuel tank pressure sensor. P0441 The EVAP VSV has the following features: (1) Purges the evaporative emissions from the fuel tank to the intake manifold. (2) Works with the CCV to create negative pressure (vacuum) inside the fuel tank and performs leak tests. Opening or closing malfunctions in the EVAP VSV prompt the ECM to set DTC P0441. The ECM checks if the EVAP VSV is ”stuck closed”. The ECM commands the EVAP VSV to open while the CCV is closed. Under these circumstances, a high negative pressure(vacuum) should develop in the fuel tank. If no negative pressure develops, the ECM determines that the EVAP VSV remains closed despite the open command. The ECM would then turn on the MIL and output a DTC. The ECM also checks if the EVAP VSV is ”stuck open”. The ECM commands the EVAP VSV to close while the CCV is closed and the fuel tank is at ambient pressure. Under these circumstances, the fuel tank should remain at ambient pressure. If negative pressure develops in the fuel tank, the ECM determines that the EVAP VSV remains open despite the close command. The ECM would then turn on the MIL and output a DTC. DTC No. P0441 DTC Detection Condition  Pressure in charcoal canister and fuel tank does not drop during purge control (2 trip detection logic)  During purge cut-off, negative is pressure entering charcoal canister and fuel tank (2 trip detection logic) Trouble Area  Vacuum hose has cracks, holes, or is blocked, damaged or disconnected  Fuel tank cap incorrectly installed  Fuel tank cap has cracks or is damaged  Open or short in vapor pressure sensor circuit  Vapor pressure sensor  Open or short in EVAP VSV circuit  EVAP VSV  Open or short in CCV circuit  CCV  Fuel tank has cracks, holes, or is damaged  Charcoal canister has cracks, holes, or is damaged  Fuel tank over fill check valve cracks, or is damaged  ECM 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 747 05-558 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) Intake Air Air Cleaner Case Throttle Valve Intake Manifold Charcoal Filter Air Cleaner Filter When EVAP VSV is opened, partial vacuum is created Leak Detection Area Purge Line EVAP VSV (Purge Valve) ECM Vapor Pressure Sensor Diaphragm (Atmospheric Pressure) Fuel Tank Cap Restrictor Passage EVAP Line Fuel Tank EVAP Service Port Purge Line Charcoal Canister When CCV is opened, air is drawn or released Charcoal Canister Filter CCV Air Inlet Line A76973 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 748 05-559 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) VSV Malfunction Condition and Leak Check EVAP VSV is Open: ON CCV is Open: OFF VSV Operation Normal driving Leak check (same as next page) Open Open Close EVAP VSV Open Open CCV Close Pressure in Fuel Tank Atmospheric Pressure Normal Condition or EVAP System Leak (Normal Pressure Line) (See next page for details) Normal Leak EVAP VSV Close Malfunction (P0441) DTC Detection Timing EVAP VSV Open Malfunction (P0441) DTC Detection Timing CCV Open Malfunction (P0446) DTC Detection Timing CCV Close Malfunction (P0446) DTC Detection Timing A85438 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 749 05-560 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) Leak Check Initial Condition:
Cold start
Engine coolant temperature/intake air temperature are nearly the same Ambient Pressure FTP: Pressure in Fuel Tank (Vapor Pressure) Gross Leak (P0455) (for ex., Fuel Tank Cap loose) (for ex., Disconnected Vacuum Hose) Start of Creation of Negat ive Pressure Small Leak (P0442) Very Small Leak (P0456) Normal Pressure Rise Open*1 EVAP VSV (Operation) Closed Closed Open*2 CCV (Operation) Open Closed P0455 Creation of Partial Vacuum P0442, P0456 Tank & Canister Vacuum is Relieved Leak Check (DTC Detection Period) *1: EVAP VSV is Open: ON *2: CCV is Open: OFF A85439 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 750 05-561 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) MONITOR STRATEGY Related DTCs P0441: Purge VSV stuck open P0441: purge VSV stuck close Required sensors / components (Main) CCV, EVAP canister, EVAP hose, Fuel cap, Fuel tank and Purge VSV Required sensors / components (Related) ECT sensor, FTP sensor, IAT sensor, MAF meter, Vehicle speed sensor Frequency of operation Once per driving cycle Duration Within 60 seconds MIL operation 2 driving cycles Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-377 Altitude Less than 7,870 ft. (2,400 m) Battery voltage 11 V or more Throttle position learning Completed IAT at engine start - ECT at engine start -7 to 11.1C (-12.6 to 20F) EVAP VSV and CCV Not operated test by scan tool Either of the following conditions is met Condition 1 or 2 1. Purge duty cycle 8% or more (vary with MAF) 2. Purge concentration for 30 seconds -5 %/% or more when vehicle speed is less than 10 km/h (6.25 mph) Refuel Not refueled with engine running FTP 12.75 mmHg (-1.7 kPa) or more ECT at engine start 4.4 to 35C (39.9 to 95F) IAT at engine start 4.4 to 35C (39.9 to 95F) IAT 4.4C (39.9F) or more Vehicle speed change Vehicle is driven by steady speed Fuel slosh No sloshing (i.e. fairly smooth road) Time after engine start Within 50 minutes FTP change before vacuum introduction Minimum change Fuel level Less than 90 % TYPICAL MALFUNCTION THRESHOLDS Purge VSV stuck close P0441: FTP change during vacuum introduction Less than 5.25 mmHg (0.7 kPa) Purge VSV stuck open P0441: Duration that of the following condition is met 4 seconds or more FTP before vacuum introduction Less than -10 mmHg (-1.333 kPa) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 751 05-562 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) MONITOR RESULT Refer to page 05-385 for detailed information. The test value and test limit information are described as shown in the following table. Check the monitor result and test values after performing the monitor drive pattern (see page 05-387 ).  TID (Test Identification Data) is assigned to each emissions-related component.  TLT (Test Limit Type): If TLT is 0, the component is malfunctioning when the test value is higher than the test limit. If TLT is 1, the component is malfunctioning when the test value is lower than the test limit.  CID (Component Identification Data) is assigned to each test value.  Unit Conversion is used to calculate the test value indicated on generic OBD ll scan tools. TID $02: EVAP system - LEV ll Vacuum monitor TLT CID Unit Conversion Description of Test Data Description of Test Limit 1 $01 Multiply by 0.183 (mmHg) Test value of EVAP VSV stuck close: Determined by fuel tank pressure change during vacuum introduction 0 $02 Multiply by 0.0655 (seconds) Test value of EVAP VSV stuck open: Determined by duration that fuel tank pressure is higher than criteria Malfunction criteria for EVAP VSV stuck open 0 $03 Multiply by 0.0655 (seconds) Test value of canister closed valve (CCV): Determined by duration that fuel tank pressure is lower than criteria Malfunction criteria for Canister Closed Valve (CCV) 0 $04 Multiply by 0.0458 (mmHg) Test value 0.04 inch leak: Determined by fuel tank pressure change Malfunction criteria for 0.04 inch leak 0 $05 Multiply by 0.0458 (mmHg) Test value 0.02 inch leak: Determined by fuel tank pressure change Malfunction criteria for 0.02 inch leak Malfunction criteria for EVAP VSV stuck closed 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 752 05-563 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05MOQ-01 DTC P0442 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (SMALL LEAK) DTC P0455 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (GROSS LEAK) DTC P0456 EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED (VERY SMALL LEAK) CIRCUIT DESCRIPTION The circuit description can be found in the EVAP INSPECTION PROCEDURE (see page 05-679 ). INSPECTION PROCEDURE Refer to the EVAP INSPECTION PROCEDURE (see page 05-679 ). MONITOR DESCRIPTION The ECM tests the Evaporative Emissions (EVAP) system using the fuel tank pressure sensor, Canister Close Valve (CCV), and EVAP VSV. The ECM closes the EVAP system and creates negative pressure (vacuum) into it. The ECM then monitors the internal pressure using the fuel tank pressure sensor (refer to the Leak Check graphic). P0442, P0455 and P0456 A leak in the evaporative emission system prompts the ECM to set DTC P0442, P0455 or P0456. The ECM checks if the EVAP has leaks. First, the ECM opens the EVAP VSV while the CCV is closed. After a sufficient amount of time has passed, a high negative pressure(vacuum) will develop in the fuel tank as air is drawn into the intake manifold. The EVAP VSV is then closed. The ECM then monitors the pressure increase (loss of vacuum) in the fuel tank. If the pressure rises beyond a specified amount, the ECM determines that the system has a leak, turns on the MIL and outputs a DTC. The ECM has separate DTCs for small and large leaks: (1) DTC P0442 is set when the internal fuel tank pressure has a large increase and the EVAP system has a small leak. (2) DTC P0455 is set when the EVAP system has a very large leak. The ECM tries to create negative pressure (vacuum) in the fuel tank by opening the EVAP VSV while the CCV is closed. However, the fuel tank pressure does not decrease beyond a specified threshold. (3) DTC P0456 is set when the internal fuel tank pressure increases slightly and the EVAP system has a very small leak. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 753 05-564 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) DTC No. DTC Detection Condition P0442 P0455 P0456  Cold engine start.  EVAP VSV has been operated and turned OFF, sealing negative pressure (vacuum) in system.  ECM begins to monitor fuel tank pressure increase and one of the following occurs (2 trip detection logic): (a) Rapid, sharp increase in pressure occurs, indicating small leak in EVAP system. DTC P0442 is set. (b) Negative pressure (vacuum) is not strong enough, indicating large hole in EVAP system. DTC P0455 is set. (c) Increase in pressure above expected amount occurs, indicating small leak in EVAP system. DTC P0456 is set. Trouble Area  Vacuum hose has cracks, holes, or is blocked, damaged or disconnected  Fuel tank cap incorrectly installed  Fuel tank cap has cracks or is damaged  Open or short in vapor pressure sensor circuit  Vapor pressure sensor  Open or short in EVAP VSV circuit  EVAP VSV  Open or short in CCV circuit  CCV  Fuel tank has cracks, holes, or is damaged  Charcoal canister has cracks, holes, or is damaged  Fuel tank over fill check valve cracks, or is damaged  ECM 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 754 05-565 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) Intake Air Air Cleaner Case Throttle Valve Intake Manifold Charcoal Filter Air Cleaner Filter When EVAP VSV is opened, partial vacuum is created Leak Detection Area Purge Line EVAP VSV (Purge Valve) ECM Vapor Pressure Sensor Diaphragm (Atmospheric Pressure) Fuel Tank Cap Restrictor Passage EVAP Line Fuel Tank EVAP Service Port Purge Line Charcoal Canister When CCV is opened, air is drawn or released Charcoal Canister Filter CCV Air Inlet Line A76973 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 755 05-566 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) VSV Malfunction Condition and Leak Check EVAP VSV is Open: ON CCV is Open: OFF VSV Operation Leak check (same as next page) Normal driving Open Open Close EVAP VSV Open Open CCV Close Pressure in Fuel Tank Atmospheric Pressure Normal Condition or EVAP System Leak (Normal Pressure Line) (See next page for details) Normal Leak EVAP VSV Close Malfunction (P0441) DTC Detection Timing EVAP VSV Open Malfunction (P0441) DTC Detection Timing CCV Open Malfunction (P0446) DTC Detection Timing CCV Close Malfunction (P0446) DTC Detection Timing A85438 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 756 05-567 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) Leak Check Initial Condition:
Cold start
Engine coolant temperature/intake air temperature are nearly the same Ambient Pressure FTP: Pressure in Fuel Tank (Vapor Pressure) Gross Leak (P0455) (for ex., Fuel Tank Cap loose) (for ex., disconnect of Vacuum Hose) Start of Creation of Negat ive Pressure Small Leak (P0442) Very Small Leak (P0456) Normal Pressure Rise EVAP VSV (Operation) Open*1 Closed Closed Open*2 CCV (Operation) Open Closed P0455 Creation of Partial Vacuum P0442, P0456 Tank & Canister Vacuum is Relieved Leak Check (DTC Detection Period) *1: EVAP VSV is Open: ON *2: CCV is Open: OFF A85439 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 757 05-568 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) MONITOR STRATEGY Related DTCs P0442: EVAP 0.04 inch leak P0455: EVAP gross leak P0456: EVAP 0.02 inch leak Required sensors / components (Main) CCV, EVAP canister, EVAP hose, Fuel cap, Fuel tank and Purge VSV Required sensors / components (Related) ECT sensor, FTP sensor, IAT sensor, MAF meter, Vehicle speed sensor Frequency of operation Once per driving cycle Duration Within 90 seconds MIL operation 2 driving cycles Sequence operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present See page 05-377 Altitude Less than 7,870 ft. (2,400 m) Battery voltage 11 V or more Throttle position learning Completed IAT at engine start - ECT at engine start -7 to 11.1C (-12.6 to 20F) EVAP VSV and CCV Not operated test by scan tool Either of the following conditions is met Condition 1 or 2 1. Purge duty cycle 8% or more (vary with MAF) 2. Purge concentration for 30 seconds -5 %/% or more when vehicle speed is less than 10 km/h (6.25 mph) Refuel Not refueled with engine running FTP 12.75 mmHg (-1.7 kPa) or more EVAP 0.02 inch leak P0456: ECT at engine start 4.4 to 32C (39.9 to 89.6F) IAT at engine start 4.4 to 32C (39.9 to 89.6F) IAT 4.4C (39.9F) or more Vehicle speed change Vehicle is driven by steady speed Fuel slosh No sloshing (i.e. fairly smooth road) Time after engine start Within 50 minutes FTP change before vacuum introduction Minimum change Fuel level Less than 90 % 0.04 inch leak Not detected CCV malfunction Not detected Vehicle speed Less than 81.25 mph (130 km/h) Purge VSV malfunction Not detected Others: ECT at engine start 4.4 to 35C (39.9 to 95F) IAT at engine start 4.4 to 35C (39.9 to 95F) IAT 4.4C (39.9F) or more Vehicle speed change Vehicle is driven by steady speed Fuel slosh No sloshing (i.e. fairly smooth road) Time after engine start Within 50 minutes FTP change before vacuum introduction Minimum change Fuel level Less than 90 % 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 758 05-569 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) TYPICAL MALFUNCTION THRESHOLDS EVAP 0.04 inch leak P0442: Both of the following conditions are met: Condition 1 and 2 1. FTP change for 5 seconds from -20 mmHg (-2.67 kPa) 1.3 mmHg (0.17 kPa) or more 2. FTP change for 5 seconds from -17 mmHg (-2.27 kPa) 1.3 mmHg (0.17 kPa) or more EVAP 0.02 inch leak P0456: Both of the following conditions are met: Condition 1 and 2 1. FTP change for 5 seconds when FTP is -17 mmHg (-2.27 kPa) 0.7 mmHg (0.09 kPa) or more 2. FTP change for 5 seconds when FTP is -20 mmHg (-2.67 kPa) 0.7 mmHg (0.09 kPa) or more EVAP gross leak P0455: FTP when vacuum introduction compleated 1.3 mmHg (0.17 kPa) or more MONITOR RESULT Refer to page 05-385 for detailed information. The test value and test limit information are described as shown in the following table. Check the monitor result and test values after performing the monitor drive pattern (see page 05-387 ).  TID (Test Identification Data) is assigned to each emissions-related component.  TLT (Test Limit Type): If TLT is 0, the component is malfunctioning when the test value is higher than the test limit. If TLT is 1, the component is malfunctioning when the test value is lower than the test limit.  CID (Component Identification Data) is assigned to each test value.  Unit Conversion is used to calculate the test value indicated on generic OBD ll scan tools. TID $02: EVAP system - LEV ll Vacuum monitor TLT CID Unit Conversion Description of Test Data Description of Test Limit 1 $01 Multiply by 0.183 (mmHg) Test value of EVAP VSV stuck close: Determined by fuel tank pressure change during vacuum introduction 0 $02 Multiply by 0.0655 (seconds) Test value of EVAP VSV stuck open: Determined by duration that fuel tank pressure is higher than criteria Malfunction criteria for EVAP VSV stuck open 0 $03 Multiply by 0.0655 (seconds) Test value of canister closed valve (CCV): Determined by duration that fuel tank pressure is lower than criteria Malfunction criteria for Canister Closed Valve (CCV) 0 $04 Multiply by 0.0458 (mmHg) Test value 0.04 inch leak: Determined by fuel tank pressure change Malfunction criteria for 0.04 inch leak 0 $05 Multiply by 0.0458 (mmHg) Test value 0.02 inch leak: Determined by fuel tank pressure change Malfunction criteria for 0.02 inch leak Malfunction criteria for EVAP VSV stuck closed 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 759 05-570 DIAGNOSTICS DTC P0446 - SFI SYSTEM (3MZ-FE) 05MOR-01 EVAPORATIVE EMISSION CONTROL SYSTEM VENT CONTROL CIRCUIT CIRCUIT DESCRIPTION The circuit description can be found in the EVAP INSPECTION PROCEDURE (see page 05-679 ). INSPECTION PROCEDURE Refer to the EVAP INSPECTION PROCEDURE (see page 05-679 ). MONITOR DESCRIPTION The ECM tests the Evaporative Emissions (EVAP) system using the fuel tank pressure sensor, Canister Close Valve (CCV), and EVAP VSV. The ECM closes the EVAP system and creates negative pressure (vacuum) into it. The ECM then monitors the internal pressure using the fuel tank pressure sensor (refer to the graphic on page 05-557 ). P0446 (FOR SYSTEM DIAGRAM AND DTC DETECTION TIMING CHART, REFER TO DTC P0441 (see page 05-557 )) The CCV is open under normal conditions. The CCV has the following features: (1) After the EVAP VSV purges the EVAP from the fuel tank into the intake manifold, the CCV draws fumes from the fuel tank into the charcoal canister. (2) Relieves pressure inside the fuel tank when the pressure has suddenly risen. (3) Along with the EVAP VSV, creates negative pressure (vacuum) inside the fuel tank and performs leak tests. The ECM checks if the CCV is ”stuck closed”. The ECM commands the CCV to open while the EVAP VSV is open. If high negative pressure (vacuum) develops in the fuel tank and stays for more than 4 seconds, the ECM determines that the CCV remains closed despite the open command. The ECM would then turn on the MIL and output a DTC. The engine coolant temperature is not related to the output of this DTC. The ECM also has a method for checking if the CCV is ”stuck open”. The ECM commands the CCV to close while the EVAP VSV is open. If a sufficient amount of negative pressure dose not develop in the fuel tank, the ECM determines that the CCV remains open despite the close command. The ECM would then turn on the MIL and output a DTC. DTC No. P0446 DTC Detection Condition Open or close malfunction in CCV (2 trip detection logic) Trouble Area
Vacuum hose has cracks, holes, or is blocked, damaged or disconnected
Fuel tank cap incorrectly installed
Fuel tank cap has cracks or is damaged
Open or short in vapor pressure sensor circuit
Vapor pressure sensor
Open or short in EVAP VSV circuit
EVAP VSV
Open or short in CCV circuit
CCV
Fuel tank has cracks, holes, or is damaged
Charcoal canister has cracks, holes, or is damaged
Fuel tank over fill check valve cracks, or is damaged
ECM 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 760 05-571 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) MONITOR STRATEGY Related DTCs P0446: CCV stuck open P0446: CCV stuck close Required sensors / components (Main) CCV, EVAP canister, EVAP hose, Fuel cap, Fuel tank and Purge VSV Required sensors / components (Related) ECT sensor, FTP sensor, IAT sensor, MAF meter, Vehicle speed sensor Frequency of operation Once per driving cycle Duration Within 60 seconds MIL operation 2 driving cycles Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-377 Altitude Less than 7,870 ft. (2,400 m) Battery voltage 11 V or more Throttle position learning Completed IAT at engine start - ECT at engine start -7 to 11.1C (-12.6 to 20F) EVAP VSV and CCV Not operated test by scan tool Either of the following conditions is met Condition 1 or 2 1. Purge duty cycle 8% or more (vary with MAF) 2. Purge concentration for 30 seconds -5 %/% or more when vehicle speed is less than 10 km/h (6.25 mph) Refuel Not refueled with engine running FTP 12.75 mmHg (-1.7 kPa) or more ECT at engine start 4.4 to 35C (39.9 to 95F) IAT at engine start 4.4 to 35C (39.9 to 95F) IAT 4.4C (39.9F) or more Vehicle speed change Vehicle is driven by steady speed Fuel slosh No sloshing (i.e. fairly smooth road) Time after engine start Within 50 minutes FTP change before vacuum introduction Minimum change Fuel level Less than 90 % TYPICAL MALFUNCTION THRESHOLDS CCV stuck close P0446: Duration that the following conditions 1 and 2 are met: 4 seconds or more 1. Accumulated purge volume 0.5 g or more 2. FTP Less than -12.75 mmHg (-1.7 kPa) CCV stuck open P0446: Purge VSV stuck closed Detected 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 761 05-572 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) MONITOR RESULT Refer to page 05-385 for detailed information. The test value and test limit information are described as shown in the following table. Check the monitor result and test values after performing the monitor drive pattern (see page 05-387 ).
TID (Test Identification Data) is assigned to each emissions-related component.
TLT (Test Limit Type): If TLT is 0, the component is malfunctioning when the test value is higher than the test limit. If TLT is 1, the component is malfunctioning when the test value is lower than the test limit.
CID (Component Identification Data) is assigned to each test value.
Unit Conversion is used to calculate the test value indicated on generic OBD ll scan tools. TID $02: EVAP system - LEV ll Vacuum monitor TLT CID Unit Conversion Description of Test Data Description of Test Limit 1 $01 Multiply by 0.183 (mmHg) Test value of EVAP VSV stuck close: Determined by fuel tank pressure change during vacuum introduction 0 $02 Multiply by 0.0655 (seconds) Test value of EVAP VSV stuck open: Determined by duration that fuel tank pressure is higher than criteria Malfunction criteria for EVAP VSV stuck open 0 $03 Multiply by 0.0655 (seconds) Test value of canister closed valve (CCV): Determined by duration that fuel tank pressure is lower than criteria Malfunction criteria for Canister Closed Valve (CCV) 0 $04 Multiply by 0.0458 (mmHg) Test value 0.04 inch leak: Determined by fuel tank pressure change Malfunction criteria for 0.04 inch leak 0 $05 Multiply by 0.0458 (mmHg) Test value 0.02 inch leak: Determined by fuel tank pressure change Malfunction criteria for 0.02 inch leak Malfunction criteria for EVAP VSV stuck closed 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 762 05-573 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EXW-05 DTC P0451 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR RANGE/PERFORMANCE DTC P0452 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR/SWITCH LOW INPUT DTC P0453 EVAPORATIVE EMISSION CONTROL SYSTEM PRESSURE SENSOR/SWITCH HIGH INPUT MONITOR DESCRIPTION DTC ”P0451, P0452 or P0453” is recorded by the ECM when the vapor pressure sensor malfunctions. P0451 The ECM monitors the vapor pressure sensor in two ways. One method examines the fluctuation of the electrical signal while the engine is idling. If the pressure signal varies beyond the specified range more than 7 times, the ECM interprets this as a fault in the vapor pressure sensor. The ECM also verifies that the pressure signal changes within the specified range. If the output of the sensor does not vary for 5 minutes while the intake air amount has been changing, the ECM interprets this as a fault in the vapor pressure sensor. DTC P0451 will be set when either of the faults occurs and the ECM will turn on the MIL. P0452 and P0453 When pressure indicated by the vapor pressure sensor deviates below -3.999 kPa (-30 mmHg) or above 1.999 kPa (15 mmHg), the ECM interprets this as a malfunction in the vapor pressure sensor. The ECM will turn on the MIL and a DTC will be set. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 763 05-574 DIAGNOSTICS Fig. 1 - SFI SYSTEM (3MZ-FE) Intake Air Air Cleaner Case Throttle Valve Intake Manifold Charcoal Filter When VSV for EVAP is opened, partial vacuum is created Leak Detection Area Purge Line ECM EVAP VSV (purge valve) Vapor Pressure Sensor Diaphragm (Atmospheric Pressure) Fuel Tank Cap Restrictor Passage EVAP Line Fuel Tank EVAP Service Port Purge Line Charcoal Canister When CCV is opened, air is drawn or released Charcoal Canister Filter CCV Air Inlet Line A76973 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 764 05-575 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) DTC No. DTC Detection Condition Trouble Area P0451 Vapor pressure sensor output changes extremely under these conditions:
Vapor pressure sensor output changes often while vehicle speed is 0 km/h (0 mph) and the engine is idling 5 to 10 seconds (2 trip detection logic)
Vapor pressure sensor output is stuck 5 minutes (2 trip detection logic)
Open or short in vapor pressure sensor circuit
Vapor pressure sensor
ECM P0452 Vapor pressure sensor output remains less than -30 mmHg (2 trip detection logic)
Open or short in vapor pressure sensor circuit
Vapor pressure sensor
ECM P0453 Vapor pressure sensor output remains more than 15 mmHg (2 trip detection logic)
Open or short in vapor pressure sensor circuit
Vapor pressure sensor
ECM MONITOR STRATEGY Related DTCs P0451: FTP Sensor Noise P0451: FTP Sensor Stuck P0452: FTP Sensor Range Check (Low voltage) P0453: FTP Sensor Range Check (High voltage) Required sensors / components (Main) FTP sensor Required sensors / components (Related) ECT sensor, IAT sensor Frequency of operation Once per driving cycle Duration 7 seconds: FTP Sensor Range Check 45 seconds: FTP Sensor Noise 5 minutes: FTP Sensor Stuck MIL operation 2 driving cycles Sequence operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present See page 05-377 FTP Sensor Noise P0451: Altitude 7,870 ft. (2,400 m) or less Battery voltage 11 V or more Throttle position learning Completed FTP sensor malfunction (P0452, P0453) Not detected IAT at engine start - ECT at engine start -7 to 11.1C (-12.6 to 20F) EVAP VSV, CCV Not operated by scan tool ECT at engine start 4.4 to 35C (40 to 95F) IAT at engine start 4.4 to 35C (40 to 95F) FTP Sensor Stuck P0451: Altitude 7,870 ft. (2,400 m) or less Battery voltage 11 V or more Throttle position learning Completed FTP sensor malfunction (P0452, P0453) Not detected IAT at engine start - ECT at engine start -7 to 11.1C (-12.6 to 20F) EVAP VSV, CCV Not operated by scan tool ECT at engine start 4.4 to 35C (40 to 95F) IAT at engine start 4.4 to 35C (40 to 95F) Time after engine start 5 seconds or more 0.04 inch leak Not detected 0.02 inch leak Not detected CCV malfunction Not detected 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 765 05-576 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) FTP Sensor Range Check P0452,P0453: ECT at engine start 10 to 35C (50 to 95F) IAT at engine start 10 to 35C (50 to 95F) IAT at engine start - ECT at engine start Less than 12C (21.6F) Engine condition Running TYPICAL MALFUNCTION THRESHOLDS FTP Sensor Noise P0451: Frequency that FTP change 6 times or more FTP Sensor Stuck P0451: FTP change No change for 5 minutes FTP Sensor Range Check (Low voltage) P0452: FTP Less than -30 mmHg (-3.999 kPa) FTP Sensor Range Check (High voltage) P0453: FTP 15 mmHg (1.999 kPa) or more COMPONENT OPERATING RANGE FTP -26 to 11 mmHg (-3.5 to 1.5 kPa) or more [734 to 771 mmHg] WIRING DIAGRAM Refer to the EVAP INSPECTION PROCEDURE (see page 05-679 ). INSPECTION PROCEDURE HINT:
If DTCs related to different system that have terminal E2 as the ground terminal are output simultaneously, terminal E2 may have an open circuit. Always troubleshoot DTCs P0441 (purge flow), P0446 (VSV for CCV), P0451, P0452 and P0453 (evaporative pressure sensor) before troubleshooting DTCs P0442, P0455 or P0456. Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air-fuel ratio was lean or rich, etc. at the time the malfunction occured. When the ENGINE RUN TIME in the freeze frame data is less than 200 seconds, carefully check the vapor pressure sensor.


1 INSPECT ECM (VC VOLTAGE) (a) (b) VC (+) E7 ECM Turn the ignition switch ON. Check the voltage of the ECM connector. Standard: Tester Connection Specified Condition E7-18 (VC) - E7-28 (E2) 4.5 to 5.5 V E2 (-) A76903 NG REPLACE ECM (See page 10-24 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 766 05-577 DIAGNOSTICS 2 - SFI SYSTEM (3MZ-FE) INSPECT ECM (PTNK VOLTAGE) E7 ECM E5 ECM E2 (-) (a) (b) PTNK (+) Turn the ignition switch ON. Check the voltage of the ECM connectors. (1) Disconnect the vacuum hose from the vapor pressure sensor. Standard (1): Tester Connection Specified Condition E5-21 (PTNK) - E7-28 (E2) 2.9 to 3.7 V (2) Vapor Pressure Sendor (1) NOTICE: The vacuum applied to the vapor pressure sensor must be less than 66.7 kPa (500 mmHg, 19.7 in.Hg). Standard (2): (2) No Vacuum Using a MITYVAC (hand-held vacuum pump), apply a vacuum of 4.0 kPa (30 mmHg, 1.18 in.Hg) to the vapor pressure sensor. Tester Connection Specified Condition E5-21 (PTNK) - E7-28 (E2) 0.5 V or less Vacuum A73688 OK REPLACE ECM (See page 10-24 ) NG 3 CHECK WIRE HARNESS (VAPOR PRESSURE SENSOR - ECM) (a) (b) (c) Wire Harness Side V11 Vapor Pressure Sensor GND PTNK VCC E7 ECM Disconnect the V11 vapor pressure sensor connector. Disconnect the E5 and E7 ECM connectors. Check the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition V11-2 (PTNK) - E5-21 (PTNK) V11-1 (GND) - E7-28 (E2) V11-3 (VCC) - E7-18 (VC) Below 1 Ω V11-2 (PTNK) or E5-21 (PTNK) - Body ground V11-3 (VCC) or E7-18 (VC) - Body ground 10 kΩ or higher E5 ECM VC PTNK E2 A87823 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE VAPOR PRESSURE SENSOR ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 767 05-578 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 059VM-21 DTC P0500 VEHICLE SPEED SENSOR ”A” DTC P0503 VEHICLE SPEED SENSOR ”A” INTERMITTENT/ERRATIC/HIGH CIRCUIT DESCRIPTION The Vehicle Speed Sensor (VSS) detects the wheel speed and sends the appropriate signals to the skid control ECU. The skid control ECU converts these wheel speed signals into a 4-pulse signal and outputs it to the ECM via the combination meter. The ECM determines the vehicle speed based on the frequency of these pulse signals. 4-Pulse From Speed Sensor Skid Control ECU 4-Pulse ECM Combination Meter A79413 DTC No. DTC Detection Condition Trouble Area P0500 P0503 The ECM detects the following conditions simultaneously for 1 second (1 trip detection logic):
No SPD (VSS) signal is output when ECM detects NC (transmission counter gear) signal is more than 300 RPM.
PNP switch is OFF (When shift lever is in other than P and N positions)
Open or short in VSS circuit
VSS
Combination meter
ECM
Skid control ECU MONITOR DESCRIPTION The ECM assumes that the vehicle is being driven when the transmission counter gear indicates more than 300 rpm and over 30 seconds have passed since the PNP switch was turned OFF. If there is no signal from the vehicle speed sensor with these conditions satisfied, the ECM concludes that the vehicle speed sensor is malfunctioning. The ECM will turn on the MIL and will set a DTC. MONITOR STRATEGY Related DTCs P0500: VSS Circuit Required sensors / components (Main) VSS, Combination meter, ABS ECU Required sensors / components (Related) Transmission counter gear Speed (CS) sensor, PNP switch, ECT sensor Frequency of operation Continuous Duration 2 seconds MIL operation Immediate Sequence operation None 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 768 05-579 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-377 Battery voltage 8 V or more Ignition switch ON Starter OFF Engine condition Running Transmission counter gear speed 300 rpm or more Either of the following condition is met: Condition 1 or 2 Condition 1 - Engine coolant temperature 20C (68F) or more ECT sensor Not malfunction (P0115 or P0116) Time after PNP switch turns from ON to OFF 2 seconds or more Condition 2 - Engine coolant temperature ECT is less than 20C (68F) ECT sensor Malfunction (P0115 or P0116) Time after PNP switch turns from ON to OFF 30 seconds or more TYPICAL MALFUNCTION THRESHOLDS VSS signal No pulse input WIRING DIAGRAM ECM C12 Combination Meter Center J/B 5V W 13 9 1 3J 3B 9 Y IL2 J7 J/C A A Y BR 17 SPD E6 1 E7 E1 BR ED A85370 INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 769 05-580 DIAGNOSTICS 1 - SFI SYSTEM (3MZ-FE) CHECK OPERATION OF SPEEDOMETER (a) Drive the vehicle and check if operation of the speedometer in the combination meter is normal. HINT: The vehicle speed sensor is operating normally if the speedometer display is normal. NG CHECK SPEEDOMETER CIRCUIT (See page 71-3 ) OK 2 INSPECT ECM (SPD VOLTAGE) E1 (-) E9 ECM (a) (b) (c) (d) SPD (+) E6 ECM Shift the lever to the neutral position. Jack up the vehicle. Turn the ignition switch ON. Check the voltage of the ECM connectors as the wheel is turned slowly. Standard: Tester Connection Specified Condition E6-17 (SPD) - E9-1 (E1) Generated intermittently HINT: The output voltage should fluctuate up and down similarly to the diagram on the left when the wheel is turned slowly. 4.5 to 5.5 V 0V Turn Wheel A67446 A62954 A85537 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE ECM (See page 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 770 05-581 DIAGNOSTICS DTC P0504 - SFI SYSTEM (3MZ-FE) 05EXF-05 BRAKE SWITCH ”A”/”B” CORRELATION CIRCUIT DESCRIPTION In addition to turning on the stop lamps, the stop lamp switch signals are used for a variety of engine, transmission, and suspension functions as well as being an input for diagnostic checks. It is important that the switch operates properly, therefore this switch is designed with two complementary signal outputs: STP and ST1-. The ECM analyzes these signal outputs to detect malfunctions in the stop lamp switch. HINT: Normal condition is as shown in the table. DTC No. P0504 Signal Brake pedal released In transition Brake pedal depressed STP OFF ON ON ST1- ON ON OFF DTC Detection Condition Conditions (a), (b) and (c) continue for 0.5 seconds or more: (a) Ignition switch ON (b) Brake pedal released (c) STP signal is OFF when the ST1- signal is OFF Trouble Area
Short in stop lamp switch signal circuit
STOP fuse
Stop lamp switch
ECM 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 771 05-582 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) WIRING DIAGRAM S15 Stop Lamp Switch Assy Passenger Side J/B 3 4L B 2 1 12 4M ECM BR 12 E6 ST1- V Y P 3 4 J3 J/C Passenger Side J/B P E E 1 4E 4 4M 19 STP E6 Instrument Panel J/B Assy W 6 1G 1 1C IGN GR STOP 1 1E 6 IG2 Instrument Panel J/B Assy I15 Ignition AM2 Switch 1 1A 7 L-Y B 2 1 1C1 Y 10 ALT AM2 1 E7 E1 F7 FL Block Assy BR 1 W A FL Main J7 J/C A BR Battery ED A88696 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 772 05-583 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. Hand-held tester: 1 (a) CHECK STOP LAMP (OPERATION) Check if the stop lamps turn on and off normally when the brake pedal is depressed and released. OK: The stop lamps turn on when you depress the brake pedal. NG REPAIR OR REPLACE STOP LAMP SWITCH CIRCUIT OK 2 INSPECT STOP LAMP SWITCH ASSY (a) Free Pushed in 2 4 1 Check the resistance of the switch terminals. Standard: Switch condition Tester Connection Specified Condition Switch pin free 1-2 Below 1 Ω Switch pin free 3-4 10 kΩ or higher Switch pin pushed in 1-2 10 kΩ or higher Switch pin pushed in 3-4 Below 1 Ω 3 A82517 NG REPLACE STOP LAMP SWITCH ASSY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 773 05-584 DIAGNOSTICS 3 - SFI SYSTEM (3MZ-FE) READ VALUE OF HAND-HELD TESTER (STP SIGNAL, ST1- VOLTAGE) Brake Pedal Depressed (a) (b) Brake Pedal Released (c) E1 (-) Turn the ignition switch ON. On the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / STOP LIGHT SW. Read the values. Standard: Brake Pedal Condition Specified Condition Depressed STP Signal ON Released STP Signal OFF Check the voltage of the ECM connectors. OK: Tester Connection ST1- (+) Brake Pedal Condition Specified Condition Depressed Below 1.5 V Released 7.5 to 14 V E6-12 (ST1-) - E9-1 (E1) E6-12 (ST1-) - E9-1 (E1) E9 ECM E6 ECM OK A72880 CHECK FOR INTERMITTENT PROBLEMS (See page 05-370 ) NG 4 CHECK WIRE HARNESS (STOP LAMP SWITCH - ECM) (a) (b) (c) Wire Harness Side Disconnect the S15 stop lamp switch connector. Disconnect the E6 ECM connector. Check the resistance of the wire harness side connectors. Standard: S15 Stop Lamp Switch Tester Connection Specified Condition S15-1 - E6-19 (STP) S15-4 - E6-12 (ST1-) Below 1 Ω S15-1 or E6-19 (STP) - Body ground S15-4 or E6-12 (ST1-) - Body ground 10 kΩ or higher E6 ECM ST1Y A56986 A67404 STP NG A87771 REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE ECM (See page 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 774 05-585 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) OBD II scan tool (excluding hand-held tester): 1 (a) CHECK STOP LAMP (OPERATION) Check if the stop lamps turn on and off normally when the brake pedal is depressed and released. OK: The stop lamps turn on when you depress the brake pedal. NG REPAIR OR REPLACE STOP LAMP SWITCH CIRCUIT OK 2 INSPECT STOP LAMP SWITCH ASSY (a) Free Pushed in 2 4 1 Check the resistance of the switch terminals. Standard: Switch condition Tester Connection Switch pin free 1-2 Specified Condition Below 1 Ω Switch pin free 3-4 10 kΩ or higher Switch pin pushed in 1-2 10 kΩ or higher Switch pin pushed in 3-4 Below 1 Ω 3 A82517 NG REPLACE STOP LAMP SWITCH ASSY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 775 05-586 DIAGNOSTICS 3 - SFI SYSTEM (3MZ-FE) INSPECT ECM (STP, ST1- VOLTAGE) Brake Pedal Depressed (a) (b) Brake Pedal Released Turn the ignition switch ON. Check the voltage of the ECM connectors. Standard: Tester Connection Brake Pedal Condition Specified Condition E6-19 (STP) - E9-1 (E1) Depressed 7.5 to 14 V E6-19 (STP) - E9-1 (E1) Released Below 1.5 V Depressed Below 1.5 V Released 7.5 to 14 V E6-12 (ST1-) - E9-1 (E1) E6-12 (ST1-) - E9-1 (E1) E1 (-) ST1- (+) E9 ECM STP (+) E6 ECM OK A72880 CHECK FOR INTERMITTENT PROBLEMS (See page 05-370 ) NG 4 CHECK WIRE HARNESS (STOP LAMP SWITCH - ECM) (a) (b) (c) Wire Harness Side Disconnect the S15 stop lamp switch connector. Disconnect the E6 ECM connector. Check the resistance of the wire harness side connectors. Standard: S15 Stop Lamp Switch Tester Connection Specified Condition S15-1 - E6-19 (STP) S15-4 - E6-12 (ST1-) Below 1 Ω S15-1 or E6-19 (STP) - Body ground S15-4 or E6-12 (ST1-) - Body ground 10 kΩ or higher E6 ECM ST1Y A56986 A67404 STP NG A87771 REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE ECM (See page 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 776 05-587 DIAGNOSTICS DTC P0505 - SFI SYSTEM (3MZ-FE) 05C1S-13 IDLE AIR CONTROL SYSTEM MONITOR DESCRIPTION The idle speed is controlled by the Electronic Throttle Control System (ETCS). The ETCS is composed of the throttle motor, which operates the throttle valve, and the throttle position sensor, which detects the opening angle of the throttle valve. The ECM controls the throttle motor to provide the proper throttle valve opening angle to obtain the target idle speed. The ECM regulates the idle speed by opening and closing the throttle valve using the ETCS. The ECM concludes that the idle speed control ECM function is malfunctioning if: 1) the actual idle RPM varies more than the specified amount five times or more during a drive cycle, or 2) a learning value of the idle speed control remains at the maximum or minimum five times or more during a drive cycle. The ECM will turn on the MIL and set a DTC. Example: If the actual idle RPM varies from the target idle RPM by more than 200* rpm five times during a drive cycle, the ECM will turn on the MIL and will set a DTC. HINT: *: RPM threshold varies with engine load. Large Idle Engine RPM Target RPM Maximum Learning Value of the Idle Speed Control 0 Actual Idle RPM Minimum Small Time Time A82389 DTC No. P0505 DTC Detection Condition Idle speed continues to vary greatly from target speed (1 trip detection logic) Trouble Area
ETCS
Air induction system
PCV hose connection 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 777 05-588 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) MONITOR STRATEGY Related DTCs P0505: IAC Functional Check P0505: IAC Range Check Required sensors / components (Main) ETCS (Electrical throttle control system) Required sensors / components (Related) CKP sensor, ECT sensor and VSS Frequency of operation Continuous Duration 10 minutes MIL Operation 2 driving cycles Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present See page 05-377 Engine Running TYPICAL MALFUNCTION THRESHOLDS Either of the following conditions is met: Condition 1 or 2 1. Frequency that both of the following conditions (a) and (b) are met: 5 times or more (a) Engine RPM - target engine RPM Less than -100 rpm, or more than 150 rpm (b) Vehicle condition Stop after vehicle was driven at 10 km/h (6.25 mph) or more 2. Frequency that both of the following conditions (a) and (b) are met: Once (a) Engine RPM - target engine RPM Less than -100 rpm, or more than 150 rpm (b) ISC flow rate learning value 1.3 L/sec or less, or 9.03 L/sec or more INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 778 05-589 DIAGNOSTICS 1 (a) - SFI SYSTEM (3MZ-FE) CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P0505) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display (DTC Output) Proceed to Only P0505 is output A P0505 and other DTCs are output B HINT: If any other codes besides P0505 are output, perform the troubleshooting for those codes first. B GO TO RELEVANT DTC CHART (See page 05-412 ) A 2 CHECK CONNECTION OF PCV HOSE OK: PCV hose is connected correctly. And PCV hose has no damage. NG REPAIR OR REPLACE PCV HOSE OK 3 (a) CHECK AIR INDUCTION SYSTEM Check for vacuum leaks in air induction system. OK: No leak in air induction system. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK CHECK ELECTRONIC THROTTLE CONTROL SYSTEM (See page 10-12 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 779 05-590 DIAGNOSTICS DTC P0560 - SFI SYSTEM (3MZ-FE) 05EXG-05 SYSTEM VOLTAGE MONITOR DESCRIPTION The battery supplies electricity to the ECM even when the ignition switch is OFF. This electricity allows the ECM store data such as DTC history, freeze frame data, fuel trim values, and other data. If the battery voltage falls below a minimum level, the ECM will conclude that there is a fault in the power supply circuit. The next time the engine starts, the ECM will turn on the MIL and a DTC will be set. DTC No. P0560 DTC Detection Condition Trouble Area
Open in back-up power source circuit
ECM Open in ECM back-up power source circuit (1 trip detection logic) HINT: If DTC P0560 is present, the ECM will not store other DTCs. MONITOR STRATEGY Related DTCs P0560: ECM System Voltage Required sensors / components (Main) ECM Required sensors / components (Related) - Frequency of operation Continuous Duration 3 seconds MIL operation Immediate (MIL will illuminate after the next engine start) Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-377 TYPICAL MALFUNCTION THRESHOLDS ECM power source Less than 3.5 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 780 05-591 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) WIRING DIAGRAM ECM Engine Room J/B W 1 2I EFI NO. 1 7 2B 11 IK2 B-W BR 3 BATT E5 3 F7 FL Block Assy 1 W BR Main 1 E7 E1 A J7 J/C Battery A BR ED A88697 INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 INSPECT FUSE (EFI NO. 1) (a) (b) Engine Room J/B EFI NO. 1 Fuse A90343 Remove the EFI NO. 1 fuse from the engine room J/B. Check the resistance of the EFI NO. 1 fuse. Standard: Below 1 Ω NG REPLACE FUSE OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 781 05-592 DIAGNOSTICS 2 - SFI SYSTEM (3MZ-FE) INSPECT ECM (BATT VOLTAGE) (a) E1 (-) BATT (+) E9 ECM Check the voltage of the ECM connectors. Standard: Tester Connection Specified Condition E5-3 (BATT) - E9-1 (E1) 9 to 14 V E5 ECM A67446 OK REPLACE ECM (See page 10-24 ) NG 3 CHECK WIRE HARNESS (ECM - EFI NO. 1 FUSE, EFI NO. 1 FUSE - BATTERY) (a) Wire Harness Side Engine Room J/B Check the wire harness between the EFI NO. 1 fuse and ECM. (1) Remove the EFI NO. 1 fuse from the engine room J/B. (2) Disconnect the E5 ECM connector. (3) Check the resistance of the wire harness side connectors. Standard: Tester Connection J/B EFI NO. 1 fuse terminal 2 - E5-3 (BATT) Below 1 Ω J/B EFI NO. 1 fuse terminal 2 or E5-3 (BATT) - Body ground 10 kΩ or higher EFI NO. 1 Fuse E5 ECM BATT A80025 A67445 A92384 Specified Condition (b) Check the wire harness between the EFI NO. 1 fuse and battery. (1) Remove the EFI NO. 1 fuse from the engine room J/B. (2) Disconnect the battery positive cable. (3) Check the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition Battery positive cable - J/B EFI NO. 1 fuse terminal 1 Below 1 Ω Battery positive cable or J/B EFI NO. 1 fuse terminal 1 Body ground 10 kΩ or higher NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK CHECK AND REPLACE ENGINE ROOM JUNCTION BLOCK ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 782 05-593 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 052O7-42 DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR DTC P0606 ECM/PCM PROCESSOR DTC P0607 CONTROL MODULE PERFORMANCE DTC P0657 ACTUATOR SUPPLY VOLTAGE CIRCUIT/OPEN MONITOR DESCRIPTION The ECM continuously monitors its internal memory status, internal circuits, and output signals to the throttle actuator. This self-check ensures that the ECM is functioning properly. If any malfunction is detected, the ECM will set the appropriate DTC and illuminate the MIL. The ECM memory status is diagnosed by internal ”mirroring” of the main CPU and the sub CPU to detect Random Access Memory (RAM) errors. The two CPUs also perform continuous mutual monitoring. The ECM sets a DTC if: 1) outputs from the 2 CPUs are different and deviate from the standards, 2) the signals to the throttle actuator deviate from the standards, 3) a malfunction is found in the throttle actuator supply voltage, and 4) any other ECM malfunction is found. DTC No. P0604 P0606 P0607 P0657 DTC Detection Condition Trouble Area ECM internal error ECM MONITOR STRATEGY Related DTCs P0604: RAM Error P0606: CPU Malfunction P0607: ECM Range Check P0657: ETCS Power Supply Required sensors / components (Main) ECM Required sensors / components (Related) - Frequency of operation Continuous Duration Within 1 second MIL operation Immediate Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-377 TYPICAL MALFUNCTION THRESHOLDS RAM Error P0604: RAM RAM check failure CPU Malfunction P0606: Either of the following conditions is met: Condition 1 or 2 1. Difference between TP of main CPU and TP of sub CPU 0.3 V or more 2. Difference between APP of main CPU and APP of sub CPU 0.3 V or more 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 783 05-594 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) ECM Range Check P0607: Either of the following conditions is met: Condition 1 or 2 1. All of the following conditions are met: Conditions (a), (b) and (c) (a) CPU reset 1 time or more (b) Difference between TP and APP learned 0.4 V or more (c) Electronic throttle actuator OFF 2. CPU reset 2 times or more ETCS Power Supply P0657: ETCS power supply when ignition switch turns from OFF to ON 7 V or more INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. REPLACE ECM (See page 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 784 05-595 DIAGNOSTICS DTC P0617 - SFI SYSTEM (3MZ-FE) 05BNV-11 STARTER RELAY CIRCUIT HIGH MONITOR DESCRIPTION While the engine is being cranked, the battery positive voltage is applied to terminal STA of the ECM. If the vehicle is being driven and the ECM detects the starter control signal (STA), the ECM concludes that the starter control circuit is malfunctioning. The ECM will turn on the MIL and will set a DTC. DTC No. P0617 DTC Detecting Condition Trouble Area When conditions (a), (b) and (c) are met and the battery (+B) voltage 10.5 V or more is applied for 20 seconds: (1 trip detection logic) (a) Vehicle speed greater than 20 km/h (12 mph) (b) Engine revolution greater than 1,000 rpm (c) STA signal ON
Short in PNP switch assy circuit
PNP switch assy
Ignition switch
ECM MONITOR STRATEGY Related DTCs P0617: Starter Signal Required sensors / components (Main) Starter Relay and PNP Switch Required sensors / components (Related) CKP Sensor and Vehicle Speed Sensor Frequency of operation Continuous Duration 20 seconds MIL operation Immediate Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-377 Battery voltage 10.5 V or more Vehicle speed 20 km/h (12.4 mph) or more Engine RPM 1,000 rpm or more TYPICAL MALFUNCTION THRESHOLDS Starter signal ON 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 785 05-596 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) WIRING DIAGRAM P1 PNP Switch B 3 B-R EB2 4 L W 2 AM1 1 1 1A B Instrument Panel J/B Assy 2 6 1C 3 B-Y IC1 B AM1 7 AM2 ST1 1 ST2 B-W 8 17 STA E7 B N P 4 EB2 2 STARTER L-W 2 1 2 B-W IC1 B 5 Engine Room R/B No. 2 I15 Ignition Switch ECM 2 5 2 2 ST Relay 1 3 Y 2 2 2 W-B W-R 1 IC1 1 E7 E1 BR L-Y 10 ALT AM2 2 4 EB1 F7 FL Block Assy B-W 1 A A J7 J/C J2 J/C W FL Main A 1 B 1 S2 BR S1 Battery Starter EH ED A88698 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 786 05-597 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand-held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. Hand-held tester: 1 (a) (b) (c) READ VALUE OF HAND-HELD TESTER (STA SIGNAL) Connect the hand-held tester to the DLC3. Turn the ignition switch ON and push the hand-held tester main switch ON. On the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / STARTER SIG. Read the values. Result: Ignition Switch Condition ON START STA Signal OFF ON OK REPLACE ECM (See page 10-24 ) NG 2 INSPECT PARK/NEUTRAL POSITION SWITCH ASSY (See page 05-1036 ) OK: When shift lever is the N position, the PNP switch is ON. When shift lever is the P position, the PNP switch is OFF. NG REPLACE PARK/NEUTRAL POSITION SWITCH ASSY (See page 40-7 ) (Go to step 3 AFTER REPLACEMENT) OK 3 (a) (b) (c) READ VALUE OF HAND-HELD TESTER (STA SIGNAL) Connect the hand-held tester to the DLC3. Turn the ignition switch ON and push the hand-held tester main switch ON. On the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / STARTER SIG. Read the values. Result: Ignition Switch Condition ON START STA Signal OFF ON OK SYSTEM OK NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 787 05-598 DIAGNOSTICS 4 - SFI SYSTEM (3MZ-FE) INSPECT IGNITION OR STARTER SWITCH ASSY (a) AM1 I15 Ignition Switch 4 3 2 1 8 7 6 5 ST2 ST1 Check the resistance of the ignition switch terminals. Standard: Switch Condition Tester Connection Specified Condition LOCK 1-2 7-8 10 kΩ or higher START 1-2 7-8 Below 1 Ω NG AM2 A56879 REPLACE IGNITION OR STARTER SWITCH ASSY (Go to next step 5 AFTER REPLACEMENT) OK 5 (a) (b) (c) READ VALUE OF HAND-HELD TESTER (STA SIGNAL) Connect the hand-held tester to the DLC3. Turn the ignition switch ON and push the hand-held tester main switch ON. On the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL / STARTER SIG. Read the values. Result: Ignition Switch Condition ON START STA Signal OFF ON OK SYSTEM OK NG REPAIR OR REPLACE HARNESS AND CONNECTOR OBD II scan tool (excluding Hand-held Tester): 1 INSPECT ECM STA (+) E7 ECM (a) (b) E1 (-) E9 ECM A76903 Turn the ignition switch ON. Check the voltage of the ECM connectors. Standard: Tester Connection Condition E7-17 (STA) - E9-1 (E1) Ignition switch ON 0V E7-17 (STA) - E9-1 (E1) Engine cranking 6 V or more OK Specified Condition REPLACE ECM (See page 10-24 ) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 788 05-599 DIAGNOSTICS 2 - SFI SYSTEM (3MZ-FE) INSPECT PARK/NEUTRAL POSITION SWITCH ASSY (See page 05-1036 ) OK: When shift lever is the N position, the PNP switch is ON. When shift lever is the P position, the PNP switch is OFF. NG REPLACE PARK/NEUTRAL POSITION SWITCH ASSY (See page 40-7 ) (Go to next step 3 AFTER REPLACEMENT) OK 3 INSPECT ECM (a) STA (+) E1 (-) E7 ECM E9 ECM A76903 Check the voltage of the ECM connectors. Standard: Tester Connection Condition Specified Condition E7-17 (STA) - E9-1 (E1) Ignition switch ON 0V E7-17 (STA) - E9-1 (E1) Engine cranking 6 V or more OK SYSTEM OK NG 4 INSPECT IGNITION OR STARTER SWITCH ASSY (a) AM1 I15 Ignition Switch ST2 4 3 2 1 8 7 6 5 AM2 ST1 A56879 Check the resistance of the ignition switch terminals. Standard: Switch Condition Tester Connection Specified Condition LOCK 1-2 7-8 10 kΩ or higher START 1-2 7-8 Below 1 Ω NG REPLACE IGNITION OR STARTER SWITCH ASSY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 789 05-600 DIAGNOSTICS 5 - SFI SYSTEM (3MZ-FE) INSPECT ECM (a) STA (+) E7 ECM E1 (-) E9 ECM A76903 Check the voltage of the ECM connectors. Standard: Tester Connection Condition E7-17 (STA) - E9-1 (E1) Ignition switch ON 0V E7-17 (STA) - E9-1 (E1) Engine cranking 6 V or more OK Specified Condition SYSTEM OK NG REPAIR OR REPLACE HARNESS AND CONNECTOR 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 790 05-601 DIAGNOSTICS DTC P0630 - SFI SYSTEM (3MZ-FE) 05MOS-01 VIN NOT PROGRAMMED OR MISMATCH ECM/PCM CIRCUIT DESCRIPTION DTC P0630 is set when the Vehicle Indication Number (VIN) is not stored in the ECM or the input VIN is not accurate. Input the VIN with the hand-held tester (see page 05-373 ). DTC No. DTC Detection Conditions Trouble Areas
VIN is not stored in ECM
Input VIN in ECM is not accurate P0630
ECM MONITOR STRATEGY Related DTCs P0630: VIN not programed Required Sensors/Components (Main) ECM Required Sensors/Components (Related)  Frequency of Operation Continuous Duration 0.5 seconds MIL Operation Immediate Sequence of Operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-377 Battery voltage 8 V or more Ignition switch ON Stater OFF TYPICAL MALFUNCTION THRESHOLDS VIN code Not programmed COMPONENT OPERATING RANGE VIN code Programmed INSPECTION PROCEDURE 1 READ CURRENT DTC NOTICE: If P0630 is present, the VIN must be input to the ECM using the hand-held tester. However, all DTCs are cleared automatically by the tester when inputting the VIN. If DTCs other than P0630 are present, check them first. NEXT 2 INPUT VIN WITH HAND-HELD TESTER (See page 05-373 ) NEXT END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 791 05-602 DIAGNOSTICS DTC P0705 - SFI SYSTEM (3MZ-FE) 059VP-12 TRANSMISSION RANGE SENSOR CIRCUIT MALFUNCTION (PRNDL INPUT) CIRCUIT DESCRIPTION When the shift lever is in the N or P position: 1) the Park/Neutral Position (PNP) switch turns on, and 2) ECM terminal NSW is grounded to the body ground via the starter relay and voltage becomes 0V. When the shift lever is in the D, 2, L or R position: 1) the PNP switch turns off, and 2) ECM terminal NSW receives current and becomes the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated control), etc. DTC No. P0705 DTC Detection Condition 2 or more switches are ON simultaneously at P R, N, D, 2 and L positions (2 trip detection logic) Trouble Area
Short in PNP switch circuit
PNP switch
ECM HINT: After confirming DTC P0705, use the hand-held tester to confirm the PNP switch signal in the ALL menu (to reach the ALL menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL). WIRING DIAGRAM Refer to DTC P0705 on page 05-1036 . INSPECTION PROCEDURE Refer to DTC P0705 on page 05-1036 . HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 792 05-603 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EXZ-05 DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH CIRCUIT DESCRIPTION The throttle motor is operated by the ECM and it opens and closes the throttle valve. The opening angle of the throttle valve is detected by the throttle position sensor which is mounted on the throttle body. The throttle position sensor provides feedback to the ECM. This feedback allows the ECM to control the throttle motor and monitor the throttle opening angle in response to driver inputs. HINT: This Electronic Throttle Control System (ETCS) does not use a throttle cable. DTC No. DTC Detection Condition Trouble Area P2102 Conditions (a) and (b) continue for 2.0 seconds: (a) Throttle control motor output duty 80 % or more (b) Throttle control motor current 0.5 A or less (1 trip detection logic)
Open in throttle control motor circuit
Throttle control motor
ECM P2103 Either of following conditions is met:
Throttle control motor current 10 A or more (0.1 seconds)
Throttle control motor current 7 A or more (0.6 seconds) (1 trip detection logic)
Short in throttle control motor circuit
Throttle control motor
Throttle valve
Throttle body Assy
ECM MONITOR DESCRIPTION The ECM monitors the flow of electrical current through the electronic throttle motor, and detects malfunctions or open circuits in the throttle motor based on the value of the electrical current. When the current deviates from the standard values, the ECM concludes that there is a fault in the throttle motor. Or, if the throttle valve is not functioning properly (for example, stuck ON), the ECM concludes that there is a fault and turns on the MIL and a DTC is set. Example: When the current is more than 10 A, or the current is less than 0.5A when the motor driving duty ratio is exceeding 80 %, the ECM concludes that the current is deviated from the standard values, turns on the MIL and a DTC is set. FAIL SAFE If the ETCS, has a malfunction, the ECM cuts off current to the throttle control motor. The throttle control valve returns to a predetermined opening angle (approximately 16) by the force of the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue at a minimal speed. If the accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly. If a ”pass” condition is detected and then the ignition switch is turned OFF, the fail-safe operation will stop and the system will return to normal condition. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 793 05-604 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) MONITOR STRATEGY Related DTCs P2102: Throttle Actuator Current (Low current) P2103: Throttle Actuator Current (High current) Required sensors / components (Main) Throttle actuator Required sensors / components (Related) - Frequency of operation Continuous Duration 2 seconds MIL operation Immediate Sequence operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present See page 05-377 P2102: Throttle actuator duty ratio 80 % or more Throttle actuator power supply 8 V or more P2103: Throttle actuator power supply 8 V or more TYPICAL MALFUNCTION THRESHOLDS P2102: Throttle actuator current Less than 0.5 A P2103: Either of the following conditions is set: Condition 1 or 2 1. Hybrid IC diagnosis signal (Throttle control motor current is 10 A or more) Fail (for 0.1 seconds) 2. Hybrid IC current limiter port (Throttle control motor current is 7 A or more) Fail (for 0.6 seconds) WIRING DIAGRAM T13 Throttle Control Motor ECM Shielded M+ 2 B 3 M+ E9 M- W 2 ME9 1 17 E9 GE01 A87825 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 794 05-605 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 INSPECT THROTTLE BODY ASSY (RESISTANCE OF THROTTLE CONTROL MOTOR) (a) (b) T13 Throttle Control Motor M+ Disconnect the T13 throttle control motor connector. Check the resistance of the throttle control motor terminals. Standard: Tester Connection Specified Condition T13-2 (M+) - T13-1 (M-) 0.3 to 100 Ω 20C (68F) MA59778 NG REPLACE THROTTLE BODY ASSY (See page 10-18 ) OK 2 CHECK WIRE HARNESS (THROTTLE CONTROL MOTOR - ECM) (a) (b) (c) Wire Harness Side T13 Throttle Control Motor M- Disconnect the T13 throttle control motor connector. Disconnect the E9 ECM connector. Check the resistance of the wire harness side connectors. Standard: M+ Tester Connection Specified Condition T13-2 (M+) - E9-3 (M+) T13-1 (M-) - E9-2 (M-) Below 1 Ω T13-2 (M+) or E9-3 (M+) - Body ground T13-1 (M-) or E9-2 (M-) - Body ground 10 kΩ or higher E9 ECM M+ MY B53781 A81698 A85540 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 795 05-606 DIAGNOSTICS 3 (a) - SFI SYSTEM (3MZ-FE) INSPECT THROTTLE BODY ASSY Visually check between the throttle valve and the housing for foreign objects. Also, check if the valve can open and close smoothly. OK: The throttle valve is not contaminated by foreign objects and can move smoothly. NG REMOVE FOREIGN OBJECT AND CLEAN THROTTLE BODY OK REPLACE ECM (See page 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 796 05-607 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EY0-05 DTC P2111 THROTTLE ACTUATOR CONTROL SYSTEM - STUCK OPEN DTC P2112 THROTTLE ACTUATOR CONTROL SYSTEM - STUCK CLOSED CIRCUIT DESCRIPTION The throttle motor is operated by the ECM and it opens and closes the throttle valve using gears. The opening angle of the throttle valve is detected by the throttle position sensor, which is mounted on the throttle body. The throttle position sensor provides feedback to the ECM to control the throttle motor and set the throttle valve angle in response to driver inputs. HINT: This Electronic Throttle Control System (ETCS) does not use a throttle cable. DTC No. DTC Detection Condition Trouble Area P2111 Throttle valve locked during ECM order to close (1 trip detection logic) P2112 Throttle valve locked during ECM order to open (1 trip detection logic)
Throttle control motor circuit
Throttle control motor
Throttle body
Throttle valve
Throttle control motor circuit
Throttle control motor
Throttle body
Throttle valve MONITOR DESCRIPTION The ECM concludes that there is a malfunction of the ETCS when the throttle valve remains at a fixed angle despite high drive current from the ECM. The ECM will turn on the MIL and will set a DTC. FAIL SAFE If the ETCS has a malfunction, the ECM cuts off current to the throttle control motor. The throttle control valve returns to a predetermined opening angle (approximately 16) by the force of the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue at a minimal speed. If the accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly. If a ”pass” condition is detected and then the ignition switch is turned OFF, the fail-safe operation will stop and the system will return to normal. MONITOR STRATEGY Related DTCs P2111: Throttle actuator stuck open P2112: Throttle actuator stuck closed Required sensors / components (Main) Throttle actuator Required sensors / components (Related) - Frequency of operation Continuous Duration 0.5 seconds MIL operation Immediate Sequence operation None 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 797 05-608 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present See page 05-377 P2111: Throttle motor current 2 A or more Throttle motor close duty ratio 80% or more P2112: Throttle actuator current 2 A or more Throttle actuator open duty ratio 80 % or more TYPICAL MALFUNCTION THRESHOLDS TP (Throttle position) sensor voltage change for 0.016 seconds Less than 0.1 V WIRING DIAGRAM Refer to DTC P2102 on page 05-603 . INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK THROTTLE BODY ASSY Display (DTC output) Proceed to P2111 or P2112 A P2111 or P2112 and other DTCs B NG REPLACE THROTTLE BODY ASSY (See page 10-18 ) OK 2 CHECK THROTTLE BODY ASSY (VISUALLY CHECK THROTTLE VALVE) Check for contamination between the throttle valve and the housing. If necessary, clean the throttle body. And check that the throttle valve moves smoothly. OK: The throttle valve is not contaminated by foreign objects and can move smoothly. NG REPLACE THROTTLE BODY ASSY (See page 10-18 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 798 05-609 DIAGNOSTICS 3 (a) (b) (c) - SFI SYSTEM (3MZ-FE) CHECK DTC OUTPUT Clear the DTC. Start the engine, and depress and release the accelerator pedal quickly (fully open and fully close). Read DTC. Result: Display (DTC output) Proceed to No DTC A P2111 and/or P2112 B B REPLACE ECM (See page 10-24 ) OK CHECK FOR INTERMITTENT PROBLEM (See page 05-370 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 799 05-610 DIAGNOSTICS DTC P2118 - SFI SYSTEM (3MZ-FE) 052NY-20 THROTTLE ACTUATOR CONTROL MOTOR CURRENT RANGE/PERFORMANCE CIRCUIT DESCRIPTION The Electronic Throttle Control System (ETCS) has a dedicated power supply circuit. The voltage (+BM) is monitored and when the voltage is low (less than 4V), the ECM concludes that the ETCS has a fault and current to the throttle control motor is cut. When the voltage becomes unstable, the ETCS condition itself becomes unstable. For this reason, when the voltage is low, the current to the motor is cut. If repairs are made and the system has returned to normal, turn the ignition switch OFF. The ECM then allows current to flow to the motor and the motor can be restarted. HINT: This ETCS does not use a throttle cable. ECM ETCS +BM From Battery Throttle Control Motor M+ M- Motor Control Circuit ME01 A87799 DTC No. P2118 DTC Detection Condition Open in ETCS power source circuit (1 trip detection logic) Trouble Area
Open in ETCS power source circuit
ETCS fuse
ECM 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 800 05-61 1 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) MONITOR DESCRIPTION The ECM monitors the battery supply voltage applied to the electronic throttle motor. When the power supply voltage drops below the threshold, the ECM concludes that the power supply circuit has an open circuit. A DTC is set and the MIL is turned on. FAIL SAFE If the ETCS has a malfunction, the ECM cuts off current to the throttle control motor. The throttle control valve returns to a predetermined opening angle (approximately 16) by the force of the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue at a minimal speed. If the accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly. If a ”pass” condition is detected and then the ignition switch is turned OFF, the fail-safe operation will stop and the system will return to normal. MONITOR STRATEGY Related DTCs P2118: Throttle Actuator Power Supply Required sensors / components (Main) Throttle actuator, ETCS fuse Required sensors / components (Related) - Frequency of operation Continuous Duration 0.8 seconds MIL operation Immediate Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present See page 05-377 Battery voltage More than 8 V TYPICAL MALFUNCTION THRESHOLDS Throttle actuator power supply voltage Less than 4 V COMPONENT OPERATING RANGE Throttle actuator power supply voltage 9 to 14 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 801 05-612 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) WIRING DIAGRAM ECM 4 IC1 R T13 Throttle Control Motor 2 ETCS M+ 2 1 6 +BM E6 W 2 Shielded 3 M+ E9 B Engine Room R/B No. 2 M- 1 Motor Control Circuit 2 ME9 W 2 17 E9 GE01 W 3 F7 FL Block Assy 4 ME01 E9 1 W Main W-B Battery EC A88699 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 802 05-613 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK FUSE (ETCS) (a) (b) Engine Room R/B No. 2 Remove the ETCS fuse from the engine room R/B No. 2. Check the resistance of the ETCS fuse. Standard: Below 1 Ω ETCS Fuse A80017 NG REPLACE FUSE OK 2 INSPECT ECM (+BM VOLTAGE) (a) E1 (-) E9 ECM +BM (+) Check the voltage of the ECM connectors. Standard: Tester Connection Specified Condition E6-6 (+BM) - E9-1 (E1) 9 to 14 V E6 ECM A67446 OK REPLACE ECM (See page 10-24 ) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 803 05-614 DIAGNOSTICS 3 SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS (ECM - ETCS FUSE, ETCS FUSE - BATTERY) (a) Wire Harness Side Engine Room R/B No. 2 ETCS Fuse E6 ECM A92543 Check the wire harness between the ETCS fuse and ECM. (1) Remove the ETCS fuse from the engine room R/B No. 2. (2) Disconnect the E6 ECM connector. (3) Check the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition R/B No. 2 ETCS fuse terminal 2 - E6-6 (+BM) Below 1 Ω R/B No. 2 ETCS fuse terminal 2 or E6-6 (+BM) Body ground 10 kΩ or higher (b) +BM A87846 A67404 - Check the wire harness between the ETCS fuse and battery. (1) Remove the ETCS fuse from the engine room R/B No. 2. (2) Disconnect the battery positive cable. (3) Check the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition Battery positive cable - R/B No. 2 ETCS fuse terminal 1 Below 1 Ω Battery positive cable or R/B No. 2 ETCS fuse terminal 1 Body ground 10 kΩ or higher NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK CHECK ENGINE ROOM RELAY BLOCK NO.2 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 804 05-615 DIAGNOSTICS DTC P2119 - SFI SYSTEM (3MZ-FE) 059VR-18 THROTTLE ACTUATOR CONTROL THROTTLE BODY RANGE/PERFORMANCE CIRCUIT DESCRIPTION The Electronic Throttle Control System (ETCS) is composed of a throttle motor that operates the throttle valve, a throttle position sensor that detects the opening angle of the throttle valve, an accelerator pedal position sensor that detects the accelerator pedal position, and the ECM that controls the ETCS system. The ECM operates the throttle motor to position the throttle valve for proper response to driver inputs. The throttle position sensor, which is mounted on the throttle body, detects the opening angle of the throttle valve and provides this signal to the ECM so that the ECM can regulate the throttle motor. DTC No. P2119 DTC Detection Condition Trouble Area Throttle opening angle continues to vary greatly from target throttle opening angle (1 trip detection logic)
ETCS
ECM MONITOR DESCRIPTION The ECM determines the ”actual” throttle angle based on the throttle position sensor signal. The ”actual” throttle position is compared to the ”target” throttle position commanded by the ECM. If the difference between these two values exceeds a specified limit, the ECM interprets this as a fault in the ETCS system. The ECM turns on the MIL and a DTC is set. FAIL SAFE If the ETCS has a malfunction, the ECM cuts off current to the throttle control motor. The throttle control valve returns to a predetermined opening angle (approximately 16) by the force of the return spring. The ECM then adjusts the engine output by controlling the fuel injection (intermittent fuel-cut) and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue at a minimal speed. If the accelerator pedal is depressed firmly and slowly, the vehicle can be driven slowly. If a ”pass” condition is detected and then the ignition switch is turned OFF, the fail-safe operation will stop and the system will return to normal. MONITOR STRATEGY Related DTCs P2119: ETCS malfunction Required sensors / components (Main) Throttle actuator Required sensors / components (Related) - Frequency of operation Continuous Duration 1 second MIL operation Immediate Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-377 TYPICAL MALFUNCTION THRESHOLDS Difference between ”target closed TP (Throttle position) ” and ”actual closed TP” Difference between ”target open TP” and ”actual open TP” 0.3 V or more for 1 seconds 0.3 V or more for 0.6 seconds WIRING DIAGRAM Refer to DTC P2102 on page 05-603 . 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 805 05-616 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 CHECK OTHER DTC OUTPUT (IN ADDITION TO DTC P2119) Display (DTC output) Proceed to Only P2119 is output A P2119 and other codes are output B B GO TO RELEVANT DTC CHART (See page 05-412 ) A 2 CHECK IF DTC OUTPUT REOCCUR (a) Clear the DTC (see page 05-400 ). (b) Allow the engine to idle for 15 seconds. (c) Pull the hand brake and shift the gear to D. (d) Depress the brake pedal securely and the accelerator pedal fully for 5 seconds. (e) Read the DTC. HINT: Actual throttle position (TP) sensor voltage can be confirmed using the hand-held tester [DATA LIST/ALL/ THROTTLE POS #1]. OK: No DTC output. NG REPLACE THROTTLE BODY ASSY (See page 10-18 ) OK NORMAL 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 806 05-617 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05IR0-02 DTC P2120 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”D” CIRCUIT DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”D” CIRCUIT LOW INPUT DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”D” CIRCUIT HIGH INPUT DTC P2125 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”E” CIRCUIT DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”E” CIRCUIT LOW INPUT DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”E” CIRCUIT HIGH INPUT DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”D”/”E” VOLTAGE CORRELATION HINT: This is the repair procedure for the ”accelerator pedal position sensor”. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 807 05-618 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) CIRCUIT DESCRIPTION HINT:

Accelerator Pedal Position Sensor Magnet IC No. 1 ECM VPA EPA VCPA VPA2 EPA2 IC No. 2 Accelerator Pedal Position Sensor Output Voltage (V) This electrical throttle system does not use a throttle cable. This accelerator pedal position sensor is a non-contact type. The accelerator pedal position sensor is mounted on the accelerator pedal bracket to detect the angle of the accelerator pedal. This sensor is electronically controlled and uses Hall-effect elements. In the accelerator pedal position sensor, the voltage applied to terminals VPA and VPA2 of the ECM changes between 0 V and 5 V in proportion to the angle of the accelerator pedal. The VPA is a signal to indicate the actual accelerator pedal angle which is used for the engine control. VPA2 is used to detect malfunctions of the sensor itself. The ECM judges the accelerator pedal angle from VPA and VPA2 signal outputs, and the ECM controls the throttle motor based on these signals. *1 *2 5 3.4 to 5.3 2.6 to 4.5 1.6 0.8 0 VCP2 Usable Range 25 Accelerator Pedal Turning Angle (deg.) Magnet *1: Accelerator Pedal Released *2: Accelerator Pedal Fully Depressed A19694 A19803 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 808 05-619 DIAGNOSTICS DTC No. - SFI SYSTEM (3MZ-FE) DTC Detection Condition (All of the following are 1trip detection logic) Trouble Area P2120 Condition (a) continues for 0.5 seconds or more: (a) VPA is 0.2 V or less or VPA is 4.8 V or more
Accelerator pedal position sensor
ECM P2122 VPA is 0.2 V or less for 0.5 seconds or more when VPA2 output indicates accelerator pedal is opened
Accelerator pedal position sensor
Open in VCP1 circuit
VPA circuit open or ground short
ECM P2123 Condition (a) continues for 2.0 seconds or more: (a) VPA is 4.8 V or more
Accelerator pedal position sensor
Open in EPA circuit
ECM P2125 Condition (a) continues for 0.5 seconds or more: (a) (VPA2 is 0.5 V or less or (VPA2 is 4.8 V or more
Accelerator pedal position sensor
ECM P2127 VPA2 is 0.5 V or less for 0.5 seconds or more when VPA output indicates accelerator pedal is opened
Accelerator pedal position sensor
Open in VCP2 circuit
VPA2 circuit open or ground short
ECM P2128 Conditions (a) and (b) continue for 2.0 seconds or more: (a) VPA2 is 4.8 V or more (b) VPA is 0.2 V or more and VPA is 3.45 V or less
Accelerator pedal position sensor
Open in EPA2 circuit
ECM P2138 Condition (a) or (b) continues for 2.0 seconds or more: (a) Difference between VPA and VPA2 is 0.02 V or less (b) VPA is 0.2 V or less and VPA2 is 0.5 V or less
VPA and VPA2 circuit are short circuit
Accelerator pedal position sensor
ECM HINT: After confirming DTC P2120, P2122, P2123, P2125, P2127, P2128 and P2138, use the hand-held tester or the OBD II scan tool to confirm the accelerator pedal position sensor output voltage. Accelerator pedal position expressed as voltage output Accelerator pedal position expressed as voltage output Accelerator pedal position expressed as voltage output Accelerator pedal position expressed as voltage output Accelerator pedal released Accelerator pedal released Accelerator pedal depressed Accelerator pedal depressed Trouble Area ACCEL POS #1 ACCEL POS #2 ACCEL POS #1 ACCEL POS #2 VCP circuit open 0 to 0.2 V 0 to 0.2 V 0 to 0.2 V 0 to 0.2 V VPA circuit open or ground short 0 to 0.2 V 1.2 to 2.0 V 0 to 0.2 V 3.4 to 5.3 V VPA2 circuit open or ground short 0.5 to 1.1 V 0 to 0.2 V 2.6 to 4.5 V 0 to 0.2 V EPA circuit open 4.5 to 5.5 V 4.5 to 5.5 V 4.5 to 5.5 V 4.5 to 5.5 V MONITOR DESCRIPTION When VPA or VPA2 deviates from the standard, or the difference between the voltage outputs of the two sensors is less than the threshold, the ECM concludes that there is a defect in the accelerator pedal position sensor. The ECM turns on the MIL and a DTC is set. Example: The voltage output of the VPA is below 0.2 V or exceeds 4.8 V. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 809 05-620 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) FAIL SAFE The accelerator pedal position sensor has 2 (main and sub) sensor circuits. If a malfunction occurs in either of the sensor circuits, the ECM detects the abnormal signal voltage difference between the two sensor circuits and switches to fail-safe mode. In fail-safe mode, the functioning circuit is used to calculate the accelerator pedal opening angle to allow the vehicle to continue driving. If both circuits malfunction, the ECM regards the opening angle of the accelerator pedal to be fully closed. In this case, the throttle valve will remain closed as if the engine is idling. If a ”pass” condition is detected and then the ignition switch is turned OFF, the fail-safe operation will stop and the system will return to normal condition. MONITOR STRATEGY Related DTCs P2120: APP Sensor 1 Range Check (Chattering) P2122: APP Sensor 1 Range Check (Low voltage) P2123: APP Sensor 1 Range Check (High voltage) P2125: APP Sensor 2 Range Check (Chattering) P2127: APP Sensor 2 Range Check (Low voltage) P2128: APP Sensor 2 Range Check (High voltage) P2138: APP Sensor Range Check (Correlation) Required sensors / components (Main) APP sensor Required sensors / components (Related) - Frequency of operation Continuous Duration 2 seconds MIL operation Immediate Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-377 TYPICAL MALFUNCTION THRESHOLDS P2120: Either of the following conditions is met: Condition 1 or 2 1. VPA1 voltage when VPA2 is 0.97 or more 0.2 V or less 2. VPA1 voltage 4.8 V or more P2122: VPA1 voltage when VPA2 is 0.97 or more 0.2 V or less P2123: VPA1 voltage 4.8 V or more P2125: Either of the following conditions is met: Condition 1 or 2 1. VPA2 voltage when VPA1 is 0.97 or more 0.5 V or less 2. VPA2 voltage when VPA1 is 0.2 to 3.45 V 4.8 V or more P2127: VPA2 voltage when VPA1 is 0.97 or more 0.5 V or less P2128: VPA2 voltage when VPA1 is 0.2 to 3.45 V 4.8 V or more P2138: Either of the following conditions is met: Condition 1 or 2 1. Difference betrween VPA 1 and VPA2 voltage 0.02 V or less Condition 2 - VPA1 voltage 0.2 V or less VPA2 voltage 0.5 V or less 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 810 05-621 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) COMPONENT OPERATING RANGE VPA1 voltage 0.5 to 4.5 V VPA2 voltage 1.2 to 4.8 V WIRING DIAGRAM A27 Accelerator Pedal Position Sensor VCP2 VPA2 EPA2 VCPA VPA EPA ECM L 27 VCP2 E5 W 23 VPA2 E5 BR 29 EPA2 E5 G 26 VCPA E5 B 22 VPA E5 R 28 EPA E5 1 3 2 4 6 5 Y A92550 A92550 INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame date can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occured. Hand-held tester: 1 READ VALUE OF HAND-HELD TESTER (ACCEL POS #1 AND ACCEL POS #2) (a) (b) (c) Depressed Connect the hand-held tester to the DLC3. Turn the ignition switch ON. On the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ETCS / ACCEL POS #1 and ACCEL POS #2. Read the values. Standard: Accelerator Pedal ACCEL POS #1 ACCEL POS #2 Released 0.5 to 1.1 V 1.2 to 2.0 V Depressed 2.6 to 4.5 V 3.4 to 5.3 V Released FI7052 OK Go to step 5 NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 811 05-622 DIAGNOSTICS 2 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS (ACCELERATOR PEDAL POSITION SENSOR - ECM) (a) Wire Harness Side A27 Accelerator Pedal Position Sensor VCP2 (b) (c) Disconnect the A27 accelerator pedal position sensor connector. Disconnect the E5 ECM connector. Measure the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition A27-6 (VCP1) - E5-26 (VCPA) A27-5 (VPA1) - E5-22 (VPA) A27-4 (VCP2) - E5-27 (VCP2) A27-3 (EP1) - E5-28 (EPA) A27-2 (VPA2) - E5-23 (VPA2) A27-1 (EP2) - E5-29 (EPA2) Below 1 Ω A27-6 (VCP1) or E5-26 (VCPA) - Body ground A27-5 (VPA1) or E5-22 (VPA) - Body ground A27-4 (VCP2) or E5-27 (VCP2) - Body ground A27-3 (EP1) or E5-28 (EPA) - Body ground A27-2 (VPA2) or E5-23 (VPA2) - Body ground A27-1 (EP2) or E5-29 (EPA2) - Body ground 10 kΩ or higher VPA EPA2 VPA2 VCPA VPA EPA VCP2 VCPA E5 ECM VPA2 EPA2 EPA B83781 A67445 A92545 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 3 INSPECT ECM (VCPA AND VCP2 VOLTAGE) (a) (b) (c) A27 Accelerator Pedal Position Sensor VCP2 (+) A19521 A53765 Disconnect the A27 accelerator pedal position sensor connector. Turn the ignition switch ON. Cheak the voltage of the E5 ECM connector. Standard: Tester Connection Specified Condition E5-26 (VCPA) - E5-28 (EPA) E5-27 (VCP2) - E5-29 (EPA2) 4.5 to 5.5 V VCPA (+) E5 ECM EPA2 (-) EPA (-) A92544 NG REPLACE ECM (See page 10-24 ) OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 812 05-623 DIAGNOSTICS 4 - SFI SYSTEM (3MZ-FE) REPLACE ACCELERATOR PEDAL ROD ASSY (See page 10-26 ) GO 5 (a) (b) (c) (d) READ OUTPUT DTC (ACCELERATOR PEDAL POSITION SENSOR DTCS ARE OUTPUT AGAIN Clear the DTC (see page 05-400 ). Start the engine. Run the engine at idle for 15 seconds or more. Read the DTC (see page 05-400 ). Result: Display (DTC Output) Proceed to P2120, P2122, P2123, P2125, P2127, P2128 and/or P2138 are output again A No DTC output B B SYSTEM OK A REPLACE ECM (See page 10-24 ) OBD II scan tool (excluding hand-held tester): 1 CHECK WIRE HARNESS (ACCELERATOR PEDAL POSITION SENSOR - ECM) (a) Wire Harness Side A27 Accelerator Pedal Position Sensor VCP2 EPA2 VPA2 A27-6 (VCP1) - E5-26 (VCPA) A27-5 (VPA1) - E5-22 (VPA) A27-4 (VCP2) - E5-27 (VCP2) A27-3 (EP1) - E5-28 (EPA) A27-2 (VPA2) - E5-23 (VPA2) A27-1 (EP2) - E5-29 (EPA2) Below 1 Ω A27-6 (VCP1) or E5-26 (VCPA) - Body ground A27-5 (VPA1) or E5-22 (VPA) - Body ground A27-4 (VCP2) or E5-27 (VCP2) - Body ground A27-3 (EP1) or E5-28 (EPA) - Body ground A27-2 (VPA2) or E5-23 (VPA2) - Body ground A27-1 (EP2) or E5-29 (EPA2) - Body ground 10 kΩ or higher VPA VCPA EPA VPA B83781 A67445 (b) (c) Disconnect the A27 accelerator pedal position sensor connector. Disconnect the E5 ECM connector. Measure the resistance of the wire harness side connectors. Standard: VCP2 VCPA E5 ECM VPA2 EPA2 EPA A92545 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 813 05-624 DIAGNOSTICS 2 - SFI SYSTEM (3MZ-FE) INSPECT ECM (VCPA AND VCP2 VOLTAGE) (a) (b) (c) A27 Accelerator Pedal Position Sensor VCP2 (+) Disconnect the A27 accelerator pedal position sensor connector. Turn the ignition switch ON. Cheak the voltage of the E5 ECM connector. Standard: Tester Connection Specified Condition E5-26 (VCPA) - E5-28 (EPA) E5-27 (VCP2) - E5-29 (EPA2) 4.5 to 5.5 V VCPA (+) E5 ECM EPA2 (-) EPA (-) A19521 A53765 A92544 NG REPLACE ECM (See page 10-24 ) OK 3 REPLACE ACCELERATOR PEDAL ROD ASSY (See page 10-26 ) GO 4 (a) (b) (c) (d) READ OUTPUT DTC (ACCELERATOR PEDAL POSITION SENSOR DTCS ARE OUTPUT AGAIN) Clear the DTC (see page 05-400 ). Start the engine. Run the engine at idle for 15 seconds or more. Read the DTC (see page 05-400 ). Result: Display (DTC Output) Proceed to P2120, P2122, P2123, P2125, P2127, P2128 and/or P2138 are output again A No DTC output B B SYSTEM OK A REPLACE ECM (See page 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 814 05-625 DIAGNOSTICS DTC P2121 - SFI SYSTEM (3MZ-FE) 05IQM-02 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”D” CIRCUIT RANGE/PERFORMANCE HINT: This is repair procedure for the ”accelerator pedal position sensor”. CIRCUIT DESCRIPTION Refer to DTC P2120 on page 05-617 . DTC No. P2121 DTC Detection Condition Trouble Area Conditions (a) continue for 0.5 seconds: (a) Difference between VPA and VPA2 exceeds the threshold (1 trip detection logic)
Open or short in accelerator pedal position sensor circuit
Accelerator pedal position sensor
ECM MONITOR DESCRIPTION The accelerator pedal position sensor is mounted on the accelerator pedal bracket. The accelerator pedal position sensor has 2 sensors elements/signal output: VPA and VPA2. VPA is used to detect the actual accelerator pedal angle (used for engine control) and VPA2 is used to detect malfunctions in VPA. When the difference between the voltage outputs of VPA and VPA2 deviates from the standard, the ECM concludes the accelerator pedal position sensor has a malfunction. ECM turns on the MIL and a DTC is set. FAIL SAFE The accelerator pedal position sensor has 2 (main and sub) sensor circuits. If a malfunction occurs in either of the sensor circuits, the ECM detects the abnormal signal voltage difference between the 2 sensor circuits and switches to fail-sefe mode. In fail-sefe mode, the functioning circuit is used to calculate the accelerator pedal opening angle to allow the vehicle to continue driving. If both circuits malfunction, the ECM regards the opening angle of the accelerator pedal to be fully closed. In this case, the throttle valve will remain closed as if the engine is idling. If a ”pass” condition is detected and then the ignition switch is turned OFF, the fail-safe operation will stop and the system will return to normal condition. MONITOR STRATEGY Related DTCs P2121: TP sensor malfunction Required sensors / components (Main) Accelerator position sensor Required sensors / components (Related) - Frequency of operation Continuous Duration 0.5 seconds MIL operation Immediate Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present See page 05-377 Ignition switch ON TYPICAL MALFUNCTION THRESHOLDS VPA1 - VPA2 (learning voltage) Below 0.4 V, or more than 1.2 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 815 05-626 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) WIRING DIAGRAM Refer to DTC P2120 on page 05-617 . INSPECTION PROCEDURE HINT: Read freeze frame data using the hand−held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame date can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction. Hand-held tester: 1 READ VALUE OF HAND-HELD TESTER (ACCEL POS #1, ACCEL POS #2) (a) (b) (c) Depressed Connect the hand-held tester to the DLC3. Turn the ignition switch ON. On the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ETCS / ACCEL POS #1 and ACCEL POS #2. Read the values. Standard: Accelerator Pedal ACCEL POS #1 ACCEL POS #2 Released 0.5 to 1.1 V 1.2 to 2.0 V Depressed 2.6 to 4.5 V 3.4 to 5.3 V Released FI7052 OK REPLACE ECM (See page 10-24 ) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 816 05-627 DIAGNOSTICS 2 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS (ACCELERATOR PEDAL POSITION SENSOR - ECM) (a) Wire Harness Side A27 Accelerator Pedal Position Sensor VCP2 (b) (c) Disconnect the A27 accelerator pedal position sensor connector. Disconnect the E5 ECM connector. Measure the resistance of the wire harness side connectors. Standard: Tester Connection Specified Condition A27-6 (VCP1) - E5-26 (VCPA) A27-5 (VPA1) - E5-22 (VPA) A27-4 (VCP2) - E5-27 (VCP2) A27-3 (EP1) - E5-28 (EPA) A27-2 (VPA2) - E5-23 (VPA2) A27-1 (EP2) - E5-29 (EPA2) Below 1 Ω A27-6 (VCP1) or E5-26 (VCPA) - Body ground A27-5 (VPA1) or E5-22 (VPA) - Body ground A27-4 (VCP2) or E5-27 (VCP2) - Body ground A27-3 (EP1) or E5-28 (EPA) - Body ground A27-2 (VPA2) or E5-23 (VPA2) - Body ground A27-1 (EP2) or E5-29 (EPA2) - Body ground 10 kΩ or higher VPA EPA2 VPA2 VCPA EPA VPA VCP2 VCPA E5 ECM VPA2 EPA2 EPA B83781 A67445 A92545 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE ACCELERATOR PEDAL ROD ASSY (See page 10-26 ) OBD II scan tool (excluding hand-held tester): 1 INSPECT ECM (VPA, VPA2 VOLTAGE) VPA2 (+) VPA (+) (a) (b) E5 ECM EPA2 (-) EPA (-) A53765 Turn the ignition switch ON. Check the voltage of the ECM connector. Tester Condition Accelerator Pedal Condition Specified Condition E5-22 (VPA) - E5-28 (EPA) Released 0.5 to 1.1 V E5-22 (VPA) - E5-28 (EPA) Depressed 2.6 to 4.5 V E5-23 (VPA2) - E5-29 (EPA2) Released 1.2 to 2.9 V E5-23 (VPA2) - E5-29 (EPA2) Depressed 3.4 to 5.5 V OK REPLACE ECM (See page 10-24 ) NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 817 05-628 DIAGNOSTICS 2 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS (ACCELERATOR PEDAL POSITION SENSOR - ECM) (a) Wire Harness Side A27 Accelerator Pedal Position Sensor VCP2 EPA2 VPA2 Tester Connection Specified Condition A27-6 (VCP1) - E5-26 (VCPA) A27-5 (VPA1) - E5-22 (VPA) A27-4 (VCP2) - E5-27 (VCP2) A27-3 (EP1) - E5-28 (EPA) A27-2 (VPA2) - E5-23 (VPA2) A27-1 (EP2) - E5-29 (EPA2) Below 1 Ω A27-6 (VCP1) or E5-26 (VCPA) - Body ground A27-5 (VPA1) or E5-22 (VPA) - Body ground A27-4 (VCP2) or E5-27 (VCP2) - Body ground A27-3 (EP1) or E5-28 (EPA) - Body ground A27-2 (VPA2) or E5-23 (VPA2) - Body ground A27-1 (EP2) or E5-29 (EPA2) - Body ground 10 kΩ or higher VPA VCPA EPA VPA B83781 A67445 (b) (c) Disconnect the A27 accelerator pedal position sensor connector. Disconnect the E5 ECM connector. Measure the resistance of the wire harness side connectors. Standard: VCP2 VCPA E5 ECM VPA2 EPA2 EPA A92545 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE ACCELERATOR PEDAL ROD ASSY (See page 10-26 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 818 05-629 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EY1-06 DTC P2195 OXYGEN (A/F) SENSOR SIGNAL STUCK LEAN (BANK 1 SENSOR 1) DTC P2196 OXYGEN (A/F) SENSOR SIGNAL STUCK RICH (BANK 1 SENSOR 1) DTC P2197 OXYGEN (A/F) SENSOR SIGNAL STUCK LEAN (BANK 2 SENSOR 1) DTC P2198 OXYGEN (A/F) SENSOR SIGNAL STUCK RICH (BANK 2 SENSOR 1) HINT: Although the title (DTC description) says ”oxygen sensor”, this DTC is related to the ”A/F sensor”. CIRCUIT DESCRIPTION The Air Fuel ratio sensor provides output voltage* approximately equal to the existing air-fuel ratio. The A/F sensor output voltage is used to provide feedback for the ECM to control the air-fuel ratio. With the A/F sensor output, the ECM can determine deviation from the stoichiometric air-fuel ratio and control proper injection time. If the A/F sensor is malfunctioning, the ECM is unable to accurately control air-fuel ratio. The A/F sensor is equipped with a heater which heats the zirconia element. The heater is also controlled by the ECM. When the intake air volume is low (the temperature of the exhaust gas is low), current flows to the heater to heat the sensor to facilitate detection of accurate oxygen concentration. The A/F sensor is a planar type. Compared to a conventional type, the sensor and heater portions are narrower. Because the heat of the heater is conducted through the alumina to zirconia (of the sensor portion), sensor activation is accelerated. To obtain a high purification rate of the CO, HC and NOx components of the exhaust gas, a three-way catalytic converter is used. The converter is most efficient when the air-fuel ratio is maintained near the stoichiometric air-fuel ratio. HINT: *: The voltage value changes on the inside of the ECM only. ECM Monitored A/F Sensor Voltage Solid Electrolyte (Zirconia Element) Alumina Heater Platinum Electrode Element Exhaust Gas A Cover Atmosphere A Air-fuel Ratio A-A Section A73819 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 819 05-630 DIAGNOSTICS DTC No. P2195 P2197 P2196 P2198 - SFI SYSTEM (3MZ-FE) DTC Detection Condition Trouble Area Conditions (a) and (b) continue for 2 sec. or more: (a) A/F sensor voltage is more than 3.8 V (b) Heated oxygen sensor voltage is 0.15 V or more (2 trip detection logic)
Open or short in A/F sensor (bank 1, 2 sensor 1) circuit
A/F sensor (bank 1, 2 sensor 1)
A/F sensor heater
A/F relay
Open or short in A/F sensor heater and relay circuits
Air induction system
Fuel pressure
Injector
PCV hose connection
ECM Conditions (a) and (b) continue for 2 sec. or more: (a) A/F sensor voltage is less than 2.8 V (b) Heated oxygen sensor voltage is less than 0.85 V (2 trip detection logic)
Open or short in A/F sensor (bank 1, 2 sensor 1) circuit
A/F sensor (bank 1, 2 sensor 1)
A/F sensor heater
A/F relay
A/F sensor heater and relay circuit
Air induction system
Fuel pressure
Injector
PCV hose connection
ECM HINT:








DTCs P2195 and P2196 indicate a malfunction related to bank 1 of the A/F sensor circuit. DTCs P2197 and P2198 indicate a malfunction related to bank 2 of the A/F sensor circuit. Bank 1 is the bank that includes cylinder No. 1. Bank 2 is the bank that includes cylinder No. 2. Sensor 1 refers to the sensor closest to the engine assembly. After confirming DTC P2195, P2196, P2197 or P2198, use the hand−held tester or the OBD II scan tool to confirm A/F sensor output voltage (AFS B1S1 / AFS B2S1) from the ALL menu (to reach the ALL menu: DIAGNOSIS / ENHANCED OBD II / DATA LIST / ALL). The A/F sensor’s output voltage and the short−term fuel trim value can be read using the OBD II scan tool or the hand−held tester. The ECM controls the voltage of the A1A+, A2A+, A1A− and A2A− terminals of the ECM to a fixed voltage. Therefore, it is impossible to confirm the A/F sensor output voltage without the OBD II scan tool or the hand-held tester. The OBD II scan tool (excluding hand−held tester) displays one fifth of the A/F sensor output voltage which is displayed on the hand−held tester. MONITOR DESCRIPTION Under the air-fuel ratio feedback control, if the voltage output of the A/F sensor indicates RICH or LEAN for more than a certain period of time, the ECM concludes that there is a fault in the A/F sensor system. The ECM will turn on the MIL and will set a DTC. Example: If the A/F sensor voltage output is less than 2.8 V (very RICH) for 10 seconds even though voltage output of the heated oxygen sensor output voltage is less than 0.85 V, the ECM sets DTC P2196 or DTC P2198. If the heated oxygen sensor output voltage is 0.15 V or more but the A/F sensor voltage output is more than 3.8 V (very LEAN) 10 seconds, DTC P2195 or DTC P2197 is set. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 820 05-631 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) MONITOR STRATEGY Related DTCs P2195: A/F Sensor Signal (Bank 1) Stuck Lean P2196: A/F Sensor Signal (Bank 1) Stuck Rich P2197: A/F Sensor Signal (Bank 2) Stuck Lean P2198: A/F Sensor Signal (Bank 2) Stuck Rich Required sensors / components (Main) A/F sensor Required sensors / components (Related) Rear HO2S Frequency of operation Continuous Duration 10 seconds MIL operation 2 driving cycles Sequence operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page 05-377 Time after engine start 30 seconds or more A/F sensor status Activated Fuel system status Closed Loop Engine condition Running TYPICAL MALFUNCTION THRESHOLDS P2195 and P2197: Both of the following conditions are met: - A/F sensor voltage More than 3.8 V Rear HO2S voltage 0.15 V or more P2196 and P2198: Both of the following conditions are met: - A/F sensor voltage Less than 2.8 V Rear HO2S voltage Less than 0.85 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 821 05-632 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) WIRING DIAGRAM A6 A/F Sensor (Bank 1 Sensor 1) 3 B-R EB1 2 +B ECM 5 HA1H E8 B-W HT 1 Shielded BR 4 G R-W Engine Room R/B No. 2 2 2 A/F AF+ 3 30 E8 A1A- Y 2 A7 A/F Sensor (Bank 2 Sensor 1) A/F Relay 1 AF- 5 3 1 2 2 R-W R-W 6 B-R EB1 2 +B 4 HA2A E8 R-W HT 1 Shielded P 4 AF- 2 AF+ 3 2 2 P-L 5 2G 22 A1A+ E8 23 A2A+ E8 31 E8 A2A- L W-B 7 2A Engine Room J/B W 5 2B 4 2F P-L 13 IK3 8 E5 B MREL 3 F7 FL Block Assy W-B 1 W A J2 J/C FL Main A A BR J7 J/C A 1 E7 E1 A BR Battery EH ED A88700 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 822 05-633 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) CONFIRMATION DRIVING PATTERN Vehicle Speed (d) 60 to 120 km/h (38 to 75 mph) Idling Ignition Switch OFF (c) 2 min. 3 to 5 min. (a), (b) Time A79199 (a) (b) (c) (d) Connect the hand-held tester to the DLC3. Switch the hand-held tester from the normal mode to the check mode (see page 05-402 ). Start the engine and warm it up with all the accessory switches OFF. Drive the vehicle at 60 to 120 km/h (38 to 75 mph) and engine speed at 1,400 to 3,200 rpm for 3 to 5 minutes. HINT: If a malfunction exists, the MIL will be illuminated during step (d). NOTICE: If the conditions in this test are not strictly followed, detection of a malfunction will not occur. If you do not have a hand-held tester, turn the ignition switch OFF after performing steps (c) and (d), then perform steps (c) and (d) again. INSPECTION PROCEDURE HINT: Hand-held tester only: It is possible the malfunctioning area can be found using the ACTIVE TEST A/F CONTROL operation. The A/F CONTROL operation can determine if the A/F sensor, heated oxygen sensor or other potential trouble areas are malfunctioning or not. (a) Perform the ACTIVE TEST A/F CONTROL operation. HINT: The A/F CONTROL operation lowers the injection volume 12.5 % or increases the injection volume 25%. (1) Connect the hand-held tester to the DLC3 on the vehicle. (2) Turn the ignition switch ON. (3) Warm up the engine by running the engine at 2,500 rpm for approximately 90 seconds. (4) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (5) Perform the A/F CONTROL operation with the engine idle (press the right or left button). Result: A/F sensor reacts in accordance with increase and decrease of injection volume: +25 % → RICH output: Less than 3.0 V -12.5 % → LEAN output: More than 3.35 V Heated oxygen sensor reacts in accordance with increase and decrease of injection volume: +25 % → RICH output: More than 0.55 V -12.5 % → LEAN output: Less than 0.4 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 823 05-634 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) NOTICE: The A/F sensor output has a few seconds of delay and the heated oxygen sensor output has about 20 seconds of delay at maximum. Output voltage of A/F sensor (sensor 1) Output voltage of heated oxygen sensor (sensor 2) Injection volume Injection volume +25 % +25 % -12.5 % -12.5 % Case 1 Output voltage More than 3.35 V Less than 3.0 V OK More than 0.55 V Injection volume +25 % -12.5 % -12.5 % Case 2 Output voltage A/F sensor (A/F sensor, heater, A/F sensor circuit) Output voltage NG Injection volume More than 0.55 V OK Less than 0.4V Injection volume +25 % +25 % -12.5 % -12.5 % Case 3 Output voltage Output voltage More than 3.35 V OK Injection volume Almost No reaction NG Injection volume +25 % +25 % -12.5 % -12.5 % Case 4 Output voltage Almost No reaction OK Less than 0.4V +25 % Less than 3.0V  Output voltage Injection volume Almost No reaction Mainly suspected Trouble Area Output voltage NG Almost No reaction NG Heated oxygen sensor (heated oxygen sensor, heater, heated oxygen sensor circuit) Extremely rich or lean actual air-fuel ratio (Injector, fuel pressure, gas leakage in exhaust system, etc.) The following A/F CONTROL procedure enables the technician to check and graph the voltage outputs of both the A/F sensor and the heated oxygen sensor. For displaying the graph, enter ”ACTIVE TEST / A/F CONTROL / USER DATA”, select ”AFS B1S1 and O2S B1S2” by pressing ”YES” and push ”ENTER”. Then press ”F4”. HINT:
If DTC P2195 or P2196 is displayed, check bank 1 sensor 1 circuit.
If DTC P2197 or P2198 is displayed, check bank 2 sensor 1 circuit.
A low A/F sensor voltage could be caused by a RICH air-fuel mixture. Check for conditions that would cause the engine to run with a RICH air-fuel mixture.
A high A/F sensor voltage could be caused by a LEAN air-fuel mixture. Check for conditions that would cause the engine to run with a LEAN air-fuel mixture.
Read freeze frame data using the hand-held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 824 05-635 DIAGNOSTICS 1 (a) - SFI SYSTEM (3MZ-FE) CHECK OTHER DTC OUTPUT (IN ADDITION TO A/F SENSOR DTC) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display Proceed to A/F sensor circuit DTC are output A A/F sensor circuit DTC and other codes are output B HINT: If any other codes besides A/F sensor DTC are output, perform the troubleshooting for those DTCs first. B GO TO RELEVANT DTC CHART (See page 05-412 ) A 2 (a) (b) (c) (d) (e) (f) (g) READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (OUTPUT VOLTAGE OF A/F SENSOR) Connect the hand-held tester or the OBD II scan tool to the DLC3. Warm up the A/F sensor (bank 1, 2 sensor 1) by running the engine at 2,500 rpm for approximately 90 seconds. Read A/F sensor voltage output on the hand-held tester or the OBD II scan tool. Hand-held tester only: On the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / SNAPSHOT / MANUAL SNAPSHOT / USER DATA. Read the values. Select ”AFS B1 S1 or AFS B2 S1 / ENGINE SPD” and press YES. Monitor the A/F sensor voltage carefully. Check the A/F sensor voltage output under the following conditions: (1) Allow the engine to idle for 30 seconds. (2) Run the engine at approximately 2,500 rpm. Do not suddenly change the rpm. (3) Raise the engine to 4,000 rpm and quickly release the accelerator pedal so that the throttle is fully closed. Standard: Condition (1) and (2) Voltage change of 3.3 V (0.66 V)* (between approximately 3.1 to 3.5 V) as shown in the illustration. Condition (3) A/F sensor voltage increases to 3.8 V (0.76 V)* or more during engine deceleration when fuel is cut as shown in the illustration. HINT: *: Voltage when using the OBD II scan tool. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 825 05-636 DIAGNOSTICS Normal Condition - SFI SYSTEM (3MZ-FE) Malfunction Condition (3) Approximately 4,000 rpm (3) Approximately 4,000 rpm (2) Approximately 2,500 rpm (2) Approximately 2,500 rpm (1) Idle A/F Sensor Voltage (1) Idle (1) Idle (1) Idle Engine RPM Engine RPM ”Condition (3)” 3.8 V or More A/F Sensor Voltage Fuel Cut Fuel Cut ”Condition (1), (2)” Change of approximately 3.3 V When A/F sensor circuit is malfunctioning, voltage output does not change A72304 HINT:
Whenever the A/F sensor output voltage remains at approximately 3.3 V (0.660 V)* (see ”Malfunction Condition” graphic) under any condition as well as the above conditions, the A/F sensor may have an open circuit. This will happen also when the A/F sensor heater has an open circuit.
Whenever the A/F sensor output voltage remains at a certain value of approximately 3.8 V (0.76 V)* or more, or 2.8 V (0.56 V)* or less (see ”Malfunction Condition” graphic) under any condition as well as the above conditions, the A/F sensor may have a short circuit.
The ECM will stop fuel injection (fuel is cut) during engine deceleration. This will cause a LEAN condition and should result in a momentary increase in A/F sensor output voltage.
The ECM must establish a closed throttle position learned value to perform fuel cut. If the battery terminal has been disconnected, the vehicle must be driven over 10 mph to allow the ECM to learn the closed throttle position.
When the vehicle is driven: The output voltage of the A/F sensor may be below 2.8 V (0.76 V)* during fuel enrichment. For the vehicle, this translates to a sudden increase in speed with the accelerator pedal fully depressed when trying to overtake another vehicle. The A/F sensor is functioning normally.
The A/F sensor is a current output element, and therefore the current is converted into voltage inside the ECM. If measuring voltage at connectors of A/F sensor or ECM, you will observe a constant voltage. *: Voltage when using the OBD II scan tool. OK Go to step 13 NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 826 05-637 DIAGNOSTICS 3 - SFI SYSTEM (3MZ-FE) INSPECT AIR FUEL RATIO SENSOR (HEATR RESISTANCE) (a) (b) AF- Disconnect the A6 or A7 A/F sensor connector. Check the resistance of the A/F sensor terminals. Resistance: Tester Connection Condition Specified Condition 1 (HT) - 2 (+B) 20C (68F) 1.8 to 3.4 Ω 1 (HT) - 4 (AF-) - 10 kΩ or higher AF+ A52607 NG REPLACE AIR FUEL RATIO SENSOR OK 4 INSPECT RELAY (A/F) 1 3 (a) (b) 2 5 5 2 Remove the A/F relay from the engine room R/B No. 2. Check the resistance of the A/F relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 1 3 B60778 NG REPLACE RELAY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 827 05-638 DIAGNOSTICS 5 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS (A/F SENSOR - ECM) (a) (b) (c) Wire Harness Side HT +B Disconnect the A6 or A7 A/F sensor connector. Disconnect the E8 ECM connector. Check the resistance of the wire harness side connectors. Standard: A6 (Bank 1) A7 (Bank 2) A/F Sensor AF+ Tester Connection Specified Condition A6-3 (AF+) - E8-22 (A1A+) A6-4 (AF-) - E8-30 (A1A-) A6-1 (HT) - E8-5 (HA1H) A7-3 (AF+) - E8-23 (A2A+) A7-4 (AF-) - E8-31 (A2A-) A7-1 (HT) - E8-4 (HA2A) Below 1 Ω A6-3 (AF+) or E8-22 (A1A+) - Body ground A6-4 (AF-) or E8-30 (A1A-) - Body ground A6-1 (HT) or E8-5 (HA1H) - Body ground A7-3 (AF+) or E8-23 (A2A+) - Body ground A7-4 (AF-) or E8-31 (A2A-) - Body ground A7-1 (HT) or E8-4 (HA2A) - Body ground 10 kΩ or higher AF- E8 ECM HA2A A1A+ A1A- HA1H A2A+ A2A- A88573 Reference (Bank 1 Sensor 1 System Drawing) A/F Relay From Battery A/F ECM A/F Sensor +B Heater HT AF- Sensor HA1H AF+ A1A+ Duty Control A1AMREL A87980 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 6 (a) CHECK AIR INDUCTION SYSTEM Check for vacuum leaks in air induction system. OK: No leak in air induction system. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 828 05-639 DIAGNOSTICS 7 (a) - SFI SYSTEM (3MZ-FE) CHECK FUEL PRESSURE (See page 11-38 ) Check fuel pressure (high or low fuel pressure). Standard: Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi). NG REPAIR OR REPLACE FUEL SYSTEM OK 8 (a) INSPECT FUEL INJECTOR ASSY (See page 11-41 ) Check injector injection (high or low fuel injection quantity or poor injection pattern). Standard: Injection volume Difference between each injector 60 to 73 cm3 (3.7 to 4.5 cu in.) per 15 seconds 13 cm3 (0.8 cu in.) or less NG REPLACE FUEL INJECTOR ASSY (See page 11-46 ) OK 9 REPLACE AIR FUEL RATIO SENSOR GO 10 PERFORM CONFIRMATION DRIVING PATTERN HINT: Clear all DTCs prior to performing the confirmation driving pattern. GO 11 (a) READ OUTPUT DTC (A/F SENSOR DTC OUTPUT AGAIN) Read the DTC using the hand-held tester or the OBD II scan tool. Result : Display Proceed to A/F sensor circuit DTC are not output A A/F sensor circuit DTC are output B B REPLACE ECM (See page 10-24 ) AND PERFORM CONFIRMATION DRIVING PATTERN A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 829 05-640 DIAGNOSTICS 12 - SFI SYSTEM (3MZ-FE) CONFIRM IF VEHICLE HAS RUN OUT OF FUEL IN PAST OK: Vehicle has run out of fuel in past. NO CHECK FOR INTERMITTENT PROBLEMS (See page 05-370 ) YES DTC IS CAUSED BY RUNNING OUT OF FUEL 13 PERFORM CONFIRMATION DRIVING PATTERN HINT: Clear all DTCs prior to performing the confirmation driving pattern. GO 14 (a) READ OUTPUT DTC (A/F SENSOR DTC OUTPUT AGAIN) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display Proceed to A/F sensor circuit DTC are output A A/F sensor circuit DTC are not output B B Go to step 18 A 15 REPLACE AIR FUEL RATIO SENSOR GO 16 PERFORM CONFIRMATION DRIVING PATTERN HINT: Clear all DTCs prior to performing the confirmation driving pattern. GO 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 830 05-641 DIAGNOSTICS 17 (a) - SFI SYSTEM (3MZ-FE) READ OUTPUT DTC (A/F SENSOR DTC OUTPUT AGAIN) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display Proceed to A/F sensor circuit DTC are not output A A/F sensor circuit DTC are output B B REPLACE ECM (See page 10-24 ) AND PERFORM CONFIRMATION DRIVING PATTERN A 18 CONFIRM IF VEHICLE HAS RUN OUT OF FUEL IN PAST OK: Vehicle has run out of fuel in past. NO CHECK FOR INTERMITTENT PROBLEMS (See page 05-370 ) YES DTC IS CAUSED BY RUNNING OUT OF FUEL 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 831 05-642 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EY2-06 DTC P2238 OXYGEN SENSOR PUMPING CURRENT CIRCUIT LOW (FOR A/F SENSOR)(BANK 1 SENSOR 1) DTC P2239 OXYGEN SENSOR PUMPING CURRENT CIRCUIT HIGH (FOR A/F SENSOR)(BANK 1 SENSOR 1) DTC P2241 OXYGEN SENSOR PUMPING CURRENT CIRCUIT LOW (FOR A/F SENSOR)(BANK 2 SENSOR 1) DTC P2242 OXYGEN SENSOR PUMPING CURRENT CIRCUIT HIGH (FOR A/F SENSOR)(BANK 2 SENSOR 1) DTC P2252 OXYGEN SENSOR REFERENCE GROUND CIRCUIT LOW (FOR A/F SENSOR)(BANK 1 SENSOR 1) DTC P2253 OXYGEN SENSOR REFERENCE GROUND CIRCUIT HIGH (FOR A/F SENSOR)(BANK 1 SENSOR 1) DTC P2255 OXYGEN SENSOR REFERENCE GROUND CIRCUIT LOW (FOR A/F SENSOR)(BANK 2 SENSOR 1) DTC P2256 OXYGEN SENSOR REFERENCE GROUND CIRCUIT HIGH (FOR A/F SENSOR)(BANK 2 SENSOR 1) HINT:


Although the title (DTC description) says ”oxygen sensor”, this DTC is related to the ”A/F sensor”. DTC P2238, P2239, P2252 and P2253 refer to the malfunction related to the bank 1 A/F sensor circuit. DTC P2241, P2242, P2255 and P2256 refer to the malfunction related to the bank 2 A/F sensor circuit. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 832 05-643 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) CIRCUIT DESCRIPTION Refer to DTC P2195 on page 05-629 . DTC No. DTC Detection Condition Trouble Area A/F sensor (bank 1 sensor 1) circuit low A/F sensor admittance is less than 0.022 1/Ω (2 trip detection logic) HINT: Main trouble area P2238 P2241 Condition (a) continues for 5.0 seconds or more : (a) A/F sensor admittance is less than 0.022 1/Ω (2 trip detection logic)
Open or short in A/F sensor circuit
A/F sensor
A/F sensor heater
A/F relay
Open or short in A/F sensor heater and relay circuits
ECM P2239 P2242 A/F sensor (bank 1 sensor 1) circuit high (2 trip detection logic) HINT: Main trouble area
Short in A/F sensor circuit Condition (a) continues for 5.0 seconds or more : (a) AF+ is more than 4.5 V (2 trip detection logic)
Open or short in A/F sensor circuit
A/F sensor
A/F sensor heater
A/F relay
Open or short in A/F sensor heater and relay circuits
ECM Condition (a) continues for 5.0 seconds or more : (a) (AF+) - (AF-) is more than 0.8 V (2 trip detection logic)
Open or short in A/F sensor circuit
A/F sensor
A/F sensor heater
A/F relay
Open or short in A/F sensor heater and relay circuits
ECM P2252 P2255 Condition (a) continues for 5.0 seconds or more : (a) AF- is 0.5 V or less (2 trip detection logic)
Open or short in A/F sensor circuit
A/F sensor
A/F sensor heater
A/F relay
Open or short in A/F sensor heater and relay circuits
ECM P2253 P2256 Condition (a) continues for 5.0 seconds or more : (a) AF- is more than 4.5 V (2 trip detection logic)
Open or short in A/F sensor circuit
A/F sensor
A/F sensor heater
A/F relay
Open or short in A/F sensor heater and relay circuits
ECM P2238 P2241 P2239 P2242 P2239 P2242 HINT:

Bank 1 is the bank that includes cylinder No.1. Bank 2 is the bank that includes cylinder No.2. MONITOR DESCRIPTION The Air-Fuel Ratio (A/F) sensor varies its voltage output in proportion to the air-fuel ratio. If impedance (alternating current resistance) or voltage output of the sensor deviates greatly from the standard, the ECM determines that an open or short is in the A/F sensor circuit. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 833 05-644 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) MONITOR STRATEGY Related DTCs P2238: A/F sensor (bank 1) open circuit between AF+ and AFP2238: A/F sensor (bank 1) short circuit between AF+ and AFP2238: A/F sensor (bank 1) short circuit between AF+ and GND P2239: A/F sensor (bank 1) short circuit between AF+ and+B P2241: A/F sensor (bank 2) open circuit betrween AF+ and AFP2241: A/F sensor (bank 2) short circuit between AF+ and AFP2241: A/F sensor (bank 2) short circuit between AF+ and GND P2242: A/F sensor (bank 2) short circuit between AF+ and +B P2252: A/F sensor (bank 1) short circuit between AF-and GND P2253: A/F sensor (bank 1) short circuit between AF-and +B P2253: A/F sensor (bank 2) short circuit between AF- and GND P2256: A/F sensor (bank 2) short circuit between AF- and +B Required sensors / components (Main) A/F sensor Required sensors / components (Related) ECT sensor, CKP sensor Frequency of operation Once per driving cycle Duration 10 seconds: A/F sensor open circuit between AF+ and AF= P2238, P2241 5 seconds: Others MIL operation Immediate Sequence operation None TYPICAL ENABLING CONDITIONS All: The monitor will run whenever these DTCs are not present See page 05-377 P2238, P2241 (A/F sensor open circuit between AF+ and AF-): Duration while all of the following conditions are met: 20 seconds or more AF+ terminal voltage 0.5 to 4.5 V AF- terminal voltage 0.5 to 4.5 V Difference between AF+ terminal and AF- terminal voltages 0.1 to 0.8 V ECT 20C (68F) or more Engine condition Running Time after engine start 20 seconds or more Fuel-cut OFF A/F sensor heater duty cycle 0 % or more Time after A/F sensor heating 20 seconds or more Battery voltage 10.5 V or more Ignition switch ON Others: Battery voltage 10.5 V or more Ignition switch ON 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 834 05-645 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) TYPICAL MALFUNCTION THRESHOLDS P2238, P2241 (A/F sensor open circuit between AF+ and AF-): A/F sensor admittance Below 0.022 1/ohm P2238, P2241 (A/F sensor short circuit between AF+ and GND): AF+ terminal voltage 0.5 V or less P2238, P2241 (A/F sensor short circuit between AF+ and AF-): Difference between AF+ terminal and AF- terminal voltages 0.1 V or less P2239, P2242 (A/F sensor short circuit between AF+ and +B): AF+ terminal voltage More than 4.5 V P2252, P2255 (A/F sensor short circuit between AF- and GND): AF- terminal voltage 0.5 V or less P2253, P2256 (A/F sensor short circuit between AF- and +B): AF- terminal voltage More than 4.5 V WIRING DIAGRAM Refer to DTC P2195 on page 05-629 . INSPECTION PROCEDURE HINT: Hand-held tester only: The malfunctioning area can be found by the ACTIVE TEST A/F CONTROL operation. The A/F CONTROL operation can determine if the A/F sensor, heated oxygen sensor or other suspected trouble areas are malfunctioning or not. (a) Perform the ACTIVE TEST A/F CONTROL operation. HINT: The A/F CONTROL operation lowers the injection volume by 12.5% or increases the injection volume by 25%. (1) Connect the hand-held tester to the DLC3 on the vehicle. (2) Turn the ignition switch ON. (3) Warm up the engine by running the engine at 2,500 rpm for approximately 90 seconds. (4) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. (5) Perform the A/F CONTROL operation with the engine idling (press the right or left button). Result: A/F sensor reacts in accordance with increase and decrease of injection volume: +25 % → RICH output: Less than 3.0 V -12.5 % → LEAN output: More than 3.35 V Heated oxygen sensor reacts in accordance with increase and decrease of injection volume: +25 % → RICH output: More than 0.55 V -12.5 % → LEAN output: Less than 0.4 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 835 05-646 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) NOTICE: The A/F sensor output has a few seconds of delay and the heated oxygen sensor output has about 20 seconds of delay at maximum. Output voltage of A/F sensor (sensor 1) Output voltage of heated oxygen sensor (sensor 2) Injection volume Injection volume +25 % +25 % -12.5 % -12.5 % Case 1 Output voltage More than 3.35 V Less than 3.0 V OK More than 0.55 V Injection volume +25 % -12.5 % -12.5 % Case 2 Output voltage A/F sensor (A/F sensor, heater, A/F sensor circuit) Output voltage NG Injection volume More than 0.55 V OK Less than 0.4V Injection volume +25 % +25 % -12.5 % -12.5 % Case 3 Output voltage Output voltage More than 3.35 V OK Injection volume Almost No reaction NG Injection volume +25 % +25 % -12.5 % -12.5 % Case 4 Output voltage Almost No reaction OK Less than 0.4V +25 % Less than 3.0V  Output voltage Injection volume Almost No reaction Mainly suspected Trouble Area Output voltage NG Almost No reaction NG Heated oxygen sensor (heated oxygen sensor, heater, heated oxygen sensor circuit) Extremely rich or lean actual air-fuel ratio (Injector, fuel pressure, gas leakage in exhaust system, etc.) The following A/F CONTROL procedure enables the technician to check and graph the voltage outputs of both the A/F sensor and the heated oxygen sensor. For displaying the graph, enter ”ACTIVE TEST / A/F CONTROL / USER DATA”, select ”AFS B1S1 and O2S B1S2” by pressing ”YES” and push ”ENTER”. Then press ”F4”. HINT:
If DTC P2238, P2239, P2252 or P2253 is displayed, check the bank 1 sensor 1 circuit.
If DTC P2241, P2242, P2255 or P2256 is displayed, check the bank 2 sensor 1 circuit.
Read freeze frame data using the hand-held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 836 05-647 DIAGNOSTICS 1 - SFI SYSTEM (3MZ-FE) INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) (b) AF- Disconnect the A6 or A7 A/F sensor connector. Check the resistance of the A/F sensor terminals. Standard: Tester Connection Condition Specified Condition 1 (HT) - 2 (+B) 20C (68F) 1.8 to 3.4 Ω 1 (HT) - 4 (AF-) - 10 kΩ or higher AF+ A52607 NG REPLACE AIR FUEL RATIO SENSOR OK 2 INSPECT RELAY (A/F) 1 3 (a) (b) 2 5 5 2 Remove the A/F relay from the engine room R/B No. 2. Check the resistance of the A/F relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 1 3 B60778 NG REPLACE RELAY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 837 05-648 DIAGNOSTICS 3 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS (HEATER RESISTANCE) (a) (b) (c) Wire Harness Side HT +B A6 (Bank 1) A7 (Bank 2) A/F Sensor AF+ Disconnect the A6 or A7 A/F sensor connector. Disconnect the E8 ECM connector. Check the resistance of the wire harness side connectors. Standard: AF- E8 ECM Tester Connection Specified Condition A6-3 (AF+) - E8-22 (A1A+) A6-4 (AF-) - E8-30 (A1A-) A6-1 (HT) - E8-5 (HA1H) A7-3 (AF+) - E8-23 (A2A+) A7-4 (AF-) - E8-31 (A2A-) A7-1 (HT) - E8-4 (HA2A) Below 1 Ω A6-3 (AF+) or E8-22 (A1A+) - Body ground A6-4 (AF-) or E8-30 (A1A-) - Body ground A6-1 (HT) or E8-5 (HA1H) - Body ground A7-3 (AF+) or E8-23 (A2A+) - Body ground A7-4 (AF-) or E8-31 (A2A-) - Body ground A7-1 (HT) or E8-4 (HA2A) - Body ground 10 kΩ or higher HA2A A1A+ A1A- HA1H A2A+ A2A- A88573 Reference (Bank 1 Sensor 1 System Drawing) A/F Relay From Battery A/F ECM A/F Sensor +B Heater HT AF- Sensor HA1H AF+ A1A+ Duty Control A1AMREL A87980 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK REPLACE ECM (See page 10-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 838 05-649 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EY3-06 DTC P2A00 A/F SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1) DTC P2A03 A/F SENSOR CIRCUIT SLOW RESPONSE (BANK 2 SENSOR 1) HINT:

DTC P2A00 refers to a malfunction related to the bank 1 A/F sensor. DTC P2A03 refers to a malfunction related to the bank 2 A/F sensor. CIRCUIT DESCRIPTION Refer to DTC P2195 on page 05-629 . DTC No. P2A00 P2A03 DTC Detection Condition In conditions (a), (b), and (c), when A/F sensor output voltage change value is below regular value against fuel trim change value, ECM judges that A/F sensor has slow response: (2 trip detection logic) (a) Engine is warmed up (b) Engine speed 1,400 rpm or more (c) Vehicle speed 40 km/h (25 mph) or more Trouble Area
Open or short in A/F sensor (bank 1, 2 sensor 1) circuit
A/F sensor (bank 1, 2 sensor 1)
A/F sensor heater
A/F relay
Open or short in A/F sensor heater and relay circuits
Air induction system
Fuel pressure
Injector
PCV hose connection
ECM HINT:


Bank 1 is the bank that includes cylinder No.1. Bank 2 is the bank that includes cylinder No.2. Sensor 1 is the sensor closest to the engine assembly. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 839 05-650 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) MONITOR DESCRIPTION Locus length A/F output (V) Fuel trim Fast sensor Slow sensor A82390 The Air-Fuel Ratio (A/F) sensor varies its output voltage in proportion to the air-fuel ratio. Based on the output voltage, the ECM determines if the air-fuel ratio is RICH or LEAN and adjusts the stoichiometric air-fuel ratio. The ECM also checks the fuel injection volume compensation value to check if the A/F sensor is deteriorating or not. The output voltage variation, known as locus length, should be high when the air-fuel ratio fluctuates. When the A/F sensor response rate has deteriorated, the locus length should be short. The ECM concludes that there is a malfunction in the ratio of the A/F sensor when the locus length is short and the response rate has deteriorated. MONITOR STRATEGY Related DTCs P2A00: A/F Sensor (Bank 1) Slow Response P2A03: A/F Sensor (Bank 2) Slow Response Required sensors / components (Main) A/F sensor Required sensors / components (Related) VSS, CKP sensor Frequency of operation Once per driving cycle Duration 60 seconds MIL operation 2 driving cycles Sequence operation None 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 840 05-651 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present See page 05-377 Engine condition Running Time after engine start 120 seconds or more Fuel system status Closed Loop A/F sensor status Activated Idle OFF Time after idle OFF 2 seconds or more Engine RPM 1,400 to 3,200 rpm Vehicle speed 60 to 120 km/h (37.5 to 75 mph) Fuel cut OFF Time after fuel cut is OFF 2 seconds or more Driving for 20 seconds or more 40 km/h (25 mph) or more and 900 rpm or more TYPICAL MALFUNCTION THRESHOLDS Response rate deterioration level 6.0 or more MONITOR RESULT Refer to page 05-385 for detailed information. The test value and test limit information are described as shown in the following table. Check the monitor result and test values after performing the monitor drive pattern (see page 05-387 ).
TID (Test Identification Data) is assigned to each emissions-related component.
TLT (Test Limit Type): If TLT is 0, the component is malfunctioning when the test value is higher than the test limit. If TLT is 1, the component is malfunctioning when the test value is lower than the test limit.
CID (Component Identification Data) is assigned to each test value.
Unit Conversion is used to calculate the test value indicated on generic OBD ll scan tools. TID $06: A/F sensor TLT CID Unit Conversion 0 $01 Multiply by 0.000244 (no dimension) 0 $11 Multiply by 0.000244 (no dimension) Description of Test Data Description of Test Limit Parameter for identify A/F sensor response rate (Bank 1) Malfunction threshold for A/F sensor deterioration Parameter for identify A/F sensor response rate (Bank 2) Malfunction threshold for A/F sensor deterioration WIRING DIAGRAM Refer to DTC P2195 on page 05-629 . INSPECTION PROCEDURE HINT: Hand-held tester only: The malfunctioning area can be found by the ACTIVE TEST A/F CONTROL operation. The A/F CONTROL operation can determine if the A/F sensor, heated oxygen sensor or other suspected trouble areas are malfunctioning or not. (a) Perform the ACTIVE TEST A/F CONTROL operation. HINT: The A/F CONTROL operation lowers the injection volume by 12.5 % or increases the injection volume by 25%. (1) Connect the hand-held tester to the DLC3 on the vehicle. (2) Turn the ignition switch ON. (3) Warm up the engine by running the engine at 2,500 rpm for approximately 90 seconds. (4) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / A/F CONTROL. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 841 05-652 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) (5) Perform the A/F CONTROL operation with the engine idling (press the right or left button). Result: A/F sensor reacts in accordance with increase and decrease of injection volume: +25 % → RICH output: Less than 3.0 V -12.5 % → LEAN output: More than 3.35 V Heated oxygen sensor reacts in accordance with increase and decrease of injection volume: +25 % → RICH output: More than 0.55 V -12.5 % → LEAN output: Less than 0.4 V NOTICE: The A/F sensor output has a few seconds of delay and the heated oxygen sensor output has about 20 seconds of delay at maximum. Output voltage of A/F sensor (sensor 1) Output voltage of heated oxygen sensor (sensor 2) Injection volume Injection volume +25 % +25 % -12.5 % -12.5 % Case 1 Output voltage More than 3.35 V Less than 3.0 V OK More than 0.55 V Injection volume +25 % -12.5 % -12.5 % Case 2 Output voltage A/F sensor (A/F sensor, heater, A/F sensor circuit) Output voltage NG Injection volume More than 0.55 V OK Less than 0.4V Injection volume +25 % +25 % -12.5 % -12.5 % Case 3 Output voltage Output voltage More than 3.35 V OK Injection volume Almost No reaction NG Injection volume +25 % +25 % -12.5 % -12.5 % Case 4 Output voltage Almost No reaction OK Less than 0.4V +25 % Less than 3.0V  Output voltage Injection volume Almost No reaction Mainly suspected Trouble Area Output voltage NG Almost No reaction NG Heated oxygen sensor (heated oxygen sensor, heater, heated oxygen sensor circuit) Extremely rich or lean actual air-fuel ratio (Injector, fuel pressure, gas leakage in exhaust system, etc.) The following A/F CONTROL procedure enables the technician to check and graph the voltage outputs of both the A/F sensor and the heated oxygen sensor. For displaying the graph, enter ”ACTIVE TEST / A/F CONTROL / USER DATA”, select ”AFS B1S1 and O2S B1S2” by pressing ”YES” and push ”ENTER”. Then press ”F4”. HINT:
DTC P2A00 or P2A03 may be also detected, when the air fuel ratio is stuck rich or lean.
A low A/F sensor voltage could be caused by a RICH air-fuel mixture. Check for conditions that would cause the engine to run with a RICH air-fuel mixture.
A high A/F sensor voltage could be caused by a LEAN air-fuel mixture. Check for conditions that would cause the engine to run with a LEAN air-fuel mixture. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 842 05-653 DIAGNOSTICS
- SFI SYSTEM (3MZ-FE) Read freeze frame data using the hand-held tester or the OBD II scan tool. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and other data from the time the malfunction occurred. 1 (a) CHECK OTHER DTC OUTPUT (IN ADDITION TO A/F SENSOR DTC) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display Proceed to DTC P2A00 and/or P2A03 are output. A DTC P2A00 and/or P2A03 and other codes are output. B HINT: If any other code besides P2A00 and/or P2A03 are output, perform the troubleshooting for those codes first. B GO TO RELEVANT DTC CHART (See page 05-412 ) A 2 (a) (b) (c) (d) (e) (f) (g) READ VALUE OF HAND-HELD TESTER OR OBD II SCAN TOOL (OUTPUT VOLTAGE OF A/F SENSOR) Connect the hand-held tester or the OBD II scan tool to the DLC3. Warm up the A/F sensor (bank 1 sensor 1 and bank 2 sensor 1) by running the engine at 2,500 rpm for approximately 90 seconds. Read A/F sensor voltage output on the hand-held tester or the OBD II scan tool. Hand-held tester only: On the hand-held tester, enter the following menus: DIAGNOSIS / ENHANCED OBD II / SNAPSHOT / MANUAL SNAPSHOT / USER DATA. Read the values. Select ”AFS B1 S1 or AFS B2 S1 / ENGINE SPD” and press YES. Monitor the A/F sensor voltage carefully. Check the A/F sensor voltage output under the following conditions: (1) Allow the engine to idle for 30 seconds. (2) Run the engine at approximately 2,500 rpm. Do not suddenly change the rpm. (3) Raise the engine speed to 4,000 rpm and quickly release the accelerator pedal so that the throttle is fully closed. Standard: Condition (1) and (2) Voltage change of 3.3 V (0.66 V)* (between approximately 3.1 to 3.5 V) as shown in the illustration. Condition (3) A/F sensor voltage increases to 3.8 V (0.76 V)* or more when fuel is cut during engine deceleration as shown in the illustration. HINT: *: Voltage when using the OBD II scan tool. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 843 05-654 DIAGNOSTICS Normal Condition - SFI SYSTEM (3MZ-FE) Malfunction Condition (3) Approximately 4,000 rpm (3) Approximately 4,000 rpm (2) Approximately 2,500 rpm (2) Approximately 2,500 rpm (1) Idle A/F Sensor Voltage (1) Idle (1) Idle (1) Idle Engine RPM Engine RPM ”Condition (3)” 3.8 V or More A/F Sensor Voltage Fuel Cut Fuel Cut ”Condition (1), (2)” Change of approximately 3.3 V When A/F sensor circuit is malfunctioning, voltage output does not change A72304 HINT:
Whenever the A/F sensor output voltage remains at approximately 3.3 V (0.660 V)* (see ”Malfunction Condition” graphic) under any condition as well as the above conditions, the A/F sensor may have an open circuit. This will happen also when the A/F sensor heater has an open circuit.
Whenever the A/F sensor output voltage remains at a certain value of approximately 3.8 V (0.76 V)* or more, or 2.8 V (0.56 V)* or less (see ”Malfunction Condition” graphic) under any condition as well as the above conditions, the A/F sensor may have a short circuit.
The ECM will stop fuel injection (fuel is cut) during engine deceleration. This will cause a LEAN condition and should result in a momentary increase in A/F sensor output voltage.
The ECM must establish a closed throttle position learned value to perform fuel cut. If the battery terminal has been disconnected, the vehicle must be driven over 10 mph to allow the ECM to learn the closed throttle position.
When the vehicle is driven: The output voltage of the A/F sensor may be below 2.8 V (0.76 V)* during fuel enrichment. For the vehicle, this translates to a sudden increase in speed with the accelerator pedal fully depressed when trying to overtake another vehicle. The A/F sensor is functioning normally.
The A/F sensor is a current output element, and therefore the current is converted into voltage inside the ECM. If measuring voltage at connectors of A/F sensor or ECM, you will observe a constant voltage. *: Voltage when using the OBD II scan tool. OK Go to step 14 NG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 844 05-655 DIAGNOSTICS 3 - SFI SYSTEM (3MZ-FE) INSPECT AIR FUEL RATIO SENSOR (HEATER RESISTANCE) (a) (b) AF- Disconnect the A6 or A7 A/F sensor connector. Check the resistance of the A/F sensor terminals. Standard: Tester Connection Condition Specified Condition 1 (HT) - 2 (+B) 20C (68F) 1.8 to 3.4 Ω 1 (HT) - 4 (AF-) - 10 kΩ or higher AF+ A52607 NG REPLACE AIR FUEL RATIO SENSOR OK 4 INSPECT RELAY (A/F) 1 3 (a) (b) 2 5 5 2 Remove the A/F relay from the engine room R/B No. 2. Check the resisitance of the A/F relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 1 3 B60778 NG REPLACE RELAY OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 845 05-656 DIAGNOSTICS 5 - SFI SYSTEM (3MZ-FE) CHECK WIRE HARNESS (A/F SENSOR - ECM) (a) (b) (c) Wire Harness Side HT +B A6 (Bank 1) A7 (Bank 2) A/F Sensor Disconnect the A6 or A7 A/F sensor connector. Disconnect the E8 ECM connector. Check the resistance of the wire harness side connectors. Standard: Tester Connection AF+ A6-3 (AF+) A6-4 (AF-) A6-1 (HT) A7-3 (AF+) A7-4 (AF-) A7-1 (HT) - AF- Specified Condition E8-22 (A1A+) E8-30 (A1A-) E8-5 (HA1H) E8-23 (A2A+) E8-31 (A2A-) E8-4 (HA2A) Below 1 Ω A6-3 (AF+) or E8-22 (A1A+) - Body ground A6-4 (AF-) or E8-30 (A1A-) - Body ground A6-1 (HT) or E8-5 (HA1H) - Body ground A7-3 (AF+) or E8-23 (A2A+) - Body ground A7-4 (AF-) or E8-31 (A2A-) - Body ground A7-1 (HT) or E8-4 (HA2A) - Body ground E8 ECM 10 kΩ or higher HA2A A1A+ A1A- HA1H A2A+ A2A- A88573 Reference (Bank 1 Sensor 1 System Drawing) A/F Relay From Battery A/F ECM A/F Sensor +B Heater HT AF- Sensor HA1H AF+ A1A+ Duty Control A1AMREL A87980 NG REPAIR OR CONNECTOR REPLACE HARNESS AND OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 846 05-657 DIAGNOSTICS 6 (a) - SFI SYSTEM (3MZ-FE) CHECK AIR INDUCTION SYSTEM Check for vacuum leaks in the air induction system. OK: There is no leak in air induction system. NG REPAIR OR REPLACE AIR INDUCTION SYSTEM OK 7 CHECK CONNECTION OF PCV HOSE OK: PCV hose is connected correctly. And PCV hose has no damage. NG REPAIR OR REPLACE PCV HOSE OK 8 (a) CHECK FUEL PRESSURE (See page 11-38 ) Check fuel pressure (high or low fuel pressure). Standard: Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 55 psi) NG REPAIR OR REPLACE FUEL SYSTEM OK 9 (a) INSPECT FUEL INJECTOR ASSY (See page 11-41 ) Check injector injection (high or low fuel injection quantity or poor injection pattern). Standard: Injection volume Difference between each injector 60 to 73 cm3 (3.7 to 4.5 cu in.) per 15 seconds 13 cm3 (0.8 cu in.) or less NG REPLACE FUEL INJECTOR ASSY (See page 11-46 ) OK 10 REPLACE AIR FUEL RATIO SENSOR GO 11 PERFORM CONFIRMATION DRIVING PATTERN (See page 05-629 ) HINT: Clear all DTCs prior to performing the confirmation driving pattern (see page 05-629 ). GO 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 847 05-658 DIAGNOSTICS 12 (a) - SFI SYSTEM (3MZ-FE) READ OUTPUT DTC (A/F SENSOR DTC OUTPUT AGAIN) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display Proceed to DTC P2A00 and/or P2A03 are not output A DTC P2A00 and/or P2A03 are output again B B REPLACE ECM (See page 10-24 ) AND PERFORM CONFIRMATION DRIVING PATTERN (See page 05-629 ) A 13 CONFIRM IF VEHICLE HAS RUN OUT OF FUEL IN PAST NO CHECK FOR INTERMITTENT PROBLEMS (See page 05-370 ) YES DTC IS CAUSED BY RUNNING OUT OF FUEL 14 PERFORM CONFIRMATION DRIVING PATTERN (See page 05-629 ) HINT: Clear all DTCs prior to performing the confirmation driving pattern (see page 05-629 ). GO 15 (a) READ OUTPUT DTC (A/F SENSOR DTC OUTPUT AGAIN) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display Proceed to DTC P2A00 and/or P2A03 are not output A DTC P2A00 and/or P2A03 are output B B Go to step 19 A 16 REPLACE AIR FUEL RATIO SENSOR GO 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 848 05-659 DIAGNOSTICS 17 - SFI SYSTEM (3MZ-FE) PERFORM CONFIRMATION DRIVING PATTERN (See page 05-629 ) HINT: Clear all DTCs prior to performing the confirmation driving pattern (see page 05-629 ). GO 18 (a) READ OUTPUT DTC (A/F SENSOR DTC OUTPUT AGAIN) Read the DTC using the hand-held tester or the OBD II scan tool. Result: Display Proceed to DTC P2A00 and/or P2A03 are output A DTC P2A00 and/or P2A03 are not output B B REPLACE ECM (See page 10-24 ) AND PERFORM CONFIRMATION DRIVING PATTERN (See page 05-629 ) A 19 CONFIRM IF VEHICLE HAS RUN OUT OF FUEL IN PAST OK: Vehicle has run out of fuel in past. NO CHECK FOR INTERMITTENT PROBLEMS (See page 05-370 ) YES DTC IS CAUSED BY RUNNING OUT OF FUEL 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 849 05-387 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05C1K-10 READINESS MONITOR DRIVE PATTERN 1.



PURPOSE OF READINESS TESTS The On-Board Diagnostic (OBD II) system is designed to monitor the performance of emission-related components, and report any detected abnormalities with Diagnostic Trouble Codes (DTCs). Since various components need to be monitored during different driving conditions, the OBD II system is designed to run separate monitoring programs called readiness monitors. The hand-held tester’s software must be version 9.0 or newer to view the readiness monitor status. From the ”ENHANCED OBD II” menu, select ”MONITOR STATUS” to view the readiness monitor status. A generic OBD II scan tool can also be used to view the readiness monitor status. When the readiness monitor status reads ”complete”, the necessary conditions have been met for running performance tests for that readiness monitor. HINT: Many state Inspection and Maintenance (I/M) programs require a vehicle’s readiness monitor status to show ”complete”.
The Readiness Monitor will be reset to ”incomplete” if:
The ECM has lost battery power or blown a fuse.
DTCs have been cleared.
The conditions for running the Readiness Monitor have not been met.
If the readiness monitor status shows ”incomplete”, follow the appropriate readiness monitor drive pattern to change the status to ”complete”. CAUTION: Strictly observe of posted speed limits, traffic laws, and road conditions when performing these drive patterns. NOTICE: The following drive patterns are the fastest method of completing all the requirements necessary for making the readiness monitor status read ”complete”. If forced to momentarily stop a drive pattern due to traffic or other factors, the drive pattern can be resumed. Upon completion of the drive pattern, in most cases, the readiness monitor status will change to ”complete”. Sudden changes in vehicle load and speed, such as driving up and down hills and / or sudden acceleration, hinder readiness monitor completion. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 577 05-388 DIAGNOSTICS 2. - SFI SYSTEM (3MZ-FE) CATALYST MONITOR (A/F SENSOR TYPE) 64 to 88 km/h (40 to 55 mph) 64 to 80 km/h (40 to 50 mph) Idling Ignition Switch OFF Warm up time (Idle Speed) 4 min. 16 min. A82401 (a) Preconditions The monitor will not run unless:
The MIL is OFF.
Engine Coolant Temperature (ECT) is 75°C (167°F) or greater.
Intake Air Temperature (IAT) is -10°C (14°F) or greater.* NOTICE: * 2002 and later MY vehicles: To completed the readiness test in cold ambient conditions (less than -10°C / 14°F), turn the ignition switch to the OFF position and then back to the ON position. Perform the drive pattern a second time. (b) Drive Pattern (1) Connect the OBD II scan tool to DLC3 to check readiness monitor status and preconditions (refer to step (a)). (2) Drive vehicle at 64 to 88 km/h (40 to 55 mph) for approximately 4 minutes. NOTICE: Drive with smooth throttle operation and avoid sudden acceleration. If IAT was less than 10°C (50°F) when the engine was started, drive the vehicle at 64 to 88 km/h (40 to 55 mph) for an additional 4 minutes. (3) Drive vehicle allowing speed to fluctuate between 64 to 80 km/h (40 to 50 mph) for about 16 minutes. NOTICE: Drive with smooth throttle operation and avoid sudden closure of the throttle. (4) Check the status of the readiness monitor on the scan tool display. If readiness monitor status did not switch to complete, ensure preconditions are met, turn the ignition OFF, and then repeat steps (2) and (3). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 578 05-389 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 3. EVAP MONITOR (VACUUM PRESSURE MONITOR) NOTICE: A cold soak must be performed prior to conducting the drive pattern to complete the internal pressure readiness monitor. (a) Cold Soak Preconditions The monitor will not run unless:
The MIL is OFF.
Fuel level is approximately 1/2 to 3/4 full.
Altitude is 2,450 m (8,000 feet) or less. (b) Cold Soak Procedure Let vehicle cold soak for 8 hours or until ”IAT - ECT” must be -7°C (-13°F) to 11.1°C (20°F) HINT:
Example 1 ECT = 24°C (75°F) IAT = 16°C (60°F) Difference between ECT and IAT is 8°C (15°F). → The monitor will not run because difference between ECT and IAT is greater than 7°C (13°F).
Example 2 ECT = 21°C (70°F) IAT = 20°C (68°F) Difference between ECT and IAT is 1°C (2°F). → The monitor will run because difference between ECT and IAT is less than 7°C (13°F). 3,000 rpm Idling Ignition Switch OFF Soak 10 sec. Warm up time (Idle speed) 15 to 50 min. (When the readiness code or diagnostic code is set, this test is completed.) A78884 (c) Preconditions The monitor will not run unless:
The MIL is OFF.
Fuel level is approximately 1/2 to 3/4 full.
The altitude is 2,450 m (8,000 feet) or less.*
ECT is between 4.4°C and 35°C (40°F and 95°F).
IAT is between 4.4°C and 35°C (40°F and 95°F).*
The cold soak procedure has been completed.
Before starting the engine, the difference between ECT and IAT must be less than 7°C (13°F). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 579 05-390 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) HINT:
Example 1 ECT = 24°C (75°F) IAT = 16°C (60°F) Difference between ECT and IAT is 8°C (15°F). → The monitor will not run because difference between ECT and IAT is greater than 7°C (13°F).
Example 2 ECT = 21°C (70°F) IAT = 20°C (68°F) Difference between ECT and IAT is 1°C (2°F). → The monitor will run because difference between ECT and IAT is less than 7°C (13°F). NOTICE: * NOTE for 2002 and later MY vehicles: The readiness test can be completed in cold ambient conditions (less than 4.4C / 40F) and / or high altitudes (more than 2,450 m/8,000 feet). Finish the drive pattern, turn the ignition switch OFF and then ON again, and repeat the drive pattern a second time. (d) Drive Pattern (1) Connect the OBD II scan tool to DLC3 to check monitor status and preconditions (refer to step ”a”). (2) Release pressure in fuel tank by removing the fuel tank cap and then reinstalling it. (3) Start the engine and allow it to idle until ECT is 75°C (167°F) or more. (4) Run the engine at 3,000 rpm for about 10 seconds. (5) With the engine idling, turn the A/C ON to create a slight electrical load. Wait 15 to 50 minutes. NOTICE: If the vehicle does not have A/C, put a slight electrical load on the engine by following the steps below:
Set the parking brake securely.
Use wheel chocks to secure the tires.
Move the shift lever to drive (position D) and allow engine to idle for 15 to 50 minutes. Check the readiness monitor status. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 580 05-391 DIAGNOSTICS 4. - SFI SYSTEM (3MZ-FE) OXYGEN / A/F SENSOR MONITOR (FRONT A/F SENSOR AND REAR O2S SYSTEM) 112 km/h (70 mph) (under 3,200 rpm) 64 km/h (40 mph) (over 1,400 rpm) Once Twice 10 times 40 km/h (25 mph) (over 900 rpm) Idling Ignition Switch OFF Over 2 min. (a) (b) Over Over Over 150 sec. 40 sec. 40 sec. Over Over Over 10 sec. 10 sec. 10 sec. Over 40 sec. A82400 Preconditions The monitor will not run unless: The MIL is OFF. Drive Pattern (1) Connect the OBD II scan tool to DLC3 to check monitor status and preconditions (refer to step ”a”). (2) Start the engine and allow it to idle for 2 minutes or more. (3) Drive the vehicle at 64 to 112 km/h (40 to 70 mph) for at least 150 seconds. (4) Stop the vehicle and allow the engine to idle for 10 seconds or more. (5) Drive the vehicle at 40 to 64 km/h (25 to 40 mph) for at least 40 seconds. (6) Stop the vehicle and allow the engine to idle for 10 seconds or more. (7) Perform steps (5) and (6) 10 times. (8) Check the readiness monitor status. If the readiness monitor status did not change to ”complete”, check the preconditions, turn the ignition switch OFF, and repeat steps (1) to (6). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 581 05-392 DIAGNOSTICS 5. - SFI SYSTEM (3MZ-FE) OXYGEN / A/F SENSOR HEATER MONITOR 40 km/h (25 mph) Idling Ignition Switch OFF Over 500 sec. Over 2 min. A78886 (a) (b) Preconditions The monitor will not run unless: The MIL is OFF. Drive Pattern (1) Connect the OBD II scan tool to DLC3 to check monitor status and preconditions (refer to step ”a”). (2) Start the engine and allow it to idle for 500 seconds or more. (3) Drive the vehicle at 40 km/h (25 mph) or more for at least 2 minutes. (4) Check the readiness monitor status. If the readiness monitor status did not change to ”complete”, check the preconditions, turn the ignition switch OFF, and repeat steps (2) to (3). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 582 05-373 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05MOL-01 REGISTRATION NOTICE: The Vehicle Identification Number (VIN) must be input into the replaced ECM. HINT: The VIN is a 17-digit alphanumeric vehicle identification number. A hand-held tester is required to register the VIN. 1. DESCRIPTION This registration section consists of three parts, Input Instructions, Read VIN and Write VIN. (a) Input Instructions: Explains the general VIN input instructions using a hand-held tester. (b) Read VIN: Explains the VIN reading process in a flowchart. This process allows the VIN stored in the ECM to be read, in order to confirm that the two VINs, provided with the vehicle and stored in the vehicle’s ECM, are the same. (c) Write VIN: Explains the VIN writing process in a flowchart. This process allows the VIN to be input into the ECM. If the ECM is changed, or the VINs do not match, the VIN can be registered, or overwritten in the ECM by following this procedure. 2. INPUT INSTRUCTIONS (a) Hand-held tester (1) The arrow buttons (UP, DOWN, RIGHT and LEFT) and numerical buttons (0 to 9) are used, in order to input the VIN. (b) Cursor Operation (1) To move the cursor around the tester screen, press the RIGHT and LEFT buttons. (c) Alphabetical Character Input (1) Press the UP and DOWN buttons to select the desired alphabetical character. (2) After selection, the cursor should move. (d) Numeric Character Input (1) Press the numerical button corresponding to the number that you want to input. (2) After input, the cursor should move. HINT: Numerical characters can be selected by using the UP and DOWN buttons. (e) Correction (1) When correcting the input character(s), put the cursor onto the character using the RIGHT or LEFT button. (2) Select or input the correct character using the UP/DOWN buttons, or the numerical buttons. (f) Finishing Input Operation (1) Make sure that the input VIN matches the vehicle VIN after input. (2) Press the ENTER button on the tester. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 563 05-374 DIAGNOSTICS 3. (a) - SFI SYSTEM (3MZ-FE) READ VIN (Vehicle Identification Number) Read VIN using a hand-held tester. READ: START Confirm vehicle VIN Preparation: 1. Connect hand-held tester to DLC3 2. Turn ignition switch to ON 3. Turn tester ON Hand-held tester operation: 1. Select DIAGNOSIS 2. Select ENHANCED OBD ll 3. Select VIN Menu Screen: VIN Select VIN READ 1. VIN READ 2. VIN WRITE DTC P0630 Set ERROR DTC P0630 was detected. P0630 [VIN Not Programmed or Mismatch - ECM/PCM] ERROR ********************************* [ VIN ] ********************************* [EXIT] ECM does not respond the VIN. 17-digit VIN displayed Please input the VIN. PRESS [EXIT] VIN Not Stored VIN Previously Stored PRESS [EXIT] Possible cause: 1: VIN is not written yet. 2: Vehicle does not support this function. PRESS [EXIT] [EXIT] [EXIT] To Menu Screen 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 564 05-375 DIAGNOSTICS 4. (a) - SFI SYSTEM (3MZ-FE) WRITE VIN Write VIN using the hand-held tester. Write: START Confirm vehicle VIN Preparation: 1. Connect hand-held tester to DLC3 2. Turn ignition switch to ON 3. Turn tester ON Hand-held tester operation: 1. Select DIAGNOSIS 2. Select ENHANCED OBD ll 3. Select VIN Menu Screen: VIN Select VIN WRITE 1. VIN READ 1. READ 2. VIN WRITE CONFIRMATION This function will erase the DTCs automatically after writing the VIN. VIN Previously Stored NOTICE This function overwrites the following VIN with a new VIN. ********************************* Do you wish to continue? [ VIN ] ********************************* [YES] or [NO] Do you wish to continue? [NO] [YES] [YES] to Continue [NO] to EXIT [YES] 17-digit VIN displayed To Menu Screen Continued on next page [YES] [NO] To Menu Screen 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 565 05-376 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) Continued from previous page New Registration SET NEW VIN VIN input method CONFIRMATION Vehicle is stopped. Engine is not running. Input Instructions [ENTER] Press [RIGHT]/[LEFT] to shift the cursor right/left. Press [UP]/[DOWN] to increase/decrease value. Or, input digit with the 10 key. PRESS [ENTER] PRESS [ENTER] [ENTER] Input a new VIN If you want to clear the VIN, press [NO] key. PRESS [ENTER] [ENTER] Input Error INPUT ERROR Your VIN is incorrect. Please enter the VIN again. NOW WRITING [EXIT] [EXIT] to RETURN Writing Succeeded WRITING COMPLETE Writing Error Communication Error WRITING FAILED COMMUNICATION ERROR Turn IG OFF, then ON. Please try again. Turn IG OFF, then ON. PRESS [EXIT] PRESS [EXIT] [EXIT] [EXIT] The following VIN has been written correctly. The DTCs have been erased correctly. PRESS [ENTER] [ENTER] To Menu Screen To Menu Screen To Menu Screen 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 566 05-363 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05EX1-05 PART AND SYSTEM NAME LIST This reference list indicates the part names used in this manual along with their definitions. TOYOTA/LEXUS name Definition Toyota HCAC system, Hydro-carbon Adsorptive Catalyst (HCAC) system, HC adsorptive three-way catalyst HC adsorptive three-way catalytic converter Variable Valve Timing sensor, VVT sensor Camshaft position sensor Variable valve timing system, VVT system Camshaft timing control system Camshaft timing oil control valve, Oil control valve, OCV, VVT, VSV Camshaft timing oil control valve Variable timing and lift, VVTL Camshaft timing and lift control Crankshaft position sensor ”A” Crankshaft position sensor Engine speed sensor Crankshaft position sensor THA Intake air temperature Knock control module Engine knock control module Knock sensor Engine knock sensor Mass or volume air flow circuit Mass air flow meter circuit Vacuum sensor Manifold air pressure sensor Internal control module, Control module, Engine control ECU, PCM Power train control module FC idle Deceleration fuel cut Idle air control valve Idle speed control CCV, Canister close valve VSV for canister control Evaporative emissions canister vent valve EVAP VSV, Vacuum switching valve assembly No. 1, EVAP VSV, Purge VSV Evaporative emissions canister purge valve VSV for pressure switching valve, Bypass VSV Evaporative emission pressure switching valve Vapor pressure sensor, EVAP pressure sensor, Evaporative emission control system pressure sensor Fuel tank pressure sensor Charcoal canister Evaporative emissions canister ORVR system On-board refueling vapor recovery system Intake manifold runner control Intake manifold tuning system Intake manifold runner valve, IMRV, IACV (runner valve) Intake manifold tuning valve Intake control VSV Intake manifold tuning solenoid valve AFS Air fuel ratio sensor O2 sensor Heater oxygen sensor Oxygen sensor pumping current circuit Oxygen sensor output signal Oxygen sensor reference ground circuit Oxygen sensor signal ground Accel position sensor Accelerator pedal position sensor Throttle actuator control motor, Actuator control motor, Electronic throttle motor, Throttle control motor Electronic throttle actuator Electronic throttle control system, Throttle actuator control system Electronic throttle control system Throttle/pedal position sensor, Throttle/pedal position switch, Throttle position sensor/switch Throttle position sensor Turbo press sensor Turbocharger pressure sensor Turbo VSV Turbocharger pressure control solenoid valve P/S pressure switch Power-steering pressure switch VSV for ACM Active control engine mount Speed sensor, Vehicle speed sensor ”A”, Speed sensor for skid control ECU Vehicle speed sensor ATF temperature sensor, Trans. fluid temp. sensor, ATF temperature sensor ”A” Transmission fluid temperature sensor Electronic controlled automatic transmission, ECT Electronically controlled automatic Intermediate shaft speed sensor ”A” Counter gear speed sensor 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 553 05-364 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) TOYOTA/LEXUS name Definition Output speed sensor Output shaft speed sensor Input speed sensor, Input turbine speed sensor ”A”, Speed sensor (NT), Turbine speed sensor Input turbine speed sensor PNP switch, NSW Park/neutral position switch Pressure control solenoid Transmission pressure control solenoid Shift solenoid Transmission shift solenoid valve Transmission control switch, Shift lock control unit Shift lock control module Engine immobilizer system, Immobilizer system Vehicle anti-theft system 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 554 05-369 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05289-40 CUSTOMER PROBLEM ANALYSIS CHECK Inspector’s Name SFI SYSTEM Check Sheet VIN Date Vehicle Brought in Production Date Licence Plate No. Odometer Reading Problem Symptoms Customer’s Name Engine Does Not Start Engine does not crank Difficult to Start Engine cranks slowly Other Poor Idling Incorrect first idle Idling rpm is abnormal Rough idling Other Poor Driveability Hesitation Knocking Engine Stall Soon after starting After accelerator pedal depressed After accelerator pedal released During A/C operation Shifting from N to D Other km miles No initial combustion Backfire Other No complete combustion High ( rpm) Low ( Muffler explosion (after-fire) rpm) Surging Other Date Problem Occurred Condition When Problem Occurs Problem Frequency Constant Other Sometimes ( times per Weather Fine Cloudy Rainy Outdoor Temperature Hot Warm Cool Place Highway Rough road Engine Temp. Cold Engine Operation Just after starting ( Starting Driving Constant speed A/C switch ON/OFF Other Suburbs Other Warming up Condition of Malfunction Indicator Light (MIL) Normal Mode (Pre-check) day/month) Snowy Various/Other
C/ Cold (approx. Inner City After Warming up Once only Uphill
F) Downhill Any temp. min.) Idling Acceleration Other Racing Deceleration Remains on Sometimes lights up Does not light up Normal Malfunction code(s) (code Freeze frame data ( ) Malfunction code(s) (code Freeze frame data ( ) ) DTC Inspection Check Mode Normal ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 559 05-412 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05284-46 DIAGNOSTIC TROUBLE CODE CHART HINT: Parameters listed in the chart may be different than your readings depending on the type of instrument used and other factors. During the DTC check, refer to the table below if a malfunction code is displayed. For details about each code, refer to the page number in the DTC Chart’s left column. DTC No. (See Page) Detection Item Trouble Area MIL*1 Memory P0010 (05-422 ) Camshaft Position ”A” Actuator Circuit (Bank 1)
Open or short in OCV (bank 1) circuit
OCV (bank 1)
ECM   P0011 (05-428 ) Camshaft Position ”A” -Timing Over-Advanced or System Performance (Bank 1)
Valve timing
OCV (bank 1)
Camshaft timing gear assy
ECM   P0012 (05-428 ) Camshaft Position ”A” -Timing Over- Retarded (Bank 1)
Same as DTC No. P0011   P0016 (05-436 ) Crankshaft Position - Camshaft Position Correlation (Bank 1 Sensor A)
Mechanical system (Timing belt has jumped tooth, belt stretched)
ECM   P0018 (05-436 ) Crankshaft Position - Camshaft Position Correlation (Bank 2 Sensor A)
Same as DTC No. P0016   P0020 (05-422 ) Camshaft Position ”A” Actuator Circuit (Bank 2)
Open or short in OCV (bank 2) circuit
OCV (bank 2)
ECM   P0021 (05-428 ) Camshaft Position ”A” -Timing Over-Advanced or System Performance (Bank 2)
Valve timing
OCV (bank 2)
Camshaft timing gear assy
ECM   P0022 (05-428 ) Camshaft Position ”A” -Timing Over- Retarded (Bank 2)
Same as DTC No. P0021   P0031*3 (05-438 ) Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 1 Sensor 1)
Open or short in heater circuit of A/F sensor
A/F sensor heater (bank 1 sensor 1)
A/F relay
ECM   P0032*3 (05-438 ) Oxygen (A/F) Sensor Heater Control Circuit High (Bank 1 Sensor 1)
Short in heater circuit of A/F sensor
A/F sensor heater (bank 1 sensor 1)
A/F relay
ECM   P0037 (05-443 ) Oxygen Sensor Heater Control Circuit Low (Bank 1 Sensor 2)
Open or short in heater circuit of heated oxygen sensor
Heated oxygen sensor heater (bank 1 sensor 2)
EFI relay
ECM   P0038 (05-443 ) Oxygen Sensor Heater Control Circuit High (Bank 1 Sensor 2)
Short in heater circuit of heated oxygen sensor
Heated oxygen sensor heater (bank 1 sensor 2)
EFI relay
ECM   P0051*3 (05-438 ) Oxygen (A/F) Sensor Heater Control Circuit Low (Bank 2 Sensor 1)
Open or short in heater circuit of A/F sensor
A/F sensor heater (bank 2 sensor 1)
A/F relay
ECM   P0052*3 (05-438 ) Oxygen (A/F) Sensor Heater Control Circuit High (Bank 2 Sensor 1)
Short in heater circuit of A/F sensor
A/F sensor heater (bank 2 sensor 1)
A/F relay
ECM   2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 602 05-413 DIAGNOSTICS DTC No. (See Page) Detection Item - SFI SYSTEM (3MZ-FE) Trouble Area MIL*1 Memory P0057 (05-443 ) Oxygen Sensor Heater Control Circuit Low (Bank 2 Sensor 2)
Open or short in heater circuit of heated oxygen sensor
Heated oxygen sensor heater (bank 2 sensor 2)
EFI relay
ECM   P0058 (05-443 ) Oxygen Sensor Heater Control Circuit High (Bank 2 Sensor 2)
Short in heater circuit of heated oxygen sensor
Heated oxygen sensor heater (bank 2 sensor 2)
EFI relay
ECM   P0100 (05-448 ) Mass or volume Air Flow Circuit
Open or short in MAF meter circuit
MAF meter
ECM   P0101 (05-455 ) Mass or volume Air Flow Circuit Range/Performance Problem
MAF meter   P0102 (05-448 ) Mass or volume Air Flow Circuit Low Input
Open in MAF meter circuit
Short in ground circuit
MAF meter
ECM   P0103 (05-448 ) Mass or volume Air Flow Circuit High Input
Short in MAF meter circuit (to +B circuit)
MAF meter
ECM   P0110 (05-457 ) Intake Air Temperature Circuit
Open or short in IAT sensor circuit
IAT sensor (built in MAF meter)
ECM   P0112 (05-457 ) Intake Air Temperature Circuit Low Input
Short in IAT sensor circuit
IAT sensor (built in MAF meter)
ECM   P0113 (05-457 ) Intake Air Temperature Circuit High Input
Open in IAT sensor circuit
IAT sensor (built in MAF meter)
ECM   P0115 (05-462 ) Engine Coolant Temperature Circuit
Open or short ECT sensor circuit
ECT sensor
ECM   P0116 (05-467 ) Engine Coolant Temperature Circuit Range/Performance Problem
ECT sensor   P0117 (05-462 ) Engine Coolant Temperature Circuit Low Input
Short in ECT sensor circuit
ECT sensor
ECM   P0118 (05-462 ) Engine Coolant Temperature Circuit High Input
Open in ECT sensor circuit
ECT sensor
ECM   P0120 (05-469 ) Throttle/Pedal Position Sensor/ Switch ”A” Circuit
Throttle position sensor (built in throttle body)
ECM   P0121 (05-478 ) Throttle/Pedal Position Sensor/ Switch ”A” Circuit Range/Performance Problem
Throttle position sensor (built in throttle body)   Throttle/Pedal Position Sensor/ Switch ”A” Circuit Low Input
Throttle position sensor (built in throttle body)
Short in VTA1 circuit
Open in VC circuit
ECM   Throttle/Pedal Position Sensor/ Switch ”A” Circuit High Input
Throttle position sensor (built in throttle body)
Open in VTA1 circuit
Open in E2 circuit
VC and VTA1 circuits are short circuited
ECM   P0122 (05-469 ) P0123 (05-469 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 603 05-414 DIAGNOSTICS DTC No. (See Page) Detection Item P0125 (05-480 ) Insufficient Coolant Temperature for Closed Loop Fuel Control P0128 (05-482 ) - SFI SYSTEM (3MZ-FE) MIL*1 Memory
Cooling system
ECT sensor
Thermostat   Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature)
Thermostat (water inlet)
Cooling system
ECT sensor
ECM   P0136 (05-485 ) Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2)
Heated oxygen sensor circuit (bank 1)
Heated oxygen sensor (bank 1)
Oxygen sensor heater (bank 1)
A/F sensor (bank 1)
A/F sensor heater (bank 1)   P0137 (05-485 ) Oxygen Sensor Circuit Low Voltage (Bank 1 Sensor 2)
Heated oxygen sensor circuit (bank 1)
Heated oxygen sensor (bank 1)
Oxygen sensor heater (bank 1)   P0138 (05-485 ) Oxygen Sensor Circuit High Voltage (Bank 1 Sensor 2)
Heated oxygen sensor circuit (bank 1)
Heated oxygen sensor (bank 1)
Oxygen sensor heater (bank 1)   P0156 (05-485 ) Oxygen Sensor Circuit Malfunction (Bank 2 Sensor 2)
Heated oxygen sensor circuit (bank 2)
Heated oxygen sensor (bank 2)
Oxygen sensor heater (bank 2)
A/F sensor (bank 2)
A/F sensor heater (bank 2)   P0157 (05-485 ) Oxygen Sensor Circuit Low Voltage (Bank 2 Sensor 2)
Heated oxygen sensor circuit (bank 2)
Heated oxygen sensor (bank 2)
Oxygen sensor heater (bank 2)   P0158 (05-485 ) Oxygen Sensor Circuit High Voltage (Bank 2 Sensor 2)
Heated oxygen sensor circuit (bank 2)
Heated oxygen sensor (bank 2)
Oxygen sensor heater (bank 2)   System too Lean (Bank 1)
Air induction system
Injector blockage
MAF meter
ECT sensor
Fuel pressure
Gas leakage in exhaust system
Open or short in A/F sensor (bank 1 sensor 1) circuit
A/F sensor (bank 1 sensor 1)
A/F sensor heater (bank 1 sensor 1)
A/F relay
PCV valve and hose
PCV hose connection   System too Rich (Bank 1)
Injector leak, blockage
MAF meter
ECT sensor
Ignition system
Fuel pressure
Gas leakage in exhaust system
Open or short in A/F sensor (bank 1 sensor 1) circuit
A/F sensor (bank 1 sensor 1)
A/F sensor heater (bank 1 sensor 1)
A/F relay   P0171 (05-498 ) P0172 (05-498 ) Trouble Area 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 604 05-415 DIAGNOSTICS DTC No. (See Page) - SFI SYSTEM (3MZ-FE) MIL*1 Memory System too Lean (Bank 2)
Air induction system
Injector blockage
MAF meter
ECT sensor
Fuel pressure
Gas leakage in exhaust system
Open or short in A/F sensor (bank 2 sensor 1) circuit
A/F sensor (bank 2 sensor 1)
A/F sensor heater (bank 2 sensor 1)
A/F relay
PCV valve and hose
PCV hose connection   P0175 (05-498 ) System too Rich (Bank 2)
Injector leak, blockage
MAF meter
ECT sensor
Ignition system
Fuel pressure
Gas leakage in exhaust system
Open or short in A/F sensor (bank 2 sensor 1) circuit
A/F sensor (bank 2 sensor 1)
A/F sensor heater (bank 2 sensor 1)
A/F relay   P0220 (05-469 ) Throttle/Pedal Position Sensor/ Switch ”B” Circuit
Same as DTC No. P0120   P0222 (05-469 ) Throttle/Pedal Position Sensor/ Switch ”B” Circuit Low Input
Throttle position sensor (built in throttle body)
Short in VTA2 circuit
Open in VC circuit
ECM   Throttle/Pedal Position Sensor/ Switch ”B” Circuit High Input
Throttle position sensor (built in throttle body)
Open in VTA2 circuit
Open in E2 circuit
VC and VTA2 circuits are short circuited
ECM   P0300 (05-511) Random/Multiple Cylinder Misfire Detected
Open or short in engine wire
Connector connection
Vacuum hose connection
Ignition system
Injector
Fuel pressure
MAF meter
ECT sensor
Compression pressure
Valve clearance
Valve timing
PCV hose connection
PCV hose
ECM *2  P0301 (05-511) Cylinder 1 Misfire Detected
Same as DTC No. P0300 *2  P0302 (05-511) Cylinder 2 Misfire Detected
Same as DTC No. P0300 *2  P0303 (05-511) Cylinder 3 Misfire Detected
Same as DTC No. P0300 *2  P0304 (05-511) Cylinder 4 Misfire Detected
Same as DTC No. P0300 *2  P0305 (05-511) Cylinder 5 Misfire Detected
Same as DTC No. P0300 *2  P0174 (05-498 ) P0223 (05-469 ) Detection Item Trouble Area 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 605 05-416 DIAGNOSTICS DTC No. (See Page) Detection Item - SFI SYSTEM (3MZ-FE) Trouble Area MIL*1 Memory *2  P0306 (05-511) Cylinder 6 Misfire Detected
Same as DTC No. P0300 P0327 (05-527 ) Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor)
Short in knock sensor 1 circuit
Knock sensor 1
ECM   P0328 (05-527 ) Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor)
Open in knock sensor 1 circuit
Knock sensor 1
ECM   P0332 (05-527 ) Knock Sensor 2 Circuit Low Input (Bank 2)
Short in knock sensor 2 circuit
Knock sensor 2
ECM   P0333 (05-527 ) Knock Sensor 2 Circuit High Input (Bank 2)
Open in knock sensor 2 circuit
Knock sensor 2
ECM   P0335 (05-532 ) Crankshaft Position Sensor ”A” Circuit
Open or short in crankshaft position sensor circuit
Crankshaft position sensor
Crankshaft timing pulley
ECM   P0339 (05-532 ) Crankshaft Position Sensor ”A” Circuit Intermittent
Same as DTC No. P0335   P0340 (05-536 ) Camshaft Position Sensor ”A” Circuit (Bank 1 or Single Sensor)
Open or short in VVT sensor circuit
VVT sensor
Camshaft timing pulley
Timing belt has a jumped tooth
ECM   P0341 (05-536 ) Camshaft Position Sensor ”A” Circuit Range/Performance (Bank 1 or Single Sensor)
Same as DTC No. P0340   P0345 (05-536 ) Camshaft Position Sensor ”A” Circuit (Bank 2)
Same as DTC No. P0340   P0346 (05-536 ) Camshaft Position Sensor ”A” Circuit Range/Performance (Bank 2)
Same as DTC No. P0340   Ignition Coil ”A” Primary/Secondary Circuit
Ignition system
Open or short in IGF1 or IGT1 circuit from ignition coil with igniter to ECM (ignition coil circuit 1)
Ignition coil with igniter (ignition coil 1)
ECM   Ignition Coil ”B” Primary/Secondary Circuit
Ignition system
Open or short in IGF1 or IGT2 circuit from ignition coil with igniter to ECM (ignition coil circuit 2)
Ignition coil with igniter (ignition coil 2)
ECM   Ignition Coil ”C” Primary/Secondary Circuit
Ignition system
Open or short in IGF1 or IGT3 circuit from ignition coil with igniter to ECM (ignition coil circuit 3)
Ignition coil with igniter (ignition coil 3)
ECM   Ignition Coil ”D” Primary/Secondary Circuit
Ignition system
Open or short in IGF1 or IGT4 circuit from ignition coil with igniter to ECM (ignition coil circuit 4)
Ignition coil with igniter (ignition coil 4)
ECM   Ignition Coil ”E” Primary/Secondary Circuit
Ignition system
Open or short in IGF1 or IGT5 circuit from ignition coil with igniter to ECM (ignition coil circuit 5)
Ignition coil with igniter (ignition coil 5)
ECM   P0351*4 (05-541 ) P0352*4 (05-541 ) P0353*4 (05-541 ) P0354*4 (05-541 ) P0355*4 (05-541 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 606 05-417 DIAGNOSTICS DTC No. (See Page) Detection Item - SFI SYSTEM (3MZ-FE) Trouble Area MIL*1 Memory   P0356*4 (05-541 ) Ignition Coil ”F” Primary/Secondary Circuit
Ignition system
Open or short in IGF1 or IGT6 circuit from ignition coil with igniter to ECM (ignition coil circuit 6)
Ignition coil with igniter (ignition coil 6)
ECM P0420 (05-551 ) Catalyst System Efficiency Below Threshold (Bank 1)
Gas leakage in exhaust system
A/F sensor (bank 1 sensor 1)
Heated oxygen sensor (bank 1 sensor 2)
Three-way catalytic converter (inside exhaust manifold)   P0430 (05-551 ) Catalyst System Efficiency Below Threshold (Bank 2)
Gas leakage in exhaust system
A/F sensor (bank 2 sensor 1)
Heated oxygen sensor (bank 2 sensor 2)
Three-way catalytic converter (inside exhaust manifold)   P0441 (05-557 ) Evaporative Emission Control System Incorrect Purge Flow
Vacuum hose has cracks, holes, or is blocked, damaged or disconnected
Fuel tank cap is incorrectly installed
Fuel tank cap has cracks, or is damaged
Open or short in vapor pressure sensor circuit
Vapor pressure sensor
Open or short in VSV circuit for EVAP
EVAP VSV
Open or short in VSV circuit for CCV
CCV
Fuel tank has cracks, holes, or is damaged
Charcoal canister has cracks, holes, or is damaged
Fuel tank over fill check valve has cracks, or is damaged
ECM   P0442 (05-563 ) Evaporative Emission Control System Leak detected (small leak)
Same as DTC No. P0441   P0446 (05-570 ) Evaporative Emission Control System Vent Control Circuit
Same as DTC No. P0441   P0451 (05-573 ) Evaporative Emission Control System Pressure Sensor/Switch Range/Performance
Open or short in vapor pressure sensor circuit
Vapor pressure sensor
ECM   P0452 (05-573 ) Evaporative Emission Control System Pressure Sensor/Switch Low Input
Open in vapor pressure sensor circuit
Vapor pressure sensor
ECM   P0453 (05-573 ) Evaporative Emission Control System Pressure Sensor/Switch High Input
Short in vapor pressure sensor circuit
Vapor pressure sensor
ECM   P0455 (05-563 ) Evaporative Emission Control System Leak Detected (gross leak)
Same as DTC No. P0441   P0456 (05-563 ) Evaporative Emission Control System Leak Detected (very small leak)
Same as DTC No. P0441   P0500 (05-578 ) Vehicle Speed Sensor ”A”
Open or short in VSS circuit
VSS sensor
Combination meter
ECM
Skid control ECU   P0503 (05-578 ) Vehicle Speed Sensor ”A” Intermittent/Erratic/High
Same as DTC No. P0500   P0504 (05-581 ) Brake Switch ”A”/”B” Correlation
Short in stop lamp switch signal circuit
Stop lamp switch
ECM   2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 607 05-418 DIAGNOSTICS DTC No. (See Page) Detection Item - SFI SYSTEM (3MZ-FE) Trouble Area MIL*1 Memory P0505 (05-587 ) Idle Air Control System
Electric throttle control system
Air induction system
PCV hose connection   P0560 (05-590 ) System Voltage
Open in back-up power source circuit
ECM   P0604 (05-593 ) Internal Control Module Random Access Memory (RAM) Error
ECM   P0606 (05-593 ) ECM/PCM Processor
ECM   P0607 (05-593 ) Control Module Performance
ECM   P0617 (05-595 ) Starter Relay Circuit High
Short in PNP switch circuit
PNP switch
Ignition switch
ECM   P0630 (05-601 ) VIN not Programmed or Mismatch - ECM/PCM
ECM   P0657 (05-593 ) Actuator Supply Voltage Circuit / Open
ECM   P0705 (05-1036 ) Transmission Range Sensor Circuit Malfunction (PRNDL Input)
Short in PNP switch circuit
PNP switch
ECM   P0710 (05-1042 ) Transmission Fluid Temperature Sensor ”A” Circuit
Electronic controlled automatic transmission (ECT)   P0711 (05-1046 ) Transmission Fluid Temperature Sensor ”A” Performance
Electronic controlled automatic transmission (ECT)   P0712 (05-1042 ) Transmission Fluid Temperature Sensor ”A” Circuit Low Input
Electronic controlled automatic transmission (ECT)   P0713 (05-1042 ) Transmission Fluid Temperature Sensor ”A” Circuit High Input
Electronic controlled automatic transmission (ECT)   P0717 (05-1049 ) Input/Turbine Speed Sensor ”A” Circuit No Signal
Electronic controlled automatic transmission (ECT)   P0724 (05-1052 ) Brake Switch ”B” Circuit High
Electronic controlled automatic transmission (ECT)   P0741 (05-1056 ) Torque Converter Clutch Solenoid Performance (Shift Solenoid Valve DSL)
Electronic controlled automatic transmission (ECT)   P0746 (05-1061 ) Pressure Control Solenoid ”A” Performance (Shift Solenoid Valve SL1)
Electronic controlled automatic transmission (ECT)   P0748 (05-1065 ) Pressure Control Solenoid ”A” Electrical (Shift Solenoid Valve SL1)
Electronic controlled automatic transmission (ECT)   P0766 (05-1068 ) Shift Solenoid ”D” Performance (Shift Solenoid Valve S4)
Electronic controlled automatic transmission (ECT)   P0771 (05-1072 ) Shift Solenoid ”E” Performance (Shift Solenoid Valve SR)
Electronic controlled automatic transmission (ECT)   P0776 (05-1077 ) Pressure Control Solenoid ”B” Performance (Shift Solenoid Valve SL2)
Electronic controlled automatic transmission (ECT)   P0778 (05-1082 ) Pressure Control Solenoid ”B” Electrical (Shift Solenoid Valve SL2)
Electronic controlled automatic transmission (ECT)   P0793 (05-1085 ) Intermediate Shaft Speed Sensor ”A” Circuit No Signal
Electronic controlled automatic transmission (ECT)   2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 608 05-419 DIAGNOSTICS DTC No. (See Page) Detection Item - SFI SYSTEM (3MZ-FE) Trouble Area MIL*1 Memory P0796 (05-1089 ) Pressure Control Solenoid ”C” Performance (Shift Solenoid Valve SL3)
Electronic controlled automatic transmission (ECT)   P0798 (05-1094 ) Pressure Control Solenoid ”C” Electrical (Shift Solenoid Valve SL3)
Electronic controlled automatic transmission (ECT)   P0982 (05-1097 ) Shift Solenoid ”D” Control Low
Electronic controlled automatic transmission (ECT)   P0983 (05-1097 ) Shift Solenoid ”D” Control High
Electronic controlled automatic transmission (ECT)   P0985 (05-1100) Pressure Control Solenoid ”E” Performance (Shift Solenoid Valve SR)
Electronic controlled automatic transmission (ECT)   P0986 (05-1100) Pressure Control Solenoid ”E” Electrical (Shift Solenoid Valve SR)
Electronic controlled automatic transmission (ECT)   P2102 (05-603 ) Throttle Actuator Control Motor Circuit Low
Open in throttle control motor circuit
Throttle control motor
ECM   P2103 (05-603 ) Throttle Actuator Control Motor Circuit High
Short in throttle control motor circuit
Throttle control motor
Throttle body
Throttle valve
ECM   P2111 (05-607 ) Throttle Actuator Control System - Stuck Open
Throttle control motor circuit
Throttle control motor
Throttle body
Throttle valve   P2112 (05-607 ) Throttle Actuator Control System - Stuck Closed
Same as DTC No. P2111   P2118 (05-610 ) Throttle Actuator Control Motor Current Range/Performance
Open in ETCS power source circuit
ECM   P2119 (05-615 ) Throttle Actuator Control Throttle Body Range/Performance
ETCS
ECM   P2120 (05-617 ) Throttle/Pedal Position Sensor/ Switch ”D” Circuit
Accelerator pedal position sensor
ECM   P2121 (05-625 ) Throttle/Pedal Position Sensor/ Switch ”D” Circuit Range/Performance
Open or short in accelerator pedal position sensor circuit
Accelerator pedal position sensor
ECM   P2122 (05-617 ) Throttle/Pedal Position Sensor/ Switch ”D” Circuit Low Input
Accelerator pedal position sensor
VCP1 circuit open
VPA1 circuit open or ground short
ECM   P2123 (05-617 ) Throttle/Pedal Position Sensor/ Switch ”D” Circuit High Input
Accelerator pedal position sensor
EPA circuit open
ECM   P2125 (05-617 ) Throttle/Pedal Position Sensor/ Switch ”E” Circuit
Same as DTC No. P2120   P2127 (05-617 ) Throttle/Pedal Position Sensor/ Switch ”E” Circuit Low Input
Accelerator pedal position sensor
VCP2 circuit open
VPA2 circuit open or ground short
ECM   P2128 (05-617 ) Throttle/Pedal Position Sensor/ Switch ”E” Circuit High Input
Accelerator pedal position sensor
EPA2 circuit open
ECM   2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 609 05-420 DIAGNOSTICS DTC No. (See Page) Detection Item - SFI SYSTEM (3MZ-FE) Trouble Area MIL*1 Memory P2135 (05-469 ) Throttle Pedal Position Sensor/ Switch ”A”/”B” Voltage Correlation
VTA1 and VTA2 circuit are short circuited
Throttle position sensor (built in throttle body)
ECM   P2138 (05-617 ) Throttle Pedal Position Sensor/ Switch ”D”/”E” Voltage Correlation
VPA1 and VPA2 circuit are short circuited
Accelerator pedal position sensor
ECM   P2195*3 (05-629 ) Oxygen (A/F) Sensor Signal Stuck Lean (Bank 1 Sensor 1)
Open or short in A/F sensor (bank 1 sensor 1) circuit
A/F sensor (bank 1 sensor 1)
A/F sensor (bank 1 sensor 1) heater
A/F relay
Open or short in A/F sensor heater and relay circuits
Air induction system
Fuel pressure
Injector
PCV hose connection
ECM   P2196*3 (05-629 ) Oxygen (A/F) Sensor Signal Stuck Rich (Bank 1 Sensor 1)
Same as DTC No. P2195   P2197*3 (05-629 ) Oxygen (A/F) Sensor Signal Stuck Lean (Bank 2 Sensor 1)
Open or short in A/F sensor (bank 2 sensor 1) circuit
A/F sensor (bank 2 sensor 1)
A/F sensor (bank 2 sensor 1) heater
A/F relay
Open or short in A/F sensor heater and relay circuits
Air induction system
Fuel pressure
Injector
PCV hose connection
ECM   P2198*3 (05-629 ) Oxygen (A/F) Sensor Signal Stuck Rich (Bank 2 Sensor 1)
Same as DTC No. P2197   P2238*3 (05-642 ) Oxygen Sensor Pumping Current Circuit Low (for A/F sensor) (Bank 1 Sensor 1)
Open or short in A/F sensor (bank 1 sensor 1) circuit
A/F sensor (bank 1 sensor 1)
A/F sensor (bank 1 sensor 1) heater
A/F relay
Open or short in A/F sensor heater and relay circuits
ECM   P2239*3 (05-642 ) Oxygen Sensor Pumping Current Circuit High (for A/F sensor) (Bank 1 Sensor 1)
Same as DTC No. P2238   P2241*3 (05-642 ) Oxygen Sensor Pumping Current Circuit Low (for A/F sensor) (Bank 2 Sensor 1)
Open or short in A/F sensor (bank 2 sensor 1) circuit
A/F sensor (bank 2 sensor 1)
A/F sensor (bank 2 sensor 1) heater
A/F relay
A/F sensor heater and relay circuit
ECM   P2242*3 (05-642 ) Oxygen Sensor Pumping Current Circuit High (for A/F sensor) (Bank 2 Sensor 1)
Same as DTC No. P2241   P2252*3 (05-642 ) Oxygen Sensor Reference Ground Circuit Low (for A/F sensor) (Bank 1 Sensor 1)
Same as DTC No. P2238   P2253*3 (05-642 ) Oxygen Sensor Reference Ground Circuit High (for A/F sensor) (Bank 1 Sensor 1)
Same as DTC No. P2238   P2255*3 (05-642 ) Oxygen Sensor Reference Ground Circuit Low (for A/F sensor) (Bank 2 Sensor 1)
Same as DTC No. P2241   2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 610 05-421 DIAGNOSTICS DTC No. (See Page) Detection Item P2256*3 (05-642 ) Oxygen Sensor Reference Ground Circuit High (for A/F sensor) (Bank 2 Sensor 1) P2716 (05-1103) - SFI SYSTEM (3MZ-FE) MIL*1 Memory
Same as DTC No. P2241   Pressure Control Solenoid ”D” Electrical
Electronic controlled automatic transmission (ECT)   P2769 (05-1106) DSL Solenoid Circuit Low
Electronic controlled automatic transmission (ECT)   P2770 (05-1106) DSL Solenoid Circuit High
Electronic controlled automatic transmission (ECT)   A/F Sensor Circuit Slow Response (Bank 1 Sensor 1)
Open or short in A/F sensor (bank 1 sensor 1) circuit
A/F sensor (bank 1 sensor 1)
A/F sensor heater
A/F relay
Open or short in A/F sensor heater and relay circuits
Air induction system
Fuel pressure
Injector
PCV hose connection
ECM   A/F Sensor Circuit Slow Response (Bank 2 Sensor 1)
Open or short in A/F sensor (bank 2 sensor 1) circuit
A/F sensor (bank 2 sensor 1)
A/F sensor heater
A/F relay
Open or short in A/F sensor heater and relay circuits
Air induction system
Fuel pressure
Injector
PCV hose connection
ECM   P2A00 (05-649 ) P2A03 (05-649 ) Trouble Area HINT: *1: MIL is illuminated. *2: MIL is illuminated or flashes continuously. *3: Although the title (DTC description) says ”oxygen sensor”, this DTC is related to the ”A/F sensor”. *4: This DTC indicates a malfunction related to primary circuit. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 611 05-366 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05288-42 HOW TO PROCEED WITH TROUBLESHOOTING HINT: The hand-held tester is used in steps 3, 4, 5, 7 and 10. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (See page 05-369 ) NEXT 3 CONNECT HAND-HELD TESTER TO DLC3 HINT: If the display indicates a communication fault in the tool, inspect DLC3. NEXT 4 CHECK DTC AND FREEZE FRAME DATA (See page 05-400 ) HINT: Record or print DTC and freeze frame data, if needed. NEXT 5 CLEAR DTC AND FREEZE FRAME DATA (See page 05-400 ) NEXT 6 VISUAL INSPECTION NEXT 7 SETTING CHECK (TEST) MODE DIAGNOSIS (See page 05-402 ) NEXT 8 PROBLEM SYMPTOM CONFIRMATION HINT: If the engine does not start, perform steps 10 and 12 first. B Malfunction does not occur A Malfunction occurs B Go to step 10 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 556 05-367 DIAGNOSTICS 9 - SFI SYSTEM (3MZ-FE) SYMPTOM SIMULATION NEXT 10 DTC CHECK (See page 05-400 ) B Malfunction code A No code B Go to step 12 A 11 DTC CHART (See page 05-412 ) NEXT Go to step 14 12 BASIC INSPECTION (See page 05-371 ) B Wrong parts not confirmed A Wrong parts confirmed B Go to step 17 A 13 PROBLEM SYMPTOMS TABLE (See page 05-393 ) B Wrong circuit confirmed A Wrong parts confirmed B Go to step 17 A 14 CHECK ECM POWER SOURCE CIRCUIT (See page 05-674 ) NEXT 15 CIRCUIT INSPECTION B Malfunction not confirmed A Malfunction confirmed B Go to step 18 A 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 557 05-368 DIAGNOSTICS 16 - SFI SYSTEM (3MZ-FE) CHECK FOR INTERMITTENT PROBLEMS (See page 05-370 ) NEXT Go to step 18 17 PARTS INSPECTION NEXT 18 IDENTIFICATION OF PROBLEM NEXT 19 ADJUSTMENT, REPAIR NEXT 20 CONFIRMATION TEST NEXT END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 558 05-365 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05285-43 LOCATION Combination Meter Assy Charcoal Canister Assy Charcoal Canister Filter CCV Vapor Pressure Sensor Assy Center J/B Mass Air Flow Meter ECM Fuel Pump Passenger Side J/B VSV for ACM Engine Room R/B No.2, J/B and FL Block Assy
A/F Relay
EFI Relay
EFI NO. 1 Fuse
ETCS Fuse DLC3 Engine Coolant Temperature Sensor EVAP VSV Instrument Panel J/B Assy R/B Sub-assy
IGN Fuse
IG2 Fuse
C/OPN Relay Accelerator Pedal Rod Assy (Accelerator Pedal Position Sensor) Knock Sensor (Bank 2) IAC Valve No. 2 Knock Sensor (Bank 1) Injector Ignition Coil Assy Throttle Body Assy (Throttle Position Sensor and Motor) Camshaft Timing Oil Control Valve Assy (Bank 2) Camshaft Timing Oil Control Valve Assy (Bank 1) VVT Sensor (Bank 2) VVT Sensor (Bank 1) A/F Sensor (Bank 1 Sensor 1) Crankshaft Position Sensor A/F Sensor (Bank 2 Sensor 1) Heated Oxygen Sensor (Bank 2 Sensor 2) Heated Oxygen Sensor (Bank 1 Sensor 2) A89566 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 555 05-393 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05287-44 PROBLEM SYMPTOMS TABLE Symptom Suspected Area See Page Engine does not crank (does not start) 1. Starter 2. Starter relay 3. PNP switch 19-36 19-36 40-11 No initial combustion (does not start) 1. ECM power source circuit 2. Fuel pump control circuit 3. ECM 05-674 05-717 01-36 No complete combustion (does not start) 1. Fuel pump control circuit 05-717 Difficult to start (engine cranks normally) 1. Starter signal circuit 2. Fuel pump control circuit 3. Compression 05-595 05-717 14-121 Difficult to start with cold engine 1. Starter signal circuit 2. Fuel pump control circuit 05-595 05-717 Difficult to start with hot engine 1. Starter signal circuit 2. Fuel pump control circuit 05-595 05-717 High engine idle speed (poor idling) 1. A/C signal circuit (Compressor circuit) 2. ECM power source circuit 05-1190 05-674 Low engine idle speed (poor idling) 1. A/C signal circuit (Compressor circuit) 2. Fuel pump control circuit 05-1190 05-717 Rough idling (poor idling) 1. Compression 2. Fuel pump control circuit 14-121 05-717 Hunting (poor idling) 1. ECM power source circuit 2. Fuel pump control circuit 05-674 05-717 Hesitation/Poor acceleration (poor driveability) 1. Fuel pump control circuit 2. A/T faulty 05-717 05-1016 Surging (poor driveability) 1. Fuel pump control circuit 05-717 Engine stalls soon after starting 1. Fuel pump control circuit 05-717 Engine stalls during A/C operation 1. A/C signal circuit (Compressor circuit) 2. ECM 05-1190 01-36 Unable to refuel/Difficult to refuel 1. ORVR system - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 583 05-394 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) 05286-32 TERMINALS OF ECM E7 E8 E9 E6 E5 A53766 Each ECM terminal’s standard voltage is shown in the table below. In the table, first follow the information under ”Condition”. Next look under ”Symbols (Terminal No.)” for the terminals to be inspected. The standard voltage between the terminals is shown under ”Specific Condition”. Use the illustration above as a reference for the ECM terminals. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specific Condition BATT (E5-3) - E1 (E7-1) BR - BR Battery (for measuring battery voltage and for ECM memory) Always 9 to 14 V +BM (E6-6) - E1 (E7-1) W - BR Power source of throttle motor Always 9 to 14 V IGSW (E5-9) - E1 (E7-1) P - BR Ignition switch Ignition switch ON 9 to 14 V +B (E5-1) - E1 (E7-1) W - BR Power source of ECM Ignition switch ON 9 to 14 V +B2 (E5-2) - E1 (E7-1) W - BR Power source of ECM Ignition switch ON 9 to 14 V OC1+ (E9-16) - OC1- (E9-15) G-W - G-R Camshaft timing (OCV) Ignition switch ON Pulse generation (See page 05-448 ) OC2+ (E9-14) - OC2- (E9-13) L-R - G-B Camshaft timing (OCV) Ignition switch ON Pulse generation (See page 05-448 ) B - BR EFI relay Ignition switch ON 9 to 14 V Y - BR Power source of sensor (specific voltage) Ignition switch ON 4.5 to 5.5 V MREL (E5-8) - E1 (E7-1) VC (E7-18) - E2 (E7-28) VG (E7-30) - E2G (E7-29) R - L-W Mass air flow meter Idling, shift lever position P or N, A/C switch OFF 0.5 to 3.0 V THA (E7-20) - E2 (E7-28) L-B - BR Intake air temperature sensor Idling, intake air temp. 20°C (68°F) 0.5 to 3.4 V THW (E7-19) - E2 (E7-28) G-B - BR Engine coolant temperature sensor Idling, engine coolant temp. 80°C (176°F) 0.2 to 1.0 V VTA1 (E7-21) - E2 (E7-28) R-W - BR Throttle position sensor (for engine control) Ignition switch ON, throttle valve fully closed 0.5 to 1.2 V VTA1 (E7-21) - E2 (E7-28) R-W - BR Throttle position sensor (for engine control) Ignition switch ON, throttle valve fully open 3.2 to 4.8 V VTA2 (E7-31) - E2 (E7-28) B-R - BR Throttle position sensor (for sensor malfunction detection) Ignition switch ON, accelerator pedal released 2.1 to 3.1 V VTA2 (E7-31) - E2 (E7-28) B-R - BR Throttle position sensor (for sensor malfunction detection) Ignition switch ON, accelerator pedal depressed 4.5 to 5.5 V VPA (E5-22) - EPA (E5-28) B-R Accelerator pedal position sensor (for engine control) Ignition switch ON, accelerator pedal released 0.5 to 1.1 V VPA (E5-22) - EPA (E5-28) B-R Accelerator pedal position sensor (for engine control) Ignition switch ON, accelerator pedal depressed 2.6 to 4.5 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 584 05-395 DIAGNOSTICS - SFI SYSTEM (3MZ-FE) Symbols (Terminal No.) Wiring Color Terminal Description Condition Specific Condition VPA2 (E5-23) - EPA2 (E5-29) W - BR Accelerator pedal position sensor (for sensor malfunction detection) Ignition switch ON, accelerator pedal released 1.2 to 2.0 V VPA2 (E5-23) - EPA2 (E5-29) W - BR Accelerator pedal position sensor (for sensor malfunction detection) Ignition switch ON, accelerator pedal depressed 3.4 to 5.3 V VCPA (E5-26) - EPA (E5-28) G-R Power source of accelerator pedal position sensor (for VPA) Ignition switch ON 4.5 to 5.5 V VCP2 (E5-27) - EPA2 (E5-29) L - BR Power source of accelerator pedal position sensor (for VPA2) Ignition switch ON 4.5 to 5.5 V Below 3.0 V HA1H (E8-5) - E04 (E8-7) HA2A (E8-4) - E05 (E8-6) B-W - W-B R-W - W-B A/F sensor heater Idling HA1H (E8-5) - E04 (E8-7) HA2A (E8-4) - E05 (E8-6) B-W - W-B R-W - W-B A/F sensor heater Ignition switch ON 9 to 14 V A1A+ (E8-22) - E1 (E7-1) BR - BR A/F sensor Ignition switch ON 3.0 to 3.6 V A2A+ (E8-23) - E1 (E7-1) P - BR A/F sensor Ignition switch ON 3.0 to 3.6 V A1A- (E8-30) - E1 (E7-1) Y - BR A/F sensor Ignition switch ON 2.7 to 3.3 V A2A- (E8-31) - E1 (E7-1) L - BR A/F sensor Ignition switch ON 2.7 to 3.3 V Below 3.0 V HT1B (E8-25) - E2 (E7-28) HT2B (E8-33) - E2 (E7-28) R-Y - BR W-L - BR Heated oxygen sensor heater Idling HT1B (E8-25) - E2 (E7-28) HT2B (E8-33) - E2 (E7-28) R-Y - BR W-L - BR Heated oxygen sensor heater Ignition switch ON OX1B (E8-21) - E2 (E7-28) OX2B (E8-29) - E2 (E7-28) W - BR B - BR Heated oxygen sensor Maintain engine speed at 2,500 rpm for 2 minutes after warming up 9 to 14 V Pulse generation #10 #20 #30 #40 #50 #60 (E7-1) (E7-2) (E7-3) (E7-4) (E7-5) (E8-3) - E01 E01 E01 E01 E01 E01 (E7-7) (E7-7) (E7-7) (E7-7) (E7-7) (E7-7) L - W-B Y - W-B B - W-B W - W-B B-W - W-B G - W-B Injector Ignition switch ON #10 #20 #30 #40 #50 #60 (E7-1) (E7-2) (E7-3) (E7-4) (E7-5) (E8-3) - E01 E01 E01 E01 E01 E01 (E7-7) (E7-7) (E7-7) (E7-7) (E7-7) (E7-7) L - W-B Y - W-B B - W-B W - W-B B-W - W-B G - W-B Injector Idling Pulse generation (See page 05-511) 9 to 14 V KNK1 (E8-1) - EKNK (E8-28) B -W Knock sensor Maintain engine speed at 4,000 rpm after warming up Pulse generation (See page 05-527 ) KNK2 (E8-2) - EKN2 (E8-20) R -G Knock sensor Maintain engine speed at 4,000 rpm after warming up Pulse generation (See page 05-527 ) VV1+ (E9-27) - NE- (E9-24) B-W - G VVT sensor Idling Pulse generation (See page 05-532 ) VV2+ (E9-26) - NE- (E9-24) L -G VVT sensor Idling Pulse generation (See page 05-532 ) NE+ (E9-25) - NE- (E9-24) R -G Crankshaft position sensor Idling Pulse generation (See page 05-532 ) Ignition coil with igniter (ignition signal) Idling Pulse generation (See page 05-541 ) IGT1 IGT2 IGT3 IGT4 IGT5 IGT6 (E7-8) - E1 (E7-1) (E7-9) - E1 (E7-1) (E7-10) - E1 (E7-1) (E7-11) - E1 (E7-1) (E7-12) - E1 (E7-1) (E7-13) - E1 (E7-1) R-L - BR P - BR Y-B - BR L-Y - BR G-Y - BR L-R - BR 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 585 05-396 DIAGNOSTICS Symbols (Terminal No.) - SFI SYSTEM (3MZ-FE) Wiring Color Terminal Description IGF1 (E7-24) - E1 (E7-1) W-R - BR Ignition coil with igniter (ignition confirmation signal) Ignition switch ON IGF1 (E7-24) - E1 (E7-1) W-R - BR Ignition coil with igniter (ignition confirmation signal) Idling PRG (E7-34) - E1 (E7-1) G - BR EVAP VSV Ignition switch ON CCV (E7-27) - E1 (E7-1) L - BR CCV Ignition switch ON 9 to 14 V PTNK (E5-21) - E1 (E7-1) L - BR Vapor pressure sensor Ignition switch ON 2.9 to 3.7 V PTNK (E5-21) - E1 (E7-1) L - BR Vapor pressure sensor Ignition switch ON, apply vacuum 4.0 kPa (30 mmHg, 1.18 in.Hg) Below 0.5 V SPD (E6-17) - E1 (E7-1) Y - BR Speed signal from combination meter Ignition switch ON, rotate driving wheel slowly Pulse generation (See page 05-578 ) STA (E7-17) - E1 (E7-1) B - BR Starter signal Cranking STP (E6-19) - E1 (E7-1) BR - BR Stop lamp switch Ignition switch ON, brake pedal is depressed 7.5 to 14 V STP (E6-19) - E1 (E7-1) BR - BR Stop lamp switch Ignition switch ON, brake pedal is released Below 1.5 V ST1- (E6-12) - E1 (E7-1) V - BR Stop lamp switch (opposite to stop) Ignition switch ON, brake pedal is depressed Below 1.5 V ST1- (E6-12) - E1 (E7-1) V - BR Stop lamp switch (opposite to stop) Ignition switch ON, brake pedal is released 7.5 to 14 V NSW (E7-16) - E1 (E7-1) B-R - BR PNP switch Ignition switch ON, shift lever position in P or N Below 3.0 V NSW (E7-16) - E1 (E7-1) B-R - BR PNP switch Ignition switch ON, except shift lever position in P or N 9 to 14 V M+ (E9-3) - ME01 (E9-4) M- (E9-2) - ME01 (E9-4) B - W-B W - W-B Throttle motor Idling Y - BR Fuel pump control Ignition switch ON FC (E5-10) - E1 (E7-1) Y - BR Fuel pump control Idling W (E5-11) - E1 (E7-1) SB - BR MIL Ignition switch ON W (E5-11) - E1 (E7-1) SB - BR MIL Idling 9 to 14 V ELS2 (E5-12) - E1 (E7-1) G - BR Electric load Power outlet OFF 0 to 1.5 V ELS2 (E5-12) - E1 (E7-1) G - BR Electric load Power outlet ON 7.5 to 14 V TC (E5-20) - E1 (E7-1) O - BR Terminal TC of DLC 3 Ignition switch ON SIL (E5-18) - E1 (E7-1) R - BR Terminal SIL of DLC3 During transmission Pulse generation TACH (E5-5) - E1 (E7-1) B - BR Engine speed Idling Pulse generation ACIS (E7-15) - E1 (E7-1) R-Y - BR VSV for ACIS Ignition switch ON 9 to 14 V ACM (E9-6) - E1 (E7-1) Y-G - BR VSV for ACM Ignition switch ON 9 to 14 V V-R Electric load (from skid control ECU) Idling Pulse generation Y-G Electric load (from skid control ECU) Idling Pulse generation PS pressure switch Ignition switch ON FC (E5-10) - E1 (E7-1) ENG+ (E5-24) ENG- (E5-30) TRC+ (E5-25) - TRC- (E5-31) PSW (E9-10) - E1 (E9-1) R-W - BR Condition Specific Condition 4.5 to 5.5 V Pulse generation (See page 05-541 ) 9 to 14 V 6 V or higher Pulse generation 9 to 14 V 0 to 3 V Below 3.0 V 9 to 14 V 9 to 14 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 586 10-2 ENGINE CONTROL SYSTEM - SFI SYSTEM (2AZ-FE) 100IO-05 INSPECTION 1. (a) Air E2 VG +B THA E2G 5 4 3 2 1 (b) 30 20 Resistance kΩ 10 INSPECT MASS AIR FLOW METER Check the output voltage. (1) Apply battery voltage across terminals 1 (+B) and 2 (E2G). (2) Connect the positive (+) tester probe to terminal 3 (VG), and negative (-) tester probe to terminal 2 (E2G). (3) Blow air into the Mass Air Flow (MAF) meter, and check that the voltage fluctuates. Measure the resistance between terminals 4 (THA) and 5 (E2). Standard: Condition Specified Condition 5 -20
C (-4
F) 13.6 to 18.4 kΩ 3 2 20
C (68
F) 2.21 to 2.69 kΩ 60
C (140
F) 0.493 to 0.667 kΩ 1 If the result is not as specified, replace the MAF meter. 0.5 0.3 0.2 0.1 -20 0 20 40 60 80 100 (-4) (32) (68) (104)(140) (176) (212) Temperature
C (
F) A93068 2. 1 2 Valve A50377 INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSY (a) Measure the resistance between the terminals. Standard: 6.9 to 7.9 Ω at 20
C (68
F) If the result is not as specified, replace the OCV assy. (b) Connect the battery’s positive (+) lead to terminal 1 and negative (-) lead to terminal 2, and check the movement of the valve. NOTICE: Confirm that the valve moves freely and does not become stuck in any position. If necessary, replace the OCV assy. HINT: If the valve cannot return properly because of foreign matter, a small pressure leak in the advanced direction may occur and a DTC will be output. Author
: Date
: 2360 10-3 ENGINE CONTROL SYSTEM SFI SYSTEM (2AZ-FE) INSPECT ACCELERATOR PEDAL ROD ASSY Check the accelerator pedal position sensor (see page 05-102 ). 4. (a) (b) 6 5 VTA VC 4 VTA2 3 E2 2 INSPECT THROTTLE BODY ASSY Check the throttle position sensor (see page 05-469 ). Check the throttle control motor. (1) Measure the resistance between terminals 2 (M+) and 1 (M-). Resistance: 0.3 to 100 Ω at 20
C (68
F) If the result is not as specified, replace the throttle body assy. 1 M+ MA75258 5. (a) INSPECT ENGINE COOLANT TEMPERATURE SENSOR Measure the resistance between terminals 1 and 2. Standard: Condition Specified Condition 20
C (68
F) 2.32 to 2.59 kΩ 80
C (176
F) 0.310 to 0.326 kΩ If the result is not as specified, replace the sensor. NOTICE: If checking the ECT sensor in the water, keep the terminals dry. After the check, wipe the sensor dry. 30 20 Resistance kΩ 3. (a) - 10 5 3 2 1 0.5 0.3 0.2 0.1 -20 0 20 40 60 80 100 (-4) (32) (68)(104) (140) (176) (212) Temperature
C (
F) A91320 6. (a) INSPECT KNOCK SENSOR Measure the resistance between the terminals. Standard: 120 to 280 kΩ at 20
C (68
F) If the result is not as specified, replace the sensor. A65174 Author
: Date
: 2361 10-4 ENGINE CONTROL SYSTEM 1 1 2 2 5 5 3 3 7. (a) (b) (c) - SFI SYSTEM (2AZ-FE) INSPECT RELAY (Marking: EFI, A/F) Remove the EFI relay from the engine room J/B. Remove the A/F relay from the engine room R/B No. 2. Measure the resistance of the relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1Ω (when battery voltage is applied to terminals 1 and 2) A93067 1 1 2 2 5 5 3 3 A93067 If the result is not as specified, replace the relay. 8. INSPECT CIRCUIT OPENING RELAY (a) Remove the circuit opening relay from the R/B sub-assy (b) Measure the resistance of the relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1Ω (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay. Author
: Date
: 2362 10-1 ENGINE CONTROL SYSTEM - SFI SYSTEM (2AZ-FE) SFI SYSTEM (2AZ-FE) 10068-07 ON-VEHICLE INSPECTION 1. (a) CHECK THROTTLE BODY Listen to the throttle control motor operating sounds. (1) Turn the ignition switch ON. (2) When pressing the accelerator pedal position sensor lever, listen to the running motor. Make sure no friction noise comes from the motor. If friction noise exists, replace the throttle body. (b) Check the throttle position sensor. (1) Connect the hand-held tester or OBD II scan tool to the DLC3. (2) Turn the ignition switch ON. (3) Check that the check engine warning light does not light up. (4) Under CURRENT DATA, the throttle valve opening percentage (THROTTLE POS) should be within the standard value range below. Standard throttle valve opening percentage: 60 % or more If the percentage is less than 60 %, replace the throttle position sensor. NOTICE: When checking the standard throttle valve opening percentage, the transmission should be in the neutral position. 2. CHECK ACCELERATOR PEDAL POSITION SENSOR (a) Turn the ignition switch ON. Under CURRENT DATA, the voltage of the throttle position sensor should be within the standard value range below. Standard: 0.6 to 1.0 V If the result is not as specified, replace the accelerator pedal position sensor. 3. CHECK CAMSHAFT TIMING OIL CONTROL VALVE (OCV) ASSY (a) Connect the hand-held tester or OBD II scan tool to the DLC3. (b) Turn the ignition switch ON. (c) Start the engine and warm it up. (d) Select the VVT from the ACTIVE TEST menu. (e) Check the engine speed when the OCV is operated by the hand-held tester or OBD II scan tool. Standard: Condition Specified Condition VVT system is OFF (OCV is OFF) Normal engine speed VVT system is ON (OCV is ON) Rough idle or engine stalled If the result is not as specified, replace the OCV assy. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2359 10-5 ENGINE CONTROL SYSTEM - THROTTLE BODY ASSY (2AZ-FE) THROTTLE BODY ASSY (2AZ-FE) 1006A-07 COMPONENTS Fuel Vapor Feed Hose MAF Meter Connector VSV Connector for EVAP Air Cleaner Cap Sub-assy 30 (305, 22) Fuel Pipe Support 30 (305, 22) Throttle Body Assy Water By-pass Hose No, 1 Water By-pass Hose No. 2
Gasket Throttle Control Motor & Throttle Position Sensor Connector N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part A93431 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2363 10-6 ENGINE CONTROL SYSTEM - THROTTLE BODY ASSY (2AZ-FE) 1006B-05 REPLACEMENT 1. 2. DRAIN ENGINE COOLANT (See page 16-6 ) REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE (See page 14-24 ) 3. REMOVE THROTTLE BODY ASSY (a) Disconnect the throttle control motor & throttle position sensor connector. (b) Disconnect the vacuum hose from the throttle body. (c) Disconnect the 2 water by-pass hoses. (d) (e) Remove the 4 bolts, fuel pipe support and throttle body. Remove the gasket. 4. (a) INSTALL THROTTLE BODY ASSY Install a new gasket to the intake manifold, as shown in the illustration. (b) Install the throttle body and fuel pipe support with the 4 bolts. Torque: 30 N⋅m (305 kgf⋅cm, 22 ft⋅lbf) Connect the 2 water by-pass hoses to the throttle body. Connect the throttle control motor & throttle position sensor connector. Connect the vacuum hose to the throttle body. A60798 B09649 (c) (d) (e) A60798 5. 6. 7. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE (See page 14-24 ) ADD ENGINE COOLANT (See page 16-6 ) CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2364 10-7 ENGINE CONTROL SYSTEM - KNOCK SENSOR (2AZ-FE) KNOCK SENSOR (2AZ-FE) 100IP-03 REPLACEMENT 1. 2. 3. DRAIN ENGINE COOLANT (See page 16-6 ) REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE (See page 14-24 ) REMOVE THROTTLE BODY ASSY (See page 10-6 ) 4. (a) REMOVE INTAKE MANIFOLD Remove the 5 bolts, 2 nuts, intake manifold and gasket. 5. (a) (b) REMOVE KNOCK SENSOR Disconnect the sensor connector. Remove the nut and sensor. A61987 A92776 6. (a) Upper 10
Engine Front 10
INSTALL KNOCK SENSOR Install the sensor with the nut. Torque: 20 N⋅m (199 kgf⋅cm, 14 ft⋅lbf) HINT:Angling the knock sensor below the horizontal (below 0
) is recommended. (b) Connect the sensor connector. A78436 7. (a) INSTALL INTAKE MANIFOLD Install a new gasket and the intake manifold with the 5 bolts and 2 nuts. Torque: 30 N⋅m (305 kgf⋅cm, 22 ft⋅lbf) A61987 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2365 10-8 ENGINE CONTROL SYSTEM 8. 9. 10. 11. - KNOCK SENSOR (2AZ-FE) INSTALL THROTTLE BODY ASSY (See page 10-6 ) INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE (See page 14-24 ) ADD ENGINE COOLANT (See page 16-6 ) CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2366 10-9 ENGINE CONTROL SYSTEM - ECM (2AZ-FE) ECM (2AZ-FE) 100IQ-02 REPLACEMENT 1. 2. 3. 4. 5. DISCONNECT BATTERY NEGATIVE TERMINAL REMOVE FRONT DOOR SCUFF PLATE RH (See page 71-10 ) REMOVE COWL SIDE TRIM SUB-ASSY RH (See page 71-10 ) REMOVE GLOVE COMPARTMENT DOOR ASSY (See page 71-10 ) REMOVE INSTRUMENT PANEL FINISH PANEL LOWER NO.2 (See page 71-10 ) 6. (a) (b) (c) REMOVE ECM Remove the 2 wire harness clamps. Disconnect the 5 ECM connectors. Remove the 2 nuts and ECM. 7. (a) REMOVE ECM BRACKET NO. 1 Remove the 2 screws and ECM bracket. 8. (a) 9. (a) REMOVE ECM BRACKET NO. 2 Remove the 2 screws and ECM bracket. INSTALL ECM BRACKET NO. 2 Install the ECM bracket with the 2 screws. 10. (a) INSTALL ECM BRACKET NO. 1 Install the ECM bracket with the 2 screws. I30545 A90275 A90283 A90275 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2367 10-10 ENGINE CONTROL SYSTEM 11. (a) (b) (c) - ECM (2AZ-FE) INSTALL ECM Install the 2 wire harness clamps. Connect the 5 ECM connectors. Install the ECM with the 2 nuts. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) I30545 12. 13. 14. 15. 16. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER NO.2 (See page 71-10 ) INSTALL GLOVE COMPARTMENT DOOR ASSY (See page 71-10 ) INSTALL COWL SIDE TRIM SUB-ASSY RH (See page 71-10 ) INSTALL FRONT DOOR SCUFF PLATE RH (See page 71-10 ) CONNECT BATTERY NEGATIVE TERMINAL 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2368 10-13 ENGINE CONTROL SYSTEM - SFI SYSTEM (3MZ-FE) 100FT-04 INSPECTION 1. (a) Air E2 VG +B THA E2G 5 4 3 2 1 (b) 30 20 Resistance kΩ 10 INSPECT MASS AIR FLOW METER Check the output voltage. (1) Apply battery voltage across terminals 1 (+B) and 2 (E2G). (2) Connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E2G. (3) Blow air into the Mass Air Flow (MAF) meter, and check that the voltage fluctuates. Measure the resistance between terminals 4 (THA) and 5 (E2). Standard: Condition Specified Condition -20
C (-4
F) 13.6 to 18.4 kΩ 5 20
C (68
F) 2.21 to 2.69 kΩ 3 2 60
C (140
F) 0.493 to 0.667 kΩ If the result is not as specified, replace the MAF meter. 1 0.5 0.3 0.2 0.1 -20 0 20 40 60 80 100 (-4) (32) (68) (104)(140) (176) (212) Temperature
C (
F) A93068 2. 1 2 Valve A50377 INSPECT CAMSHAFT TIMING OIL CONTROL VALVE ASSY (a) Measure the resistance between the terminals. Standard: 6.9 to 7.9 Ω at 20
C (68
F) If the result is not as specified, replace the OCV assy. (b) Connect the battery’s positive (+) lead to terminal 1 and negative (-) lead to terminal 2, and check the movement of the valve. NOTICE: Confirm that the valve moves freely and does not become stuck in any position. If necessary, replace the OCV assy. HINT: If the valve cannot return properly because of foreign matter, a small pressure leak in the advanced direction may occur and a DTC will be output. Author
: Date
: 2371 10-14 ENGINE CONTROL SYSTEM SFI SYSTEM (3MZ-FE) INSPECT ACCELERATOR PEDAL ROD ASSY Check the acceletor pedal position sensor (see page 05-469 ). 4. (a) (b) 6 5 VTA VC 4 VTA2 3 E2 2 INSPECT THROTTLE BODY ASSY Check the throttle position sensor (see page 05-469 ). Check the throttle control motor. (1) Measure the resistance between terminals 2 (M+) and 1 (M-). Resistance: 0.3 to 100 Ω at 20
C (68
F). If the result is not as specified, replace the throttle body assy. 1 M+ MA75258 5. (a) INSPECT ENGINE COOLANT TEMPERATURE SENSOR Measure the resistance between each terminal. Standard: Condition Specified Condition 20
C (68
F) 2.32 to 2.59 kΩ 80
C (176
F) 0.310 to 0.326 kΩ If the result is not as specified, replace the sensor. NOTICE: If checking the ECT sensor in the water, keep the terminals dry. After the check, wipe the sensor dry. 30 20 Resistance kΩ 3. (a) - 10 5 3 2 1 0.5 0.3 0.2 0.1 -20 0 20 40 60 80 100 (-4) (32) (68)(104) (140) (176) (212) Temperature
C (
F) A91320 6. (a) INSPECT KNOCK SENSOR Measure the resistance between the terminals. Resistance: 120 to 280 kΩ at 20
C (68
F) If the result is not as specified, replace the sensor. A65174 Author
: Date
: 2372 10-15 ENGINE CONTROL SYSTEM 1 1 2 2 5 5 3 3 7. (a) (b) (c) - SFI SYSTEM (3MZ-FE) INSPECT RELAY (Marking: EFI, A/F) Remove the EFI relay from the engine room J/B. Remove the A/F relay from the engine room R/B No. 2. Measure the resistance of the relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1Ω (when battery voltage is applied to terminals 1 and 2) A93067 1 1 2 2 5 5 3 3 A93067 If the result is not as specified, replace the relay. 8. INSPECT CIRCUIT OPENING RELAY (a) Remove the circuit opening relay from the R/B sub-assy. (b) Measure the resistance of the relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1Ω (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay. Author
: Date
: 2373 10-12 ENGINE CONTROL SYSTEM - SFI SYSTEM (3MZ-FE) SFI SYSTEM (3MZ-FE) 100FS-06 ON-VEHICLE INSPECTION 1. (a) CHECK THROTTLE BODY Listen to the throttle control motor operating sounds. (1) Turn the ignition switch ON. (2) When pressing the accelerator pedal position sensor lever, listen to the running motor. Make sure no friction noise comes from the motor. If friction noise exists, replace the throttle body. (b) Inspect the throttle position sensor. (1) Connect the hand-held tester or OBD II scan tool to the DLC3. (2) Turn the ignition switch ON. (3) Check that the MIL is off. (4) Under CURRENT DATA, the throttle valve opening percentage (THROTTLE POS) should be within the standard value range below. Standard throttle valve opening percentage: 60 % or more If the percentage is less than 60 %, replace the throttle position sensor. NOTICE: When checking the standard throttle valve opening percentage, the transmission should be in the neutral position. 2. CHECK ACCELERATOR PEDAL POSITION SENSOR (a) Turn the ignition switch ON. Under CURRENT DATA, the voltage of the throttle position sensor should be within the standard value range below. Standard: 0.6 to 1.0 V If the result is not as specified, replace the accelerator pedal position sensor. 3. CHECK CAMSHAFT TIMING OIL CONTROL VALVE (OCV) ASSY (a) Connect the hand-held tester or OBD II scan tool to the DLC3. (b) Turn the ignition switch ON. (c) Start the engine and warm it up. (d) Select the VVT from the ACTIVE TEST menu. (e) Check the engine speed when the OCV is operated by the hand-held tester or OBD II scan tool. Standard: Condition Specified Condition VVT system is OFF (OCV is OFF) Normal engine speed VVT system is ON (OCV is ON) Rough idle or engine stalled If the result is not as specified, replace the OCV assy. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2370 10-16 ENGINE CONTROL SYSTEM - THROTTLE BODY ASSY (3MZ-FE) THROTTLE BODY ASSY (3MZ-FE) 100IU-03 COMPONENTS 80 (815, 59) x2 Spacer w/ Performance Rod: Front Suspension Upper Brace Center 7.9 (81, 70 in.⋅lbf) 80 (815, 59) x3 x2 V-Bank Cover Sub-assy Spacer Fuel Vapor Feed Hose Assy Vacuum Hose MAF Meter Connector Vacuum Hose Air Cleaner Cap Sub-assy Air Cleaner Filter Element Sub-assy N·m (kgf·cm, ft·lbf) : Specified torque A93427 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2374 10-17 ENGINE CONTROL SYSTEM - THROTTLE BODY ASSY (3MZ-FE)
Gasket Throttle Body Assy Throttle Control Motor & Throttle Position Sensor Connector Water By-pass Hose No. 2 11 (112, 8) Water By-pass Hose No. 3 N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part A82430 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2375 10-18 ENGINE CONTROL SYSTEM - THROTTLE BODY ASSY (3MZ-FE) 100IV-02 REPLACEMENT 1. 2. (a) DRAIN ENGINE COOLANT (See page 16-26 ) REMOVE FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER Remove the 2 nuts and upper brace. 3. (a) (b) REMOVE V-BANK COVER SUB-ASSY Using a socket hexagon wrench 5, remove the 3 nuts. Remove the V-bank cover. A88625 4. 5. REMOVE AIR CLEANER INLET ASSY (See page 14-149 ) REMOVE AIR CLEANER ASSY (See page 14-149 ) (b) (b) (c) 6. (a) (b) (c) REMOVE INTAKE AIR RESONATOR Remove the ventilation hose No. 2. Remove the fuel vapor feed hose from the 2 hose clamps. Loosen the air cleaner hose clamp bolt, and then remove the intake air resonator. 7. (a) (b) (c) REMOVE THROTTLE BODY ASSY Disconnect the throttle control motor & throttle position sensor connector. Disconnect the water by-pass hose No. 2. Disconnect the water by-pass hose No. 3. (d) (e) Remove the 2 bolts, 2 nuts and throttle body. Remove the gasket. (a) A81196 (a) (b) (c) A81197 A81198 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2376 10-19 ENGINE CONTROL SYSTEM 8. (a) (b) (c) (d) (e) 9. 10. 11. 12. 13. 14. 15. (a) (b) 16. (a) - THROTTLE BODY ASSY (3MZ-FE) INSTALL THROTTLE BODY ASSY Install a new gasket to the intake air connector. Install the throttle body with the 2 bolts and 2 nuts. Torque: 11 N⋅m (112 kgf⋅cm, 8 ft⋅lbf) Connect the water by-pass hose No. 3. Connect the water by-pass hose No. 2. Connect the throttle control motor & throttle position sensor connector. INSTALL INTAKE AIR RESONATOR INSTALL AIR CLEANER ASSY (See page 14-149 ) INSTALL AIR CLEANER INLET ASSY (See page 14-149 ) CHECK CONNECTION OF VACUUM HOSE (See page 14-149 ) ADD ENGINE COOLANT (See page 16-26 ) CHECK FOR ENGINE COOLANT LEAKS (See page 16-20 ) INSTALL V-BANK COVER SUB-ASSY Fit the 2 retainers and install the V-bank cover. Using a socket hexagon wrench 5, tighten the 3 nuts. Torque: 7.9 N⋅m (81 kgf⋅cm, 70 in.⋅lbf) INSTALL FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER Install the upper brace with the 2 nuts. Torque: 80 N⋅m (815 kgf⋅cm, 59 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2377 10-20 ENGINE CONTROL SYSTEM - KNOCK SENSOR (3MZ-FE) KNOCK SENSOR (3MZ-FE) 100FX-03 REPLACEMENT 1. 2. 3. 4. 5. 6. DISCHARGE FUEL SYSTEM PRESSURE (See page 11-35 ) DRAIN ENGINE COOLANT (See page 16-26 ) REMOVE V-BANK COVER SUB-ASSY (See page 14-149 ) REMOVE AIR CLEANER CAP SUB-ASSY (See page 14-149 ) REMOVE EMISSION CONTROL VALVE SET (See page 14-149 ) REMOVE INTAKE AIR SURGE TANK (See page 14-149 ) 7. (a) Pull Pinch Pinch REMOVE INTAKE MANIFOLD Disconnect the fuel pipe No. 1. (1) Remove the fuel pipe clamp. (2) Pinch the tube connector and pull out the fuel pipe No. 1. Fuel Pipe Clamp A81199 Nylon Tube Tube Connector O-ring Pipe A75650 NOTICE:
Check the connector for dirt, mud or other contamination. Clean if necessary.
Be sure to keep the tube connector, pipe and O-ring clean. They can become contaminated easily.
Do not use tools when disconnecting the fuel pipe.
Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
When the pipe and the connector are stuck, push and pull the connector to release it. Then pull the connector out carefully. (b) (c) Lock the hose clamp, as shown in the illustration. Disconnect the heater inlet water hose. (c) (b) A79759 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2378 10-21 ENGINE CONTROL SYSTEM (e) (d) (d) (e) (e) (e) (e) - KNOCK SENSOR (3MZ-FE) Remove the nut and disconnect the ground cable. Disconnect the 6 fuel injector connectors. (e) (e) A81200 (f) Loosen and remove the intake manifold’s 9 bolts and 2 nuts little by little in the numerical order shown in the illustration. (g) Remove the intake manifold. NOTICE: Fully removing each bolt and nut one by one may damage the intake manifold, bolts and nuts. 10 4 2 6 8 3 11 5 9 7 1 A81201 8. REMOVE ENGINE MOVING CONTROL ROD (See page 14-149 ) 9. (a) (a) REMOVE WATER OUTLET Disconnect the radiator hose inlet. A81202 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2379 10-22 ENGINE CONTROL SYSTEM (b) (c) (d) (e) (e) (b) - KNOCK SENSOR (3MZ-FE) (f) Disconnect the ECT sensor connector. Remove the clamp. Remove the 2 bolts, 2 nuts and 2 washers. Lock the hose clamp as shown in the illustration. Then remove the water outlet together with the water by-pass hose No. 1. Remove the 2 gaskets from the 2 cylinder heads. 10. (a) (b) REMOVE KNOCK SENSOR Disconnect the 2 sensor connectors. Remove the 2 nuts and 2 sensors. 11. (a) INSTALL KNOCK SENSOR Install the 2 sensors with the 2 nuts, as shown in the illustration. Torque: 20 N⋅m (199 kgf⋅cm, 14 ft⋅lbf) Connect the 2 sensor connectors. (c) A81203 A79749 Upper 0 to 5 (b) Engine Front A79750 12. (a) (b) (c) (d) (e) (f) 13. INSTALL WATER OUTLET Install 2 new gaskets to the 2 cylinder heads. Install the water outlet together with the water by-pass hose No. 1 and unlock the hose clamp. Tighten the 2 bolts, 2 nuts and 2 washers. Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf) Install the clamp. Connect the ECT sensor connector. Connect the radiator hose inlet. INSTALL ENGINE MOVING CONTROL ROD (See page 14-149 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2380 10-23 ENGINE CONTROL SYSTEM - KNOCK SENSOR (3MZ-FE) 14. (a) 2 8 10 6 4 9 1 5 INSTALL INTAKE MANIFOLD Tighten the intake manifolds’s 9 bolts and 2 nuts little by little in the numerical order shown in the illustration. Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf) NOTICE: In this case, fully tightening one of these bolts or nuts without partially tightening the other bolts or nuts in the group may damage the intake manifold, bolts and nuts. (b) Retighten the water outlet mounting bolts and nuts. Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf) (c) Install the ground cable with the nut. Torque: 8.4 N⋅m (86 kgf⋅cm, 74 in.⋅lbf) (d) Connect the heater inlet water hose. 7 3 11 A81201 (e) Push A81204 15. 16. 17. 18. 19. 20. 21. 22. Connect the fuel pipe No. 1. (1) Push the quick connector into the pipe until it makes ”click” sound. NOTICE:
Check if there is any damage or contamination on the connected part.
After connecting, confirm that the connector and pipe are securely connected by trying to pull them apart. (2) Install the fuel pipe clamp. INSTALL INTAKE AIR SURGE TANK (See page 14-149 ) INSTALL EMISSION CONTROL VALVE SET (See page 14-149 ) INSTALL AIR CLEANER CAP SUB-ASSY (See page 14-149 ) CHECK CONNECTION OF VACUUM HOSE (See page 14-149 ) ADD ENGINE COOLANT (See page 16-26 ) CHECK FOR ENGINE COOLANT LEAKS (See page 16-20 ) CHECK FOR FUEL LEAKS INSTALL V-BANK COVER SUB-ASSY (See page 14-149 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2381 10-24 ENGINE CONTROL SYSTEM - ECM (3MZ-FE) ECM (3MZ-FE) 100IW-02 REPLACEMENT 1. 2. 3. 4. 5. DISCONNECT BATTERY NEGATIVE TERMINAL REMOVE FRONT DOOR SCUFF PLATE RH (See page 71-10 ) REMOVE COWL SIDE TRIM SUB-ASSY RH (See page 71-10 ) REMOVE GLOVE COMPARTMENT DOOR ASSY (See page 71-10 ) REMOVE INSTRUMENT PANEL FINISH PANEL LOWER NO.2 (See page 71-10 ) 6. (a) (b) (c) REMOVE ECM Remove the 2 wire harness clamps. Disconnect the 5 ECM connectors. Remove the 2 nuts and ECM. 7. (a) REMOVE ECM BRACKET NO. 1 Remove the 2 screws and ECM bracket. 8. (a) 9. (a) REMOVE ECM BRACKET NO. 2 Remove the 2 screws and ECM bracket. INSTALL ECM BRACKET NO. 2 Install the ECM bracket with the 2 screws. 10. (a) INSTALL ECM BRACKET NO. 1 Install the ECM bracket with the 2 screws. I30545 A90275 A90283 A90275 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2382 10-25 ENGINE CONTROL SYSTEM 11. (a) (b) (c) - ECM (3MZ-FE) INSTALL ECM Install the 2 wire harness clamps. Connect the 5 ECM connectors. Install the ECM with the 2 nuts. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) I30545 12. 13. 14. 15. 16. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER NO.2 (See page 71-10 ) INSTALL GLOVE COMPARTMENT DOOR ASSY (See page 71-10 ) INSTALL COWL SIDE TRIM SUB-ASSY RH (See page 71-10 ) INSTALL FRONT DOOR SCUFF PLATE RH (See page 71-10 ) CONNECT BATTERY NEGATIVE TERMINAL 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2383 10-26 ENGINE CONTROL SYSTEM - ACCELERATOR PEDAL ROD ASSY (3MZ-FE) ACCELERATOR PEDAL ROD ASSY (3MZ-FE) 100MJ-01 REPLACEMENT 1. (a) (b) 2. (a) (b) REMOVE ACCELERATOR PEDAL ROD ASSY Disconnect the accelerator pedal position sensor connector. Remove the 2 bolts and pedal rod. INSTALL ACCELERATOR PEDAL ROD ASSY Install the pedal rod with the 2 bolts. Torque: 4.9 N⋅m (50 kgf⋅cm, 43 in.⋅lbf) Connect the accelerator pedal position sensor connector. A81214 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2384 10-1 1 ENGINE CONTROL SYSTEM - ACCELERATOR PEDAL ROD ASSY (2AZ-FE) ACCELERATOR PEDAL ROD ASSY (2AZ-FE) 100MI-01 REPLACEMENT 1. (a) (b) 2. (a) (b) REMOVE ACCELERATOR PEDAL ROD ASSY Disconnect the accelerator pedal position sensor connector. Remove the 2 bolts and pedal rod. INSTALL ACCELERATOR PEDAL ROD ASSY Install the pedal rod with the 2 bolts. Torque: 4.9 N⋅m (50 kgf⋅cm, 43 in.⋅lbf) Connect the acceleator pedal position sensor connector. A81214 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2369 11-7 FUEL - FUEL SYSTEM (2AZ-FE) 11024-07 INSPECTION 1. (a) INSPECT FUEL INJECTOR ASSY Check the injector resistance. (1) Measure the resistance between the terminals. Standard: 11.6 to 12.4 Ω at 20C (68F) If the result is not as specified, replace the injector. (b) Check the injector injection. CAUTION:
This test involves high-pressure fuel and electricity.
Take every precaution regarding safe handling of both the fuel and the electricity.
Perform this test in a safe area, and avoid any sparks or flame.
Do not smoke. (1) Fuel Tube Connector Purchase a new fuel tube and disconnect the fuel tube connector from its pipe. Fuel tube: Part No. 23801-20180 A50710 (2) Connect SST and fuel tube connector to the fuel pipe. SST 09268-41047 CAUTION: Always read the precautions (see page 11-1 ) before connecting the fuel tube connector (quick type). Fuel Tube Connector SST (Hose) B12947 (3) (4) Install the O-ring to the injector. Connect SST (union and hose) to the injector, and hold the injector and union with SST (clamp). SST 09268-41047 (09268-41110, 09268-41300) (5) Put the injector into a graduated cylinder. SST (Hose) SST (Union) O-Ring SST (Clamp) Vinyl Tube A51875 HINT: Install a suitable vinyl tube onto the injector to contain the gasoline spray. (6) Operate the fuel pump (see page 11-4 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2391 11-8 FUEL - FUEL SYSTEM (2AZ-FE) (7) (8) Connect SST to the connector of injector. Connect SST (wire) to the battery for 15 seconds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 time. SST 09842-30080 Standard: SST Item Specified Condition Injection Volume 76 to 92 cm3 (4.6 to 5.6 cu in.) per 15 seconds Difference Between Each Injector 16 cm3 (1.0 cu in.) or less A50700 NOTICE: Always turn on and off the voltage on the battery side, not the fuel pump side. If the injection volume is not as specified, replace the injector. (c) Check fuel leakage. (1) In the condition above, disconnect the test probes of SST (wire) from the battery and check the fuel leakage from the injector. Fuel drop: 1 drop or less per 12 minutes B00069 2. (a) (-) A16628 (+) A91308 INSPECT FUEL PUMP ASSY Check fuel pump resistance. (1) Measure the resistance between the terminals. Resistance: 0.2 to 3.0 Ω at 20C (68F) (b) Check fuel pump operation. (1) Apply battery voltage to both terminals. Check that the pump operates. NOTICE:
These tests must be done within 10 seconds to prevent the coil from burning out.
Keep the fuel pump as far away from the battery as possible.
Always turn on and off the voltage on the battery side, not the fuel pump side. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2392 11-4 FUEL - FUEL SYSTEM (2AZ-FE) ON-VEHICLE INSPECTION 1. (a) CHECK FUEL PUMP OPERATION AND FUEL LEAKS When using the hand-held tester: Check fuel pump operation. (1) Connect the hand-held tester to the DLC3. (2) Turn the ignition switch ON and push the hand-held tester main switch ON. NOTICE: Do not start the engine. (3) Select the ACTIVE TEST mode on the hand-held tester. (4) Please refer to the hand-held tester’s instruction manual for further details. (5) Turn the ignition switch OFF. (6) Disconnect the hand-held tester from the DLC3. 11023-07 (b) R/B Sub-assy FP +B ÇÇ ÇÇ Circuit Opening Relay A92782 When not using the hand-held tester: Check fuel pump operation. (1) Remove the circuit opening relay from the R/B subassy. (2) Using a service wire, connect terminals FP and +B of the R/B sub-assy. NOTICE: Pay close attention to the terminal connecting position to avoid a malfunction. (3) Turn the ignition switch ON and check that the fuel pump operates. NOTICE: Do not start the engine. (c) Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. (d) Turn the ignition switch OFF. (e) Remove the servive wire from the R/B sub-assy. (f) Install the circuit opening relay to the R/B sub-assy. 2. (a) (b) Fuel Tube Connector (c) CHECK FUEL PRESSURE Check that the battery positive voltage is above 12 V. Disconnect the negative (-) terminal cable from the battery. Purchase a new fuel tube and take out the fuel tube connector from its pipe. Fuel tube: Part No. 23801-20180 A50710 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2388 11-5 FUEL (d) Fuel Pipe Clamp No. 1 - FUEL SYSTEM (2AZ-FE) Remove the fuel pipe clamp No. 1 from the fuel tube connector. A60083 (e) Disconnect the fuel tube connector from the fuel pipe by pinching part A with fingers, as shown in the illustration. CAUTION:
Always read the precautions (see page 11-1 ) before disconnecting the fuel tube connector (quick type).
The fuel pipe line may spray fuel as a result of retained pressure that remains in it. Do not allow fuel to be sprayed in the engine compartment. A A B12941 (f) SST (Clip) SST SST (T-Joint) Fuel Tube SST (Hose) Fuel Tube Connector A93071 Install SST (pressure gauge) and fuel tube connecter using SST as shown in the illustration. SST 09268-41047, 09268-45014 (09268-41250) (g) Wipe up any gasoline. (h) Reconnect the negative (-) battery cable. (i) When using the hand-held tester: Operate the fuel pump (see step 1 (a)). (j) When not using the hand-held tester: Operate the fuel pump (see step 1 (b)). (k) Measure the fuel pressure. Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi) If the pressure is high, replace the fuel pressure regulator. If the pressure is low, check the fuel hoses and connections, fuel pump, fuel filter and fuel pressure regulator. (l) Start the engine. (m) Measure the fuel pressure at idle. Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi) (n) Stop the engine. (o) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/cm2, 21 psi) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. (p) After checking the fuel pressure, disconnect the negative (-) battery cable and carefully remove SST and fuel tube connector to prevent gasoline from spraying. (q) Reconnect the fuel inlet tube (fuel tube connector). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2389 11-6 FUEL - FUEL SYSTEM (2AZ-FE) CAUTION: Always read the precautions (see page 11-1 ) before connecting the fuel tube connector (quick type). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2390 11-1 FUEL - FUEL SYSTEM (2AZ-FE) FUEL SYSTEM (2AZ-FE) 110XE-03 PRECAUTION CAUTION:
Before working on the fuel system, disconnect the negative (-) terminal cable from the battery.
Do not smoke or be near an open flame when working on the fuel system.
Keep gasoline away from rubber or leather parts. 1. DISCHARGE FUEL SYSTEM PRESSURE CAUTION:
Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
Even after discharging the fuel pressure, place a shop rag over fittings as you separate them to reduce risk of fuel spray on yourself or in the engine compartment. (a) (b) R/B Sub-assy ÇÇ ÇÇ Circuit Opening Relay A93007 Remove the circuit opening relay from the R/B sub-assy. Start the engine. After the engine has stopped, turn the ignition switch OFF. HINT: There is a case that DTC P0171 (system to lean) is output. (c) Check that the engine does not start. (d) Remove the fuel tank cap, and let the air out of the fuel tank. (e) Reinstall the circuit opening relay. 2. (a) FUEL SYSTEM When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures. (1) Perform step 2 to prevent gasoline from spilling out. (2) Put a container under the connection. (3) Disconnect the fuel pump tube (see page 11-16 ). (4) Drain the fuel remained inside the fuel pump tube. (5) To protect the disconnected fuel pump tube from damage and contamination, cover it with a vinyl bag. B00679 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2385 11-2 FUEL New O-Ring CORRECT - FUEL SYSTEM (2AZ-FE) (b) Observe these precautions when removing and installing the injector. (1) Never reuse O-rings. (2) When placing a new O-ring on the injector, take care not to damage it. (3) Coat a new O-rings with grease or gasoline before installing. Never use engine, gear or brake oil. (c) Install the injector to the delivery pipe and cylinder head, as shown in the illustration. Before installing the injector, be sure to apply grease or gasoline on the place where the delivery pipe touches the O-ring of the injector. (d) Observe these precautions when disconnecting the fuel delivery pipe. Grommet Delivery Pipe Injector INCORRECT A94329 Delivery Pipe O-Ring Grommet A94330 O-ring Retainer Pipe HINT: The structure of the metallic connector is shown as left. (1) Remove the fuel pipe clamp No. 2. Nylon Tube Housing A50709 (2) Find the metallic connector of the fuel tube assembly, pull it out towards the rear and hold it as it is. (3) Assemble SST to the connection as shown. SST 09268-21010 SST A60818 (4) (5) Retainer (at 4 places) Turn SST, align the retainers inside the connector with SST chamfered parts and insert SST into the connector. Slide SST and the connector together towards the fuel tube assembly. B09615 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2386 11-3 FUEL (e) Fuel Pipe Clamp No.1 - FUEL SYSTEM (2AZ-FE) Observe these following precautions when disconnecting the fuel tube connector (quick type). (1) Remove the fuel pipe clamp No. 1. (2) Check for dirt or mud on the pipe and around the connector before disconnection. Clean if nesessary. A60083 (3) Disconnect the connector from the hose while pinching part A with fingers as shown in the illustration. (4) If the connector and the pipe are stuck, pinch the fuel pipe, push and pull the connector to disconnect and pull it out. Do not use any tools. Inspect for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary. A A B12941 (5) B12944 (6) Vinyl Bag To protect the disconnected pipe and connector from damage and contamination, cover it with a vinyl bag. A52581 3. (a) CHECK FUEL LEAK Check that there are no fuel leaks after doing maintenance anywhere on the fuel system (see page 11-4 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2387 11-9 FUEL - FUEL INJECTOR ASSY (2AZ-FE) FUEL INJECTOR ASSY (2AZ-FE) 1109L-05 COMPONENTS Fuel Vapor Feed Hose MAF Meter Connector VSV Connector for EVAP Engine Wire 20 (204, 15) Fuel Delivery Pipe 9.0 (92, 80 in.⋅lbf) Air Cleaner Cap w/ Air Cleaner Hose
O-ring Fuel Injector Assy
Insulator Engine Cover Sub-assy No. 1 Ventilation Hose No. 2 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part A93432 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2393 11-10 FUEL - FUEL INJECTOR ASSY (2AZ-FE) 11021-08 REPLACEMENT 1. 2. 3. 4. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See page 11-1 ) REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE REMOVE ENGINE COVER SUB-ASSY NO.1 DISCONNECT FUEL TUBE SUB-ASSY (See page 16-6 ) A93072 6. (a) 5. REMOVE FUEL DELIVERY PIPE W/INJECTOR NOTICE: Be careful not to drop the injectors when removing the delivery pipe. (a) Remove the ventilation hose No. 2. (b) Disconnect the 4 injector connecters from the injector. (c) Remove the 2 clamps and wire harnesses from the delivery pipe. (d) Remove the 2 bolts and the delivery pipe together with the 4 injectors. (e) Remove the 2 spacers from the cylinder head. REMOVE FUEL INJECTOR ASSY Pull out the 4 injectors from the delivery pipe. 7. (a) (b) Insulator O-Ring INSTALL FUEL INJECTOR ASSY Install a new insulator to each injector. Apply a light coat of grease or gasoline to a new O-ring and install to each injector. A50145 (c) Push Turn Connector B09635 Apply a light coat of grease or gasoline on the place where a delivery pipe touches the O-ring. (d) To install the fuel injector into the fuel delivery pipe, push the fuel injector while twisting it back and forth. (e) Install the 4 injectors. NOTICE:
Be careful not to twist the O-ring.
After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O-ring. (f) Position the injector connector downward. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2394 11-1 1 FUEL 8. (a) (b) Spacer - FUEL INJECTOR ASSY (2AZ-FE) INSTALL FUEL DELIVERY PIPE W/INJECTOR Place the 2 spacers in position on the cylinder head. Place the delivery pipe together with the 4 injectors in position on the cylinder head. B09636 (c) A93072 9. 10. 11. 12. Temporarily install the 2 bolts holding the delivery pipe to the cylinder. NOTICE: After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O-ring. (d) Position the injector connector outward. (e) Tighten the 2 bolts holding the delivery pipe to the cylinder head. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) CONNECT FUEL TUBE SUB-ASSY INSPECT FOR FUEL LEAKS (See page 11-4 ) INSTALL ENGINE COVER SUB-ASSY NO.1 (See page 14-24 ) INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE (See page 14-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2395 11-12 FUEL - FUEL PUMP ASSY (2AZ-FE) FUEL PUMP ASSY (2AZ-FE) 1111T-01 COMPONENTS w/ Rear No. 2 Seat Deck Board Rear Seat Assy RH Seat Track Bracket Cover Inner Rear Seat Assy LH Rear Seat Track Bracket Cover Outer x2 x4 37 (375, 27) Seat Track Bracket Cover Inner Rear Seat Track Bracket Cover Outer x4 37 (375, 27) Rear Door Scuff Plate LH N·m (kgf·cm, ft·lbf) : Specified torque A92780 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2396 11-13 FUEL - FUEL PUMP ASSY (2AZ-FE) w/o Rear No. 2 Seat Deck Board x5 Clip 9.0 (92, 80 in.⋅lbf) 9.0 (92, 80 in.⋅lbf) x 3 Clip Rear Seat Assy RH Rear Seat Assy LH Rear Seat Track Bracket Cover Outer x2 x4 37 (375, 27) Rear Seat Track Bracket Cover Outer x4 x2 37 (375, 27) Rear Door Scuff Plate LH N·m (kgf·cm, ft·lbf) : Specified torque A92781 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2397 11-14 FUEL - FUEL PUMP ASSY (2AZ-FE) Rear Floor Service Hole Cover Fuel Pump & Sender Gage Connector Fuel Pump Tube Tube Joint Clip
Fuel Pump Gage Retainer Fuel Suction Tube Assy w/ Pump & Gage
Fuel Suction Tube Gasket
Non-reusable part A92785 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2398 11-15 FUEL - FUEL PUMP ASSY (2AZ-FE) Fuel Suction Plate Sub-assy Fuel Pump Harness
O-Ring Fuel Pump Spacer Clip Fuel Pump
O-Ring Fuel Tube Joint No. 1 Fuel Pressure Regulator Assy Fuel Filter Assy
O-Ring
O-Ring
Clip Fuel Suction Support No. 1 Fuel Sender Gage Assy
Non-reusable part A81632 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2399 11-16 FUEL - FUEL PUMP ASSY (2AZ-FE) 1111U-01 REPLACEMENT 1. DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1 ) 2. (a) REMOVE DECK BOARD SUB-ASSY Disengage the 5 clips and turn up the front side of the deck board. B51632 3. 4. 5. 6. REMOVE REAR SEAT TRACK BRACKET COVER OUTER REMOVE REAR SEAT ASSY RH (See page 72-35 ) REMOVE REAR SEAT ASSY LH (See page 72-28 ) REMOVE REAR DOOR SCUFF PLATE LH 7. (a) (b) REMOVE REAR FLOOR SERVICE HOLE COVER Remove the rear floor service hole cover. Disconnect the fuel pump & sender gage connector. 8. REMOVE FUEL SUCTION TUBE ASSY W/ PUMP & GAGE Disconnect the fuel pump tube. (1) Remove the tube joint clip, and pull out the fuel pump tube. A81633 Tube Joint Clip (a) A81634 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2400 11-17 FUEL Nylon Tube Fuel Tube Joint O-Ring Tube Joint Clip Fuel Suction Plate A81635 - FUEL PUMP ASSY (2AZ-FE) NOTICE:
Before this operation, check the connector for dirt, mud or other contamination. Clean if necessary.
Be careful of mud. The connector’s O-ring, which seals the pipe and connector, becomes contaminated easily.
Do not use any tool in this operation.
Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
When the pipe and connector are stuck, push and pull the connector to release and pull the connector out carefully. (b) SST Rib A81636 Using SST, loosen the fuel pump gage retainer. SST 09808- 14020 (09808- 01410, 09808- 01420, 09808-01430) NOTICE: Loosen the retainer by turning it counterclockwise while holding the SST down. Do not allow the claw of the tank suction tube support to slip out of its groove on the fuel tank. HINT: A rib on the fuel pump gage retainer can be fitted into a tip of the SST. (c) Remove the fuel pump gage retainer. (d) Remove the fuel suction tube. NOTICE: Be careful not to bend the arm of the fuel sender gage. (e) Remove the gasket from the fuel tank. A80531 9. (a) (b) Unlock REMOVE FUEL SENDER GAGE ASSY Disconnect the fuel sender gage connector. Unlock the fuel sender gage and slide it to remove. (a) Slide A79768 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2401 11-18 FUEL REMOVE FUEL SUCTION PLATE SUB-ASSY Using a screwdriver with the tip wrapped in tape, disconnect the 4 snap-claws from the claw holes and remove the fuel suction plate. NOTICE: Do not damage the fuel suction plate and fuel suction support No. 1. A82448 11. (a) (b) Tape (a) FUEL PUMP ASSY (2AZ-FE) 10. (a) Tape 4 Claws - 2 Claws A82449 REMOVE FUEL PUMP ASSY Disconnect the fuel pump connector. Using a small screwdriver with its tip wrapped in tape, disconnect the 2 snap-claws from the claw holes and pull out the fuel pump. NOTICE: Do not damage the fuel pump and fuel suction plate. (c) Remove the O-ring and fuel pump spacer from the fuel pump. 12. (a) (b) REMOVE FUEL PUMP FILTER Using a small screwdriver, pry out the clip. Remove the fuel filter from the fuel pump. A79771 13. (a) (b) REMOVE FUEL TUBE JOINT NO.1 Disconnect the connector. Using a screwdriver with its tip wrapped in tape, disconnect the snap-claw from the claw hole and pull out the fuel tube joint. NOTICE: Do not damage the fuel tube joint and fuel suction plate. Tape (a) Claw A82453 14. (a) REMOVE FUEL PUMP HARNESS Remove the harness from the fuel tube joint No. 1. A79773 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2402 11-19 FUEL 15. (a) (b) Clip (c) - FUEL PUMP ASSY (2AZ-FE) REMOVE FUEL PRESSURE REGULATOR ASSY Remove the clip. Pull out the pressure regulator from the fuel tube joint No. 1. Remove the 2 O-rings from the fuel tube joint No. 1. A79774 16. (a) New O-Ring (b) (c) INSTALL FUEL PRESSURE REGULATOR ASSY Apply a light coat of gasoline or spindle oil to the 2 new O-rings, and install them to the fuel pressure regulator. Apply a light coat of gasoline or spindle oil to the 2 O-rings again, and install the fuel pressure regulator to the fuel tube joint No. 1. Install the clip. A79775 17. INSTALL FUEL PUMP HARNESS 18. (a) New O-Ring (b) (c) INSTALL FUEL TUBE JOINT NO.1 Apply a light coat of gasoline or spindle oil to a new Oring, and install it to the fuel tube joint No. 1. Apply a light coat of gasoline or spindle oil to the O-ring again, and install the fuel tube joint No. 1 to the fuel suction plate. Connect the connector. A79776 19. (a) INSTALL FUEL PUMP FILTER Install the fuel filter with a new clip. 20. (a) (b) New O-Ring (c) Fuel Pump Spacer (d) INSTALL FUEL PUMP ASSY Install the fuel pump spacer to the fuel pump. Apply a light coat of gasoline or spindle oil to a new Oring, and install it to the fuel pump. Apply a light coat of gasoline or spindle oil to a the O-ring again, and install the fuel pump to the fuel suction plate. Connect the fuel pump connector. A81604 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2403 11-20 FUEL 21. (a) New O-Ring (b) - FUEL PUMP ASSY (2AZ-FE) INSTALL FUEL SUCTION PLATE SUB-ASSY Apply a light coat of gasoline or spindle oil to a new Oring, and install it to the fuel tube joint No. 1. Apply a light coat of gasoline or spindle oil to the O-ring again, and install the fuel suction plate to the fuel suction support No. 1. A79777 22. INSTALL FUEL SENDER GAGE ASSY Keyway Key A81637 ”S” Mark 23. INSTALL FUEL SUCTION TUBE ASSY W/ PUMP & GAGE (a) Install a new gasket to the fuel tank. (b) Attach the fuel suction tube to the fuel tank. NOTICE: Be careful not to bend the arm of the fuel sender gage. (c) Align the keyway of the fuel suction tube support with the key of the fuel suction tube. (d) Apply MP grease to the entire interior surface of the fuel pump gage retainer. (e) Align the triangle mark on new fuel pump gage retainer with the ”S” mark on the fuel tank while pushing down the fuel suction tube, attach the fuel pump gage retainer. Triangle Mark A82455 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2404 11-21 FUEL - FUEL PUMP ASSY (2AZ-FE) (f) Rotate the fuel pump gage retainer by hand, then tighten it one complete turn and half using SST. Triangle mark on the fuel pump gage retainer must be positioned between ”A” and ”MAX.” indications on the fuel tank. SST 09808- 14020 (09808- 01410, 09808- 01420, 09808-01430) NOTICE: Do not use other tools in this operation. Damage to the fuel pump gage retainer and the fuel tank may result. HINT: A rib on the fuel pump gage retainer can be fitted into a tip of the SST. SST Rib Triangle Mark ”A” Mark ”MAX.” Mark A93073 (g) 24. Connect the fuel pump tube. (1) Install the fuel pump tube and the tube joint clip. NOTICE:
Check that there are no scratches or foreign objects on the connecting part. Collar
Check that the fuel tube joint is inserted securely.
Check that the tube joint clip is on the collar of the fuel tube joint. Tube Joint Clip
After installing the tube joint clip, check that the fuel A81640 tube joint has not been pulled off. CHECK FOR FUEL LEAKS (See page 11-4 ) 25. (a) (b) (c) INSTALL REAR FLOOR SERVICE HOLE COVER Install a new butyl tape to the rear floor service hole cover. Connect the fuel pump & sender gage connector. Install the rear floor service hole cover. New Butyl Tape A81633 26. 27. 28. 29. 30. INSTALL REAR DOOR SCUFF PLATE LH INSTALL REAR SEAT ASSY LH (See page 72-28 ) INSTALL REAR SEAT ASSY RH (See page 72-35 ) INSTALL REAR SEAT TRACK BRACKET COVER OUTER INSTALL DECK BOARD SUB-ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2405 11-22 FUEL - FUEL TANK ASSY (2AZ-FE) FUEL TANK ASSY (2AZ-FE) 1111V-01 COMPONENTS w/ Rear No. 2 Seat Deck Board Rear Seat Assy RH Rear Seat Assy LH Rear Seat Track Bracket Cover Outer x2 x4 37 (375, 27) Rear Seat Track Bracket Cover Outer x4 37 (375, 27) Rear Door Scuff Plate LH N·m (kgf·cm, ft·lbf) : Specified torque A92780 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2406 11-23 FUEL - FUEL TANK ASSY (2AZ-FE) w/o Rear No. 2 Seat: Deck Board x5 Clip 9.0 (92, 80 in.⋅lbf) 9.0 (92, 80 in.⋅lbf) x3 Clip Rear Seat Assy RH Rear Seat Assy LH Rear Seat Track Bracket Cover Outer x2 x4 37 (375, 27) Rear Seat Track Bracket Cover Outer x4 x2 37 (375, 27) Rear Door Scuff Plate LH N·m (kgf·cm, ft·lbf) : Specified torque A92781 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2407 11-24 FUEL - FUEL TANK ASSY (2AZ-FE) Rear Floor Service Hole Cover Fuel Pump &Sender Gage Connector Fuel Pump Tube Tube Joint Clip
Fuel Pump Gage Retainer Fuel Suction Tube Assy w/ Pump & Gage
Fuel Suction Tube Gasket
Non-reusable part A92785 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2408 11-25 FUEL - FUEL TANK ASSY (2AZ-FE) Front Floor Heat Insulator No. 3 4.9 (50, 43 in.⋅lbf) x4
Exhaust Pipe Gasket Center Exhaust Pipe Assy Center x2 Compression Spring 48 (490, 35) 4WD Type: Exhaust Pipe Support Bracket No. 4
Exhaust Pipe Gasket 22 (224, 16) x2 x2 Washer x4 48 (490, 35) Compression Spring 74 (750, 55) Washer 37 (375, 27) x4 4WD Type: Propeller w/ Center Bearing Shaft Assy N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part A93064 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2409 11-26 FUEL - FUEL TANK ASSY (2AZ-FE) Fuel Tank Assy Fuel Tube Protector No. 1 x2 20 (200, 14) x2 Clip x2 39 (400, 29) Fuel Tank Band Sub-assy RH x2 39 (400, 29) Fuel Tank Band Sub-assy LH Fuel Tank Protector Sub-assy No. 1
Clip x3 x6 5.5 (56, 49 in.⋅lbf) Fuel Tank Protector No. 1 x4 5.5 (56, 49 in.⋅lbf) N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part A94218 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2410 11-27 FUEL - FUEL TANK ASSY (2AZ-FE)
Tank Suction Tube Support Fuel Pump Tube Sub-assy Fuel Tank Vent Hose Fuel Tank Cushion Set 30 (306, 22) Fuel Tank Side Plate x2 Fuel Tank to Filler Pipe Hose Fuel Tank Assy Fuel Tank Cushion No. 5 Fuel Tank Bracket N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part A94219 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2411 11-28 FUEL - FUEL TANK ASSY (2AZ-FE) 110UL-02 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. DISCHARGE FUEL SYSTEM PRESSURE (See page 11-1 ) REMOVE DECK BOARD SUB-ASSY REMOVE REAR SEAT TRACK BRACKET COVER OUTER REMOVE REAR SEAT ASSY RH (See page 72-35 ) REMOVE REAR SEAT ASSY LH (See page 72-28 ) REMOVE REAR DOOR SCUFF PLATE LH REMOVE REAR FLOOR SERVICE HOLE COVER (See page 11-16 ) REMOVE FUEL SUCTION TUBE ASSY W/ PUMP & GAGE (See page 11-16 ) DRAIN FUEL REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY (4WD TYPE) (See page 30-4 ) REMOVE EXHAUST PIPE ASSY CENTER (See page 15-2 ) REMOVE FRONT FLOOR HEAT INSULATOR NO.3 (See page 12-1 1) 13. (a) REMOVE EXHAUST PIPE SUPPORT BRACKET NO.4 (4WD TYPE) Remove the 2 bolts and support bracket. A80549 14. (a) REMOVE FUEL TUBE PROTECTOR NO.1 Remove the 2 clips and unfasten the claw, and remove the tube protector. 15. (a) REMOVE FUEL TANK PROTECTOR NO.1 Remove the 4 nuts and tank protector. A80550 A80551 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2412 11-29 FUEL
1 - FUEL TANK ASSY (2AZ-FE) 16. (a) REMOVE FUEL TANK PROTECTOR SUB-ASSY NO.1 Remove the 3 clips (
1), 6 nuts and tank protector. 17. (a) REMOVE FUEL TANK ASSY Disconnect the fuel pump tube. (1) Pinch the projection of the retainer to remove the lock claws and pull down it as shown in the illustration. (2) Pull out the fuel pump tube.
1
1
1 A81225 (1) (1) (2) (1) Retainer A81688 Quick Connector Retainer Nylon Tube O-ring Pipe A81689 NOTICE:  Before this operation, check the connector for dirt, mud or other contamination. Clean if necessary.  Be careful of mud. The connector’s O-ring, which seals the pipe and connector, becomes contaminated easily.  Do not use any tool in this operation.  Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.  When the pipe and connector are stuck, push and pull the connector to release it. Then pull out the connector from the pipe. (b) A (1) (2) (2) Disconnect the fuel tank vent hose. (1) Push the connector deep into the charcoal canister to release the locking tab. (2) Pinch portion A. (3) Pull out the connector. A A81211 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2413 11-30 FUEL (c) (2) (2) - FUEL TANK ASSY (2AZ-FE) Disconnect the fuel tank breather tube No. 3. (1) Lower the connector checker slightly. (2) Pinch the tube connector. (3) Pull out the breather tube. (3) (1) A93428 Nylon Tube Tube Connector Pipe O-Ring Checker B79934 NOTICE:  Before this operation, check the connector for dirt, mud or other contamination. Clean if necessary.  Be careful of mud. The connector’s O-ring, which seals the pipe and connector, becomes contaminated easily.  Do not use any tool in this operation.  Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.  When the pipe and connector are stuck, push and pull the connector to release it. Then pull out the connector from the pipe. (d) Loosen the hose clamp bolt and disconnect the fuel tank to filler pipe hose. A93430 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2414 11-31 FUEL (e) (f) (g) (h) - FUEL TANK ASSY (2AZ-FE) Set up a transmission jack under the fuel tank. Remove the 4 bolts and 2 fuel tank bands. Remove the 2 nuts. Operate the transmission jack and remove the fuel tank. (f) (f) (g) (f) (f) (g) A94220 : 2 Claws 18. (a) REMOVE FUEL PUMP TUBE SUB-ASSY Unfasten the 2 claws and remove the tube. 19. (a) REMOVE FUEL TANK TO FILLER PIPE HOSE Loosen the hose clamp bolt and remove the hose. A81690 A81221 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2415 11-32 FUEL 20. (a) (a) A (b) - FUEL TANK ASSY (2AZ-FE) (b) (c) (d) REMOVE FUEL TANK VENT HOSE Push the connector deep into the charcolal canister to release the locking tab. Pinch portion A. Pull out the connector. Unfasten the claw and remove the vent hose. 21. (a) REMOVE TANK SUCTION TUBE SUPPORT Remove the tube support from the fuel tank. 22. (a) REMOVE FUEL TANK SIDE PLATE Remove the bolt and nut side plate and tank bracket. 23. (a) REMOVE FUEL TANK CUSHION SET Remove the cushion set and cushion No. 5. (b) : Claw A A81224 A80561 Side Plate Tank Bracket A82407 Cushion Set Cushion No. 5 A82470 24. 25. INSTALL FUEL TANK CUSHION SET INSTALL FUEL TANK SIDE PLATE Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2416 11-33 FUEL 26. (a) - FUEL TANK ASSY (2AZ-FE) INSTALL TANK SUCTION TUBE SUPPORT Install a new tube support as shown in the illustration. A82408 27. 28. 29. INSTALL FUEL TANK VENT HOSE INSTALL FUEL TANK TO FILLER PIPE HOSE INSTALL FUEL PUMP TUBE SUB-ASSY 30. INSTALL FUEL TANK ASSY (a) Set up the fuel tank to the transmission jack. (b) Operate the transmission jack and the install the fuel tank. (c) Tighten the 2 nuts. Torque: 20 N⋅m (200 kgf⋅cm, 14 ft⋅lbf) (d) Install the 2 fuel tank bands with the 4 bolts. Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) (e) Install the connector clamp. (f) Connect the fuel tank wire connector. (g) Connect the fuel tank to filler pipe hose. (h) (1) (2) A94322 Connect the fuel tank breather tube No. 3. (1) Push the quick connector to the pipe until it makes ”click” sound. NOTICE:  Check if there is any damage or foreign objects on the connected part.  After connecting, check if the quick connector and the pipe are securely connected by trying to pull them apart. (2) Return the connecter checker to its original position. (i) Connect the fuel tank vent hose. (j) (1) (2) Retainer A82411 Connect the fuel pump tube. (1) Push the quick connector in the direction of the white arrow. NOTICE:  Check if there is any damage or foreign objects on the connected part.  After connecting, check if the quick connector and the pipe are securely connected by pulling on them. (2) Push up on the retainer until the claws lock. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2417 11-34 FUEL 31. (a) (b) 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. - FUEL TANK ASSY (2AZ-FE) INSTALL FUEL TANK PROTECTOR SUB-ASSY NO.1 Install the tank protector with the 6 nuts. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) Install 3 new clips. INSTALL FUEL TANK PROTECTOR NO.1 Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) INSTALL FUEL TUBE PROTECTOR NO.1 INSTALL EXHAUST PIPE SUPPORT BRACKET NO.4 (4WD TYPE) Torque: 22 N⋅m (224 kgf⋅cm, 16 ft⋅lbf) INSTALL FRONT FLOOR HEAT INSULATOR NO.3 (See page 12-1 1) INSTALL EXHAUST PIPE ASSY CENTER (See page 15-2 ) ADD FUEL INSTALL FUEL SUCTION TUBE ASSY W/ PUMP & GAGE (See page 11-16 ) CHECK FOR FUEL LEAKS (See page 11-4 ) CHECK FOR EXHAUST GAS LEAKS INSTALL REAR FLOOR SERVICE HOLE COVER (See page 11-16 ) INSTALL REAR DOOR SCUFF PLATE LH INSTALL REAR SEAT ASSY LH (See page 72-28 ) INSTALL REAR SEAT ASSY RH (See page 72-35 ) INSTALL REAR SEAT TRACK BRACKET COVER OUTER INSTALL DECK BOARD SUB-ASSY INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY (4WD TYPE) (See page 30-12 ) FULLY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSY (4WD TYPE) (See page 30-12 ) ADD TRANSFER OIL (4WD TYPE) (See page 31-4 ) INSPECT TRANSFER OIL (4WD TYPE) (See page 31-4 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2418 11-41 FUEL - FUEL SYSTEM (3MZ-FE) 110UO-04 INSPECTION 1. (a) INSPECT FUEL INJECTOR ASSY Check the injector resistance. (1) Measure the resistance between the terminals. Standard: 13.4 to 14.2 Ω at 20C (68F) If the result is not as specified, replace the injector. (b) Check the injector injection. CAUTION:
This test involves high-pressure fuel and electricity.
Take every precaution regarding safe handling of both the fuel and the electricity.
Perform this test in a safe area, and avoid any sparks or flame.
Do not smoke. (1) Fuel Tube Connector Purchase a new fuel tube and disconnect fuel tube connector from its pipe. Fuel tube: Parts No. 23801-20180 A50710 (2) Connect SST and the fuel tube connector to the fuel pipe. SST 09268-41047 CAUTION: Always read the precautions (see page 11-35 ) before connecting the fuel tube connector (quick type). Fuel Tube Connector SST (Hose) B12947 (3) (4) Install the O-ring to the injector. Connect SST (union and hose) to the injector, and hold the injector and union with SST (clamp). SST 09268-41047 (09268-41110, 09268-41300) (5) Put the injector into a graduated cylinder. SST (Hose) SST (Union) O-Ring SST (Clamp) Vinyl Tube A94173 HINT: Install a suitable vinyl tube onto the injector to contain the gasoline spray. (6) Operate the fuel pump (see page 11-38 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2425 11-42 FUEL - FUEL SYSTEM (3MZ-FE) (7) (8) Connect SST to the connector of injector Connect SST (wire) to the battery for 15 seconds, and measure the injector volume with a graduated cylinder. Test each injector 2or 3 time. SST 09842-30070 Standard: Item Specified Condition Injection Volume 60 to 73 cm3 (3.7 to 4.5 cu in.) per 15 seconds Difference Between Each Injector 13 cm3 (0.8 cu in.) or less A94174 NOTICE: Always turn on and off the voltage on the battery side, not the fuel pump side. If the injection volume is not as specified, replace the injector. (c) Check fuel leakage. (1) In the condition above, disconnect the test probes of SST (wire) from the battery and check the fuel leakage from the injector. Fuel drop: 1 drop or less per 12 minutes B00069 2. (a) (-) A16628 (+) A91308 INSPECT FUEL PUMP Check the fuel pump resistance. (1) Measure the resistance between the terminals. Standard: 0.2 to 3.0 Ω at 20C (68F) (b) Check fuel pump operation. (1) Apply battery voltage to both terminals. Check that the pump operates. NOTICE:
These tests must be done within 10 seconds to prevent the coil from burning out.
Keep the fuel pump as far away from the battery as possible.
Always turn on and off the voltage on the battery side, not the fuel pump side. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2426 11-38 FUEL - FUEL SYSTEM (3MZ-FE) 110UN-04 ON-VEHICLE INSPECTION 1. (a) CHECK FUEL PUMP OPERATION AND FUEL LEAKS When using the hand-held tester: Check fuel pump operation. (1) Connect the hand-held tester to the DLC3. (2) Turn the ignition switch ON and push the hand-held tester main switch ON. NOTICE: Do not start the engine. (3) Select the ACTIVE TEST mode on the hand-held tester. (4) Please refer to the hand-held tester’s instruction manual for further details. (5) Turn the ignition switch OFF. (6) Disconnect the hand-held tester from the DLC3. (b) FP +B ÇÇ ÇÇ Circuit Opening Relay A92782 When not using the hand-held tester: Check fuel pump operation. (1) Remove the circuit opening relay from the R/B subassy. (2) Using a service wire, connect terminals FP and +B of the R/B sub-assy. NOTICE: Pay close attention to the terminal connecting position to avoid a malfunction. (3) Turn the ignition switch ON and check that the fuel pump operates. NOTICE: Do not start the engine. (c) Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. (d) Turn the ignition switch OFF. (e) Remove the servive wire from the R/B sub-assy. (f) Install the circuit opening relay to the R/B sub-assy. 2. (a) (b) Fuel Tube Connector (c) CHECK FUEL PRESSURE Check that the battery positive voltage is above 12 V. Disconnect the negative (-) terminal cable from the battery. Purchase a new fuel tube and take out the fuel tube connector from its pipe. Fuel tube: Part No. 23801-20180 A50710 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2422 11-39 FUEL (d) Fuel Pipe Clamp No. 1 - FUEL SYSTEM (3MZ-FE) Remove the fuel pipe clamp No. 1 from the fuel tube connector. A60083 (e) Disconnect the fuel tube connector from the fuel pipe by pinching part A with fingers, as shown in the illustration. CAUTION:
Always read the precautions (see page 11-35 ) before disconnecting the fuel tube connector (quick type).
The fuel pipe line may spray fuel as a result of retained pressure that remains in it. Do not allow fuel to be sprayed in the engine compartment. A A B12941 (f) SST (Clip) SST SST (T-Joint) Fuel Tube SST (Hose) Fuel Tube Connector A93071 Install SST (pressure gauge) and fuel tube connecter using SST as shown in the illustration. SST 09268-41047, 09268-45014 (09268-41250) (g) Wipe up any gasoline. (h) Reconnect the negative (-) battery cable. (i) When using the hand-held tester: Operate the fuel pump (see step 1 (a)). (j) When not using the hand-held tester: Operate the fuel pump (see step 1 (b)). (k) Measure the fuel pressure. Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi) If the pressure is high, replace the fuel pressure regulator. If the pressure is low, check the fuel hoses and connections, fuel pump, fuel filter and fuel pressure regulator. (l) Start the engine. (m) Measure the fuel pressure at idle. Fuel pressure: 304 to 343 kPa (3.1 to 3.5 kgf/cm2, 44 to 50 psi) (n) Stop the engine. (o) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/cm2, 21 psi) If the pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. (p) After checking the fuel pressure, disconnect the negative (-) battery cable and carefully remove SST and fuel tube connector to prevent gasoline from spraying. (q) Reconnect the fuel inlet tube (fuel tube connector). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2423 11-40 FUEL - FUEL SYSTEM (3MZ-FE) CAUTION: Always read the precautions (see page 11-35 ) before connecting the fuel tube connector (quick type). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2424 11-35 FUEL - FUEL SYSTEM (3MZ-FE) FUEL SYSTEM (3MZ-FE) 110UM-04 PRECAUTION CAUTION:
Before working on the fuel system, disconnect the negative (-) terminal cable from the battery.
Do not smoke or be near an open flame when working on the fuel system.
Keep gasoline away from rubber or leather parts. 1. DISCHARGE FUEL SYSTEM PRESSURE CAUTION:
Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
Even after discharging the fuel pressure, place a shop rag over fittings as you separate them to reduce risk of fuel spray on yourself or in the engine compartment. R/B Sub-assy Circuit Opening Relay ÇÇ ÇÇ A93007 (a) (b) Remove the circuit opening relay from the R/B sub-assy. Start the engine. After the engine has stopped, turn the ignition switch OFF. HINT: There is a case that DTC P0171 (system to lean) is output. (c) Check that the engine does not start. (d) Remove the fuel tank cap, and allow the air out of the fuel tank. (e) Reinstall the circuit opening relay. 2. (a) FUEL SYSTEM When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures. (1) Perform the step 2 to prevent gasoline from spilling out. (2) Put a container under the connection. (3) Disconnect the fuel pump tube (see page 11-55 ). (4) Drain the fuel remaining inside the fuel pump tube. (5) To protect the disconnected fuel pump tube from damage and contamination, cover it with a vinyl bag. B00679 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2419 11-36 FUEL New O-Ring CORRECT - FUEL SYSTEM (3MZ-FE) (b) Observe the following precautions when removing and installing the fuel injectors. (1) Never reuse O-rings. (2) When installing a new O-ring on the injector, be careful not to damage it. (3) Coat new O-rings with grease or gasoline before installing. Never use engine oil, gear oil or brake oil. (c) Install the injector to the delivery pipe and cylinder head, as shown in the illustration. Before installing the injector, be sure to apply grease or gasoline on the place where the delivery pipe touches the O-ring of the injector. (d) Observe these precautions when disconnecting the fuel tube connectors. (1) Remove the fuel pipe clamp from the connector. (2) Check for dirt or mud on the pipe and around the connector before disconnection. Clean if necessary. Grommet Delivery Pipe Injector INCORRECT A94329 Delilvery Pipe O-Ring Grommet Spacer Insulator A62371 Fuel Pipe Clamp No. 1 A60083 (3) Disconnect the connector from the hose while pinching part A with fingers, as shown in the illustration. (4) If the connector and the pipe are stuck, pinch the fuel pipe, push and pull the connector to disconnect it and pull it out. Do not use any tools. If dirt or any other substance is found on the sealing surface that might interfere with the seal, clean the area thoroughly before assembly. A A B12941 (5) B12944 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2420 11-37 FUEL - (6) Vinyl or Plastic Bag FUEL SYSTEM (3MZ-FE) To protect the disconnected pipe and connector from damage and contamination, cover it with a vinyl bag. A79119 (e) Push A71366 Observe these precautions when connecting the fuel tube connector. (1) Check that there is no damage or contamination in the connected part of the pipe. (2) Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a ”click” sound. If the connection is tight, apply little amount of fresh engine oil on the tip of the pipe. (3) (4) (5) Pull After having finished the connection, check if the pipe and the connector are securely connected by trying to pull them apart. Install the fuel pipe clamp to the connector. Check if there is any fuel leakage. A71366 3. (a) CHECK FOR FUEL LEAKS Check that there are no fuel leaks after doing maintenance anywhere on the fuel system (see page 11-38 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2421 11-43 FUEL - FUEL INJECTOR ASSY (3MZ-FE) FUEL INJECTOR ASSY (3MZ-FE) 110XH-02 COMPONENTS 7.9 (81, 70 in.⋅lbf) x3 V-Bank Cover Sub-assy Fuel Vapor Feed Hose Assy Vacuum Hose MAF Meter Connector Vacuum Hose Air Cleaner Cap Sub-assy Air Cleaner Filter Element Sub-assy N·m (kgf·cm, ft·lbf) : Specified torque A93429 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2427 11-44 FUEL - FUEL INJECTOR ASSY (3MZ-FE) VSV Connector 7.8 (80, 69 in.⋅lbf) 8.0 (82, 71 in.⋅lbf) x3 Pressure Feed Tube Assy x2 Fuel Vapor Feed Hose Emission Control Valve Set 28 (286, 21) 20 (204, 15) x3 20 (204, 15) x2 x2 x2 Emission Control Valve Bracket Surge Tank Stay x2 No. 1 Engine Hanger No. 1 20 (204, 15) Intake Air Surge Tank Surge Tank Stay No. 2 Union to Check Valve Hose Throttle Motor Connector
Gasket Water By-pass Hose No. 3 Water By-pass Hose No. 2 N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part A81592 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2428 11-45 FUEL
Fuel Injector O-ring
Fuel Injector Grommet - FUEL INJECTOR ASSY (3MZ-FE) 10 (102, 7) Fuel Injector Assy Fuel Injector Connector Fuel Delivery Pipe Sub-assy
Injector Vibration Insulator Delivery Pipe No. 1 Spacer 10 (102, 7) Fuel Delivery Pipe No. 2 20 (204, 15)
Fuel Pump Hose Gasket Fuel Pressure Pulsation Damper Assy
Injector Vibration Insulator 33 (337, 24) Fuel Pipe Sub-assy No. 1
Fuel Pipe No. 2 Gasket 33 (337, 24) Fuel Injector Connector Delivery Pipe No. 1 Spacer Fuel Pipe No. 2 Union Bolt N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part A81676 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2429 11-46 FUEL - FUEL INJECTOR ASSY (3MZ-FE) 110XI-03 REPLACEMENT 1. 2. 3. (a) 4. DISCHARGE FUEL SYSTEM PRESSURE (See page 11-35 ) DRAIN ENGINE COOLANT (See page 16-26 ) REMOVE FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER (w/ Performance Rod) Remove the 2 nuts and upper brace. REMOVE V-BANK COVER SUB-ASSY (See page 14-149 ) (c) 5. (a) (b) (c) (d) (f) (a) (b) (b) (b) (e) REMOVE AIR CLEANER CAP SUB-ASSY Disconnect the MAF meter connector. Disconnect the 3 vacuum hoses. Disconnect the ventilation hose No. 2. Loosen the air cleaner hose clamp bolt, and remove the air cleaner cap. Remove the air cleaner filter element. 6. (a) (b) REMOVE EMISSION CONTROL VALVE SET Disconnect the 2 VSV connectors. Remove the wire harness clamp. (c) (d) (e) (f) (g) Disconnect the fuel vapor feed hose No. 1. Disconnect the fuel vapor feed hose No. 2. Disconnect the 2 vacuum hoses. Remove the clamp. Remove the 2 nuts and the emission control valve set. 7. (a) (b) (c) (d) REMOVE INTAKE AIR SURGE TANK Disconnect the throttle motor connector. Disconnect the water by-pass hose No. 3. Disconnect the water by-pass hose No. 2. Disconnect the union to check valve hose. A93066 (a) (b) (a) A79751 (d) (e) (e) (f) (c) A82428 (d) (a) (c) (b) A81623 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2430 11-47 FUEL - FUEL INJECTOR ASSY (3MZ-FE) (e) Disconnect the ventilation hose. (f) Remove the 3 nuts and separate the pressure feed tube. (g) (h) (i) Remove the 2 bolts and engine hanger No. 1. Remove the 2 bolts and surge tank stay No. 1. Remove the 2 bolts and surge tank stay No. 2. (j) (k) Using a socket hexagon wrench 8, remove the 4 bolts. Remove the 2 nuts, emission control valve bracket and intake air surge tank. Remove the gasket from the intake air surge tank. (e) A79706 (f) A81678 (h) (g) (i) A81674 (l) A82427 8. (a) (b) (b) (c) (c) SEPARATE FUEL PIPE SUB-ASSY NO.1 Remove the bolt and disconnect the fuel pipe No. 1. Remove the fuel pressure pulsation damper and 2 gaskets. Remove the fuel pipe No. 2 union bolt and 2 gaskets. (a) A79710 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2431 11-48 FUEL 9. (a) - FUEL INJECTOR ASSY (3MZ-FE) REMOVE FUEL INJECTOR ASSY Disconnect the 6 fuel injector connectors. A82436 (b) Remove the 4 bolts and 2 fuel delivery pipes together with the 6 fuel injectors. NOTICE: Be careful not to drop the fuel injectors when removing the fuel delivery pipe. A82437
2 (c) Remove the 4 delivery pipe No. 1 spacers (
1) and 6 insulators (
2) from the intake manifold. (d) Pull out the fuel injector from the fuel delivery pipe. 10. (a) (b) INSTALL FUEL INJECTOR ASSY Install a new grommet to each injector. Apply a light coat of grease or gasoline to a new O-ring, and install it to each injector.
1
2 A82446 A81137 New O-Ring New Grommet A79762 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2432 11-49 FUEL - FUEL INJECTOR ASSY (3MZ-FE) (c) Apply a light coat of grease or gasoline on the place where the fuel delivery pipe contacts the O-ring. (d) Push the fuel injector while twisting it back and forth to install it in the fuel delivery pipe. NOTICE:  Be careful not to twist the O-ring.  After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O-ring. Turn Push A81139 (e) 11. (a) (b) (c) 12. (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) Install 6 new insulators and the 4 delivery pipe No. 1 spacers to the intake manifold. (f) Place the 2 fuel delivery pipes and 6 fuel injectors together on the intake manifold. NOTICE: Be careful not to drop the fuel injectors when installing the fuel delivery pipe. (g) Temporarily install the 4 bolts which are used to attach the Turn fuel delivery pipe to the intake manifold. A82447 NOTICE: After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O-ring. (h) Tighten the 4 bolts. Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) (i) Connect the 6 fuel injector connectors. INSTALL FUEL PIPE SUB-ASSY NO.1 Install 2 new gaskets and the fuel pipe No. 2 union bolt. Torque: 33 N⋅m (337 kgf⋅cm, 24 ft⋅lbf) Install 2 new gaskets and the fuel pressure pulsation damper. Torque: 33 N⋅m (337 kgf⋅cm, 24 ft⋅lbf) Install the fuel pipe No. 1 with the bolt. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) INSTALL INTAKE AIR SURGE TANK Install a new gasket to the intake air surge tank. Install the intake air surge tank and emission control valve bracket with the 2 nuts. Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) Using a socket hexagon wrench 8, tighten the 4 bolts. Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) Install the surge tank stay No. 2 with the 2 bolts. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) Install the surge tank stay No. 1 with the 2 bolts. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) Install the engine hanger No. 1 with the 2 bolts. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) Install the pressure feed tube with the 3 nuts. Torque: 7.8 N⋅m (80 kgf⋅cm, 69 in.⋅lbf) Connect the ventilation hose. Connect the union to check valve hose. Connect the water bypass hose No. 2. Connect the water bypass hose No. 3. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2433 11-50 FUEL (l) 13. 14. 15. 16. 17. 18. 19. 20. (a) - FUEL INJECTOR ASSY (3MZ-FE) Connect the throttle motor connector. INSTALL EMISSION CONTROL VALVE SET Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) INSTALL AIR CLEANER CAP SUB-ASSY CHECK CONNECTION OF VACUUM HOSE (See page 14-149 ) ADD ENGINE COOLANT (See page 16-26 ) CHECK FOR ENGINE COOLANT LEAKS (See page 16-20 ) CHECK FOR FUEL LEAKS (See page 11-38 ) INSTALL V-BANK COVER SUB-ASSY (See page 14-149 ) INSTALL FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER (w/ Performance Rod) Install the upper brace with the 2 nuts. Torque: 80 N⋅m (815 kgf⋅cm, 59 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2434 11-51 FUEL - FUEL PUMP ASSY (3MZ-FE) FUEL PUMP ASSY (3MZ-FE) 1111W-01 COMPONENTS w/ Rear No. 2 Seat Deck Board Rear Seat Assy RH Seat Track Bracket Cover Inner Rear Seat Assy LH Rear Seat Track Bracket Cover Outer x2 x4 37 (375, 27) Seat Track Bracket Cover Inner Rear Seat Track Bracket Cover Outer x4 37 (375, 27) Rear Door Scuff Plate LH N·m (kgf·cm, ft·lbf) : Specified torque A92780 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2435 11-52 FUEL - FUEL PUMP ASSY (3MZ-FE) w/o Rear No. 2 Seat Deck Board x5 Clip 9.0 (92, 80 in.⋅lbf) 9.0 (92, 80 in.⋅lbf) x3 Rear Seat Assy RH Clip Rear Seat Assy LH Rear Seat Track Bracket Cover Outer x2 x4 37 (375, 27) Rear Seat Track Bracket Cover Outer x4 x2 37 (375, 27) Rear Door Scuff Plate LH N·m (kgf·cm, ft·lbf) : Specified torque A92781 A81630 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2436 11-53 FUEL - FUEL PUMP ASSY (3MZ-FE) Rear Floor Service Hole Cover Fuel Pump & Sender Gauge Connector Fuel Pump Tube Tube Joint Clip
Fuel Pump Gage Retainer Fuel Suction Tube Assy w/ Pump & Gage
Fuel Suction Tube Gasket
Non-reusable part A92785 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2437 11-54 FUEL - FUEL PUMP ASSY (3MZ-FE) Fuel Suction Plate Sub-assy Fuel Pump Harness
O-Ring Fuel Pump Spacer Clip Fuel Pump
O-Ring Fuel Tube Joint No. 1 Fuel Pressure Regulator Assy Fuel Filter Assy
O-Ring
O-Ring
Clip Fuel Suction Support No. 1 Fuel Sender Gage Assy
Non-reusable part A81632 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2438 11-55 FUEL - FUEL PUMP ASSY (3MZ-FE) 1111X-02 REPLACEMENT 1. DISCHARGE FUEL SYSTEM PRESSURE (See page 11-35 ) 2. (a) REMOVE DECK BOARD SUB-ASSY Disengage the 5 clips and turn up the front side of the deck board. B51632 3. 4. 5. 6. REMOVE REAR SEAT TRACK BRACKET COVER OUTER REMOVE REAR SEAT ASSY RH (See page 72-35 ) REMOVE REAR SEAT ASSY LH (See page 72-28 ) REMOVE REAR DOOR SCUFF PLATE LH 7. (a) (b) REMOVE REAR FLOOR SERVICE HOLE COVER Remove the rear floor service hole cover. Disconnect the fuel pump & sender gauge connector. 8. REMOVE FUEL SUCTION TUBE ASSY W/ PUMP & GAGE Disconnect the fuel pump tube. (1) Remove the tube joint clip, and pull out the fuel pump tube. A81633 Tube Joint Clip (a) A81634 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2439 11-56 FUEL Nylon Tube Fuel Tube Joint O-Ring Tube Joint Clip Fuel Suction Plate A81635 - FUEL PUMP ASSY (3MZ-FE) NOTICE:
Before this operation, check the connector for dirt, mud or other contamination. Clean if necessary.
Be careful of mud. The connector’s O-ring, which seals the pipe and connector, becomes contaminated easily.
Do not use any tool in this operation.
Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.
When the pipe and connector are stuck, push and pull the connector to release it. Then pull the connector from the pipe. (b) SST Rib A81636 Using SST, loosen the fuel pump gage retainer. SST 09808- 14020 (09808- 01410, 09808- 01420, 09808-01430) NOTICE: Loosen the retainer by turning it counterclockwise while holding the SST down. Do not allow the claw of the tank suction tube support to slip out of its groove on the fuel tank. HINT: A rib on the fuel pump gage retainer can be fitted into a tip of the SST. (c) Remove the fuel pump gage retainer. (d) Remove the fuel suction tube. NOTICE: Be careful not to bend the arm of the fuel sender gage. (e) Remove the gasket from the fuel tank. A80531 9. (a) (b) Unlock REMOVE FUEL SENDER GAGE ASSY Disconnect the fuel sender gage connector. Unlock the fuel sender gage and slide it to remove. (a) Slide A79768 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2440 11-57 FUEL REMOVE FUEL SUCTION PLATE SUB-ASSY Using a screwdriver with the its wrapped in tape, disconnect the 4 snap-claws from the claw holes and remove the fuel suction plate. NOTICE: Do not damage the fuel suction plate and fuel suction support No. 1. A82448 11. (a) (b) Tape (a) FUEL PUMP ASSY (3MZ-FE) 10. (a) Tape 4 Claws - 2 Claws A82449 REMOVE FUEL PUMP ASSY Disconnect the fuel pump connector. Using a small screwdriver with the its wrapped in tape, disconnect the 2 snap-claws from the claw holes and pull out the fuel pump. NOTICE: Do not damage the fuel pump and fuel suction plate. (c) Remove the O-ring and fuel pump spacer from the fuel pump. 12. (a) (b) REMOVE FUEL PUMP FILTER Using a small screwdriver, pry out the clip. Remove the fuel filter from the fuel pump. A79771 13. (a) (b) REMOVE FUEL TUBE JOINT NO.1 Disconnect the connector. Using a screwdriver with the its wrapped in tape, disconnect the snap-claw from the claw hole and pull out the fuel tube joint. NOTICE: Do not damage the fuel tube joint and fuel suction plate. Tape (a) Claw A82453 14. (a) REMOVE FUEL PUMP HARNESS Remove the harness from the fuel tube joint No. 1. A79773 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2441 11-58 FUEL 15. (a) (b) Clip (c) - FUEL PUMP ASSY (3MZ-FE) REMOVE FUEL PRESSURE REGULATOR ASSY Remove the clip. Pull out the pressure regulator from the fuel tube joint No. 1. Remove the 2 O-rings from the fuel tube joint No. 1. A79774 16. (a) New O-Ring (b) (c) INSTALL FUEL PRESSURE REGULATOR ASSY Apply a light coat of gasoline or spindle oil to the 2 new O-rings, and install them to the fuel pressure regulator. Apply a light coat of gasoline or spindle oil to the 2 O-rings again, and install the fuel pressure regulator to the fuel tube joint No. 1. Install the clip. A79775 17. INSTALL FUEL PUMP HARNESS 18. (a) New O-ring (b) (c) INSTALL FUEL TUBE JOINT NO.1 Apply a light coat of gasoline or spindle oil to a new Oring, and install it to the fuel tube joint No. 1. Apply a light coat of gasoline or spindle oil to the O-ring again, and install the fuel tube joint No. 1 to the fuel suction plate. Connect the connector. A79776 19. (a) INSTALL FUEL PUMP FILTER Install the fuel filter with a new clip. 20. (a) (b) New O-Ring (c) Fuel Pump Spacer (d) INSTALL FUEL PUMP ASSY Install the fuel pump spacer to the fuel pump. Apply a light coat of gasoline or spindle oil to a new Oring, and install it to the fuel pump. Apply a light coat of gasoline or spindle oil to the O-ring again, and install the fuel pump to the fuel suction plate. Connect the fuel pump connector. A81604 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2442 11-59 FUEL 21. (a) New O-Ring (b) - FUEL PUMP ASSY (3MZ-FE) INSTALL FUEL SUCTION PLATE SUB-ASSY Apply a light coat of gasoline or spindle oil to a new Oring, and install it to the fuel tube joint No. 1. Apply a light coat of gasoline or spindle oil to the O-ring again, and install the fuel suction plate to the fuel suction support No. 1. A79777 22. INSTALL FUEL SENDER GAGE ASSY Keyway Key A81637 ”S” Mark 23. INSTALL FUEL SUCTION TUBE ASSY W/ PUMP & GAGE (a) Install a new gasket to the fuel tank. (b) Attach the fuel suction tube to the fuel tank. NOTICE: Be careful not to bend the arm of the fuel sender gage. (c) Align the keyway of the fuel suction tube support with the key of the fuel suction tube. (d) Apply MP grease to the entire interior surface of the fuel pump gage retainer. (e) Align the triangle mark on new fuel pump gauge retainer with the ”S” mark on the fuel tank while pushing down the fuel suction tube, attach the fuel pump gauge retainer. Triangle Mark A82455 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2443 11-60 FUEL - FUEL PUMP ASSY (3MZ-FE) (f) Rotate the fuel pump gage retainer by hand, then tighten it one complete turn and half using SST. Triangle mark on the fuel pump gauge retainer must be positioned between ”A” and ”MAX.” indications on the fuel tank. NOTICE: Do not use other tools in this operation. Damage to the fuel pump gage retainer and the fuel tank may result. HINT: A rib on the fuel pump gage retainer can be fitted into a tip of the SST. SST Rib Triangle Mark ”A” Mark ”MAX.” Mark A93073 (g) 24. Connect the fuel pump tube. (1) Install the fuel pump tube and the tube joint clip. NOTICE:
Check that there are no scratches or foreign objects on the connecting part. Collar
Check that the fuel tube joint is inserted securely.
Check that the tube joint clip is on the collar of the fuel tube joint. Tube Joint Clip
After installing the tube joint clip, check that the fuel A81640 tube joint has not been pulled off. CHECK FOR FUEL LEAKS (See page 11-38 ) 25. (a) (b) (c) INSTALL REAR FLOOR SERVICE HOLE COVER Install a new butyl tape to the rear floor service hole cover. Connect the fuel pump & sender gage connector. Install the rear floor service hole cover. New Butyl Tape A81633 26. 27. 28. 29. 30. INSTALL REAR DOOR SCUFF PLATE LH INSTALL REAR SEAT ASSY LH (See page 72-28 ) INSTALL REAR SEAT ASSY RH (See page 72-35 ) INSTALL REAR SEAT TRACK BRACKET COVER OUTER INSTALL DECK BOARD SUB-ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2444 11-61 FUEL - FUEL TANK ASSY (3MZ-FE) FUEL TANK ASSY (3MZ-FE) 1111Y-01 COMPONENTS w/ Rear No. 2 Seat Deck Board Rear Seat Assy RH Rear Seat Assy LH Rear Seat Track Bracket Cover Outer x2 x4 37 (375, 27) Rear Seat Track Bracket Cover Outer x4 37 (375, 27) Rear Door Scuff Plate LH N·m (kgf·cm, ft·lbf) : Specified torque A92780 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2445 11-62 FUEL - FUEL TANK ASSY (3MZ-FE) w/o Rear No. 2 Seat: Deck Board x5 Clip 9.0 (92, 80 in.⋅lbf) 9.0 (92, 80 in.⋅lbf) x3 Clip Rear Seat Assy RH Rear Seat Assy LH Rear Seat Track Bracket Cover Outer x2 x4 37 (375, 27) Rear Seat Track Bracket Cover Outer x4 x2 37 (375, 27) Rear Door Scuff Plate LH N·m (kgf·cm, ft·lbf) : Specified torque A92781 A81630 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2446 11-63 FUEL - FUEL TANK ASSY (3MZ-FE) Rear Floor Service Hole Cover Fuel Pump &Sender Gage Connector Fuel Pump Tube Tube Joint Clip
Fuel Pump Gage Retainer Fuel Suction Tube Assy w/ Pump & Gage
Fuel Suction Tube Gasket
Non-reusable part A92785 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2447 11-64 FUEL - FUEL TANK ASSY (3MZ-FE) Front Floor Heat Insulator No. 3 4.9 (50, 43 in.⋅lbf) x4
Exhaust Pipe Gasket Center Exhaust Pipe Assy Center x2 Compression Spring 48 (490, 35) 4WD Type: Exhaust Pipe Support Bracket No. 4
Exhaust Pipe Gasket 22 (224, 16) x2 x2 Washer x4 48 (490, 35) Compression Spring 74 (750, 55) Washer 37 (375, 27) x4 4WD Type: Propeller w/ Center Bearing Shaft Assy N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part A93064 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2448 11-65 FUEL - FUEL TANK ASSY (3MZ-FE) Fuel Tank Assy Fuel Tube Protector No. 1 x2 20 (200, 14) x2 Clip x2 39 (400, 29) Fuel Tank Band Sub-assy RH x2 39 (400, 29) Fuel Tank Band Sub-assy LH Fuel Tank Protector Sub-assy No. 1
Clip x3 x6 5.5 (56, 49 in.⋅lbf) Fuel Tank Protector No. 1 x4 5.5 (56, 49 in.⋅lbf) N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part A81215 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2449 11-66 FUEL - FUEL TANK ASSY (3MZ-FE) Fuel Tank Wire Vapor Pressure Sensor Assy Tube Joint Clip
Tank Suction Tube Support Fuel Pump Tube Sub-assy Fuel Tank Vent Hose Fuel Tank Cushion Set 30 (306, 22) Fuel Tank Side Plate x2 Fuel Tank to Filler Pipe Hose Fuel Tank Assy Fuel Tank Cushion No. 5 Fuel Tank Bracket N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part A81216 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2450 11-67 FUEL - FUEL TANK ASSY (3MZ-FE) 110UL-03 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. DISCHARGE FUEL SYSTEM PRESSURE (See page 11-35 ) REMOVE DECK BOARD SUB-ASSY REMOVE REAR SEAT TRACK BRACKET COVER OUTER REMOVE REAR SEAT ASSY RH (See page 72-35 ) REMOVE REAR SEAT ASSY LH (See page 72-28 ) REMOVE REAR DOOR SCUFF PLATE LH REMOVE REAR FLOOR SERVICE HOLE COVER (See page 11-55 ) REMOVE FUEL SUCTION TUBE ASSY W/ PUMP & GAGE (See page 11-55 ) DRAIN FUEL REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY (4WD TYPE) (See page 30-4 ) REMOVE EXHAUST PIPE ASSY CENTER (See page 15-5 ) REMOVE FRONT FLOOR HEAT INSULATOR NO.3 (See page 12-28 ) 13. (a) REMOVE EXHAUST PIPE SUPPORT BRACKET NO.4 (4WD TYPE) Remove the 2 bolts and support bracket. A80549 14. (a) REMOVE FUEL TUBE PROTECTOR NO.1 Remove the 2 clips and unfasten the claw, and remove the tube protector. 15. (a) REMOVE FUEL TANK PROTECTOR NO.1 Remove the 4 nuts and fuel tank protector. A80550 A80551 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2451 11-68 FUEL
1 - FUEL TANK ASSY (3MZ-FE) 16. (a) REMOVE FUEL TANK PROTECTOR SUB-ASSY NO.1 Remove the 3 clips (
1), 6 nuts and tank protector. 17. (a) REMOVE FUEL TANK ASSY Disconnect the fuel pump tube. (1) Pinch the projection of the retainer to remove the lock claws and pull down it as shown in the illustration. (2) Pull out the fuel pump tube.
1
1
1 A81225 (1) (1) (2) (1) Retainer A81688 Quick Connector Retainer Nylon Tube O-ring Pipe A81689 NOTICE:  Before this operation, check the connector for dirt, mud or other contamination. Clean if necessary.  Be careful of mud. The connector’s O-ring, which seals the pipe and connector, becomes contaminated easily.  Do not use any tool in this operation.  Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.  When the pipe and connector are stuck, push and pull the connector to release it. Then pull out the connector from the pipe. (b) A (1) (2) (2) Disconnect the fuel tank vent hose hose. (1) Push the connector deep into the charcoal canister to release the locking tab. (2) Pinch portion A. (3) Pull out the connector. A A81211 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2452 11-69 FUEL (c) (2) (2) - FUEL TANK ASSY (3MZ-FE) Disconnect the fuel tank breather tube No.3. (1) Lower the connector checker slightly. (2) Pinch the tube connector. (3) Pull out the breather tube. (3) (1) A93428 Nylon Tube Tube Connector Pipe O-Ring Checker B79934 NOTICE:  Before this operation, check the connector for dirt, mud or other contamination. Clean if necessary.  Be careful of mud. The connector’s O-ring, which seals the pipe and connector, becomes contaminated easily.  Do not use any tool in this operation.  Do not bend or twist the nylon tube. Protect the connector by covering it with a vinyl or plastic bag.  When the pipe and connector are stuck, push and pull the connector to release it. Then pull out the connector from the pipe. (d) Loosen the hose clamp bolt and disconnect the fuel tank to filler pipe hose. A93430 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2453 11-70 FUEL (e) (f) (g) (h) (i) (j) - FUEL TANK ASSY (3MZ-FE) Disconnect the fuel tank wire connector. Remove the connector clamp. Set up a transmission jack under the fuel tank. Remove the 4 bolts and 2 fuel tank bands. Remove the 2 nuts. Operate the transmission jack and remove the fuel tank. (f) (h) (e) (h) (i) (h) (h) (i) A81220 18. (a) : 2 Claws REMOVE FUEL PUMP TUBE SUB-ASSY Unfasten the 2 claws and remove the tube. A81690 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2454 11-71 FUEL - FUEL TANK ASSY (3MZ-FE) 19. (a) REMOVE FUEL TANK TO FILLER PIPE HOSE Loosen the hose clamp bolt and remove the hose. 20. (a) (b) REMOVE FUEL TANK WIRE Disconnect the vapor pressure sensor connector. Unfasten the 4 claws and remove the wire. 21. (a) (b) REMOVE VAPOR PRESSURE SENSOR ASSY Remove the tube joint clip. Pull out the vapor pressure sensor. 22. (a) (b) (c) (d) REMOVE FUEL TANK VENT HOSE Push the connector deep into the charcoal canister to release the locking tab. Pinch portion A. Pull out the connector. Unfasten the claw and remove the vent hose. 23. (a) REMOVE TANK SUCTION TUBE SUPPORT Remove the tube support from the fuel tank. A81221 : 4 Claws A81222 (b) (a) Tube Joint Clip A81223 (a) A (b) (b) : Claw A A81224 A80561 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2455 11-72 FUEL - FUEL TANK ASSY (3MZ-FE) 24. (a) REMOVE FUEL TANK SIDE PLATE Remove the bolt and nut, and then remove the fuel tank side plate and the fuel tank bracket. 25. (a) REMOVE FUEL TANK CUSHION SET Remove the cushion set and cushion No. 5. Side Plate Tank Bracket A82407 Cushion Set Cushion No. 5 A82470 26. 27. INSTALL FUEL TANK CUSHION SET INSTALL FUEL TANK SIDE PLATE Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) 28. (a) INSTALL TANK SUCTION TUBE SUPPORT Install a new tube support as shown in the illustration. A82408 29. INSTALL FUEL TANK VENT HOSE (a) (b) Collar Tube Joint Clip A82409 30. INSTALL VAPOR PRESSURE SENSOR ASSY (a) Push and hold down the vapor pressure sensor. (b) Install the fuel tube joint clip to the sensor. NOTICE:  Check that there are no scratches or foreign objects on the connecting parts.  Check that the fuel tube joint is fully inserted.  Check that the fuel tube joint clip is on the collar of the fuel tube joint. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2456 11-73 FUEL - FUEL TANK ASSY (3MZ-FE)  (1) (2) A94322 Connect the fuel pump tube. (1) Push the quick connector in the direction of the white arrow. NOTICE:  Check if there is any damage or foreign objects on the (2) connected part.  After connecting, check if the quick connector and the pipe are securely connected by trying to pull Retainer them. A82411 (2) Push up on the retainer until the claws lock. INSTALL FUEL TANK PROTECTOR SUB-ASSY NO.1 Install the tank protector with the 6 nuts. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) Install 3 new clips. INSTALL FUEL TANK PROTECTOR NO.1 Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) INSTALL FUEL TUBE PROTECTOR NO.1 INSTALL EXHAUST PIPE SUPPORT BRACKET NO.4 (4WD TYPE) Torque: 22 N⋅m (224 kgf⋅cm, 16 ft⋅lbf) INSTALL FRONT FLOOR HEAT INSULATOR NO.3 (See page 12-28 ) (1) 35. (a) (b) 36. 37. 38. 39. After installing the tube joint clip, check if the fuel joint is securely connected by trying to pull it. 31. INSTALL FUEL TANK WIRE 32. INSTALL FUEL TANK TO FILLER PIPE HOSE 33. INSTALL FUEL PUMP TUBE SUB-ASSY 34. INSTALL FUEL TANK ASSY (a) Set up the fuel tank to the transmission jack. (b) Operate the transmission jack and install the fuel tank. (c) Tighten the 2 nuts. Torque: 20 N⋅m (200 kgf⋅cm, 14 ft⋅lbf) (d) Install the 2 fuel tank bands with the 4 bolts. Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) (e) Install the connector clamp. (f) Connect the fuel tank wire connector. (g) Connect the fuel tank to filler pipe hose. (h) Connect the fuel tank breather tube No. 3. (1) Push the quick connector to the pipe until it makes ”click” sound. NOTICE:  Check if there is any damage or foreign objects on the connected part.  After connecting, check if the quick connector and the pipe are securely connected by trying to pull them apart. (2) Return the connecter checker to its original position. (i) Connect the fuel tank vent hose. (j) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2457 11-74 FUEL 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. - FUEL TANK ASSY (3MZ-FE) INSTALL EXHAUST PIPE ASSY CENTER (See page 15-5 ) ADD FUEL INSTALL FUEL SUCTION TUBE ASSY W/ PUMP & GAGE (See page 11-55 ) CHECK FOR FUEL LEAKS (See page 11-38 ) CHECK FOR EXHAUST GAS LEAKS INSTALL REAR FLOOR SERVICE HOLE COVER (See page 11-55 ) INSTALL REAR DOOR SCUFF PLATE LH INSTALL REAR SEAT ASSY LH (See page 72-28 ) INSTALL REAR SEAT ASSY RH (See page 72-35 ) INSTALL REAR SEAT TRACK BRACKET COVER OUTER INSTALL DECK BOARD SUB-ASSY INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY (4WD TYPE) (See page 30-4 ) FULLY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSY (4WD TYPE) (See page 30-4 ) ADD TRANSFER OIL (4WD TYPE) (See page 31-4 ) INSPECT TRANSFER OIL (4WD TYPE) (See page 31-4 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2458 12-6 EMISSION CONTROL - EMISSION CONTROL SYSTEM (2AZ-FE) 120E3-01 INSPECTION 1. (a) (b) INSPECT VENTILATION VALVE SUB-ASSY Install a clean hose to the ventilation valve. Check ventilation valve operation. (1) Blow air into the cylinder head side, and check that air passes through easily. CAUTION: Do not suck air through the valve. Petroleum substances inside the valve are harmful. Cylinder Head Side Clean Hose A92662 (2) Blow air into the intake manifold side, and check that air passes through with difficulty. If operation is not as specified, replace the ventilation valve. (c) Remove the hose from the ventilation valve. Intake Manifold Side Clean Hose A92661 2. (a) INSPECT FUEL TANK CAP ASSY Visually check if the cap and gasket are deformed or damaged. If necessary, repair or replace the cap and/or gasket. Gasket A92657 3. (a) INSPECT CHARCOAL CANISTER ASSY Visually check the charcoal canister for cracks or damage. If cracks or damage is found, replace the charcoal canister assy. A92445 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2464 12-7 EMISSION CONTROL - EMISSION CONTROL SYSTEM (2AZ-FE) (b) Vent Port Air Inlet Port Air Purge Port Check charcoal canister operation. (1) While holding the purge port closed, blow air (0.39 kPa, 4.0 gf/cm2, 0.06 psi) into the vent port, and check that air flows from the air inlet port. If the result is not as specified, replace the charcoal canister assy. A92446 (2) Vent Port Air Inlet Port Air While holding the air inlet port closed, blow air (0.39 kPa, 4.0 gf/cm2, 0.06 psi) into the vent port, and check that air flows from the purge port. If the result is not as specified, replace the charcoal canister assy. Purge Port A92447 (3) Vent Port Vacuum Air Inlet Port While holding the air inlet port closed, apply vacuum (3.43 kPa, 25.7 gf/cm2, 1.01 psi) to the vent port, and check that air is sucked in from the purge port. If the result is not as specified, replace the charcoal canister assy. Purge Port A92448 Purge Port Vent Port Vacuum Air Inlet Port A92449 A Vacuum B Vent Port (c) Check the air tightness. (1) While holding the vent and air inlet ports closed, apply vacuum (3.43 kPa, 25.7 gf/cm2, 1.01 psi) to the purge port, and check that the vacuum is maintained for 1 minute. HINT: In order to maintain air tightness, the check should be performed while holding the CCV terminal port closed. If the result is not as specified, replace the charcoal canister assy. (d) Check the diaphragm. (1) Remove the air hose between ports A and B. (2) While holding the vent, purge and air inlet ports closed, apply vacuum (1.42 kPa, 11 mmHg, 0.42 in.Hg) into port A, and check that air is sucked in from port B. Purge Port Air Inlet Port A92450 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2465 12-8 EMISSION CONTROL EMISSION CONTROL SYSTEM (2AZ-FE) (3) A Vacuum Vent Port - Purge Port Air Inlet Port While holding the vent, purge and air inlet ports closed, apply vacuum (1.42 kPa, 11 mmHg, 0.42 in.Hg) into port A, and measure how long it takes for vacuum to drop. Vacuum drop time: 10 seconds or more If the result is not as specified, replace the charcoal canister assy. (4) Reinstall the air hose between ports A and B. A92451 (e) Check pump module operation. (1) Check that air flows from port A to ports B and C. If the result is not as specified, replace the pump module. C A B Air A92453 (2) Apply battery positive voltage across the terminals. (3) Check that the valve is closed. If the result is not as specified, replace the pump module. Valve Closed Battery A92454 (4) Check that air does not flow from port A to port B. (5) Check that air flows from port A to port C. If the result is not as specified, replace the pump module. C B Air Battery A No Air A92455 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2466 12-9 EMISSION CONTROL 4. Ohmmeter (a) 26 to 30 Ω - EMISSION CONTROL SYSTEM (2AZ-FE) INSPECT VACUUM SWITCHING VALVE ASSY FOR EVAP Measure the VSV resistance between the terminals. Standard: Tester Connection Specified Condition 1-2 26 to 30 Ω at 20
C (68
F) 1 - Body ground 2 - Body ground 10 MΩ or higher If the resistance is not as specified, replace the VSV assy. Ohmmeter 10 MΩ or Higher A92675 (b) Check VSV operation. (1) Check that air does not flow from the port as shown in the illustration. If the result is not as specified, replace the VSV assy. No Air Air A92676 (2) Apply battery positive voltage across the terminals. (3) Check that air flows from the ports. If the result is not as specified, replace the VSV assy. Air Battery A92681 5. (a) +B AF- HT AF+ INSPECT A/F SENSOR (BANK 1 SENSOR 1) Measure the resistance between terminals 1 (HT) and 2 (+B). Standard: Condition Specified Condition 20
C (68
F) 0.8 to 1.4 Ω 800
C (1,472
F) 1.8 to 3.2 Ω If the result is not as specified, replace the sensor. A75325 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2467 12-10 EMISSION CONTROL 6. +B (a) HT - EMISSION CONTROL SYSTEM (2AZ-FE) INSPECT HEATED OXYGEN SENSOR (BANK 1 SENSOR 2) Measure the resistance between terminals 1 (HT) and 2 (+B). Standard: Condition E1 OX A82934 Specified Condition 20
C (68
F) 11 to 16 Ω 800
C (1,472
F) 23 to 32 Ω If the result is not as specified, replace the sensor. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2468 12-3 EMISSION CONTROL - EMISSION CONTROL SYSTEM (2AZ-FE) 120E2-01 ON-VEHICLE INSPECTION 1. E1 INSPECT AIR-FUEL RATIO COMPENSATION SYSTEM Measure the voltage between the terminals of the ECM connectors. Standard: (a) E7 E8 E6 E9 E5 A1A+ A1A- A59588 Tester Connection Condition Specified Condition E8-23 (A1A+) - E9-1(E1) Ignition switch ON 3.3 V E8-31 (A1A-) - E9-1(E1) Ignition switch ON 2.9 V NOTICE: Connect test leads to the connector’s backside. The connectors should not be disconnected from the ECM. HINT: Voltage between the terminals of the ECM is kept constant regardless of the voltage of the A/F sensor. (b) Connect the hand-held tester to the DLC3. (c) Select ”DATA MONITOR”. Then select ”A/FS B1 S1”, and ”O2S B1 S2” to display the monitors. (d) Warm up the A/F sensor with the engine speed at 2,500 rpm for approximately 2 minutes. (e) Keep Engine Speed Lean Keep the engine speed at 2,500 rpm and confirm that the display of ”A/FS B1 S1” is as shown in the illustration. HINT:
(V) Air-fuel 14.6 Ratio 3.3V (f) Rich Time 2. (a) (b) (c)
A92668 The illustration may slightly differ from the display on the hand-held tester. Only the hand-held tester displays the waveform of the A/F sensor. Confirm that the display of ”O2S B1 S2” changes between 0 to 1 V with the engine speed at 2,500 rpm. INSPECT FUEL CUT OFF/RESTART RPM Increase the engine speed to at least 3,500 rpm. Use a sound scope to check for the injector operating noise. When the accelerator pedal is released, injector operating noise stops momentarily and then resumes. Standard: Item Specified Condition Fuel cut off rpm 2,500 rpm Fuel injector restart rpm 1,400 rpm If the result is not as specified, check for DTCs. If a DTC is present, follow the repair procedures according to the DTC. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2461 12-4 EMISSION CONTROL 3. B11449 - EMISSION CONTROL SYSTEM (2AZ-FE) VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS Check for cracks, leaks or damage. (a) HINT: Removal or problems with the engine oil dipstick, oil filler cap, PCV hose and other components may cause the engine to run improperly. Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause the engine to run improperly. Be sure to check the areas indicated by the arrow marks. If necessary, replace any damaged parts. 4. (a) (b) (c) (d) INSPECT FUEL CUTOFF VALVE AND FILL CHECK VALVE Disconnect the vent line hose from the fuel tank (see page 12-1 1). Connect the pressure gauge to the fuel tank. Fill the fuel tank with fuel. Apply pressure of 4 kPa (41 gf/cm2, 0.58 psi) to the vent port of the fuel tank. HINT: It is necessary to check the amount of fuel in the fuel tank. When the fuel tank is full, the float valve of the fill check valve is closed and no air can pass through. (e) Remove the fuel tank cap, and check that pressure drops. If pressure does not drop, replace the fuel tank assembly. (f) Reconnect the vent line hose to the fuel tank. Fuel Tank Cap Vent Line Hose A85597 5. (a) CHECK AIR INLET LINE Disconnect the air inlet line hose from the charcoal canister. (b) Check that air can flow freely into the air inlet line. If air cannot flow freely into the air inlet line, repair or replace it. (c) Reconnect the air inlet line hose to the charcoal canister. Air Inlet Line Hose Air A92684 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2462 12-5 EMISSION CONTROL 6. (a) VC (+) E2 (-) E7 E8 E6 E5 E9 - EMISSION CONTROL SYSTEM (2AZ-FE) INSPECT PUMP MODULE (PRESSURE SENSOR) Measure the power source voltage of the ECM connectors. Standard Tester Connection Condition Specified Condition E7-18 (VC) - E7-28 (E2) Ignition switch ON 4.5 to 5.5 V If the voltage is not as specified, replace the ECM. (b) Measure the power output of the ECM connectors. (1) Remove the fuel tank cap. Standard Tester Connection Condition Specified Condition E5-21 (PPMP) - E7-28 (E2) Ignition switch ON 1.425 to 4.150 V If the voltage is not as specified, replace the ECM. (2) Install the fuel tank cap. PPMP (+) Pressure Sensor Specification Malfunction Area Output Voltage 4.900 V 4.150 V Usable Range 1.425 V Malfunction Area 0.450 V 60 kPa 110 kPa Pressure HINT: Atmospheric Pressure at altitude: 0 is 101.3 kPa A92658 A71562 A92687 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2463 12-1 EMISSION CONTROL - EMISSION CONTROL SYSTEM (2AZ-FE) EMISSION CONTROL SYSTEM (2AZ-FE) 120BH-02 LOCATION Ventilation Valve ECM VSV Assy for EVAP Heated Oxygen Sensor (Bank 1 Sensor 2) A/F Sensor (Bank 1 Sensor 1) Pump Module Charcoal Canister Filter Charcoal Canister Fuel Tank Cap Fuel Tank Assy A85596 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2459 12-2 EMISSION CONTROL - EMISSION CONTROL SYSTEM (2AZ-FE) 120E1-01 SYSTEM DIAGRAM The emission control system is determined by the ECM based on signals from various sensors. Carbon Filter Air Cleaner ECM Charcoal Canister Filter Pump Module VSV Assy for EVAP Charcoal Canister Fuel Tank Cap Fuel Tank A92660 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2460 12-1 1 EMISSION CONTROL - CHARCOAL CANISTER ASSY (2AZ-FE) CHARCOAL CANISTER ASSY (2AZ-FE) 120E4-01 REPLACEMENT 1. (a) (b) (c) REMOVE EXHAUST PIPE ASSY CENTER Remove the 4 bolts and 2 compression springs. Remove the exhaust pipe center from the 4 exhaust pipe supports. Remove the 2 gaskets from the exhaust pipe front and exhaust pipe center. (a) (b) (a) (a) (b) (b) (a) (b) A92669 2. (a) REMOVE FRONT FLOOR HEAT INSULATOR NO.3 Remove the 4 bolts and heat insulator. 3. (a) (b) (c) REMOVE CHARCOAL CANISTER ASSY Disconnect the pump module connector. Disconnect the fuel emission hose. Disconnect the air inlet line hose. A92664 A92685 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2469 12-12 EMISSION CONTROL Push Pinch CHARCOAL CANISTER ASSY (2AZ-FE) (d) Disconnect the fuel tank vent hose. (1) Push the connector deeply into the charcoal canister to release the locking tab. (2) Pinch portion A. (3) Pull out the connector. (e) 4. (a) Remove the 3 nuts and charcoal canister. INSTALL CHARCOAL CANISTER ASSY Install the charcoal canister with the 3 nuts. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) 5. (a) INSTALL FRONT FLOOR HEAT INSULATOR NO.3 Install the heat insulator with the 4 nuts. Torque: 4.9 N⋅m (50 kgf⋅cm, 43 in.⋅lbf) 6. (a) INSTALL EXHAUST PIPE ASSY CENTER Install the exhaust pipe center to the 4 exhaust pipe supports. Install a new gasket and the pipe center to the pipe front with the 2 bolts. Torque: 56 N⋅m (571 kgf⋅cm, 41 ft⋅lbf) A Pinch - A A92665 A92457 A92664 (b) (c) A77857 Using a vernier caliper, measure the free length of the compression spring. Minimum length: 40.5 mm (1.594 in.) for center to tail If the free length is less than minimum, replace the compression spring. (d) Install a new gasket and the pipe center to the pipe tail with the 2 bolts and 2 compression springs. Torque: 48 N⋅m (489 kgf⋅cm, 35 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2470 12-13 EMISSION CONTROL - CHARCOAL CANISTER ASSY (2AZ-FE) 7. CHECK FOR EXHAUST GAS LEAKS If gas is leaking, tighten the areas necessary to stop the leak. If damaged, replace it. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2471 12-14 EMISSION CONTROL - VENTILATION VALVE SUB-ASSY (2AZ-FE) VENTILATION VALVE SUB-ASSY (2AZ-FE) 120BQ-04 REPLACEMENT 1. (a) (b) REMOVE VENTILATION VALVE SUB-ASSY Disconnect the ventilation hose from the ventilation valve. Remove the ventilation valve. 2. (a) Adhesive A88710 (b) INSTALL VENTILATION VALVE SUB-ASSY Install the ventilation valve. (1) Apply adhesive to 2 or 3 threads. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent (2) Install the ventilation valve. Torque: 19 N⋅m (193 kgf⋅cm, 14 ft⋅lbf) Connect the ventilation hose to the ventilation valve. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2472 12-23 EMISSION CONTROL - EMISSION CONTROL SYSTEM (3MZ-FE) 120BP-06 INSPECTION 1. (a) (b) INSPECT VENTILATION VALVE SUB-ASSY Install a clean hose to the ventilation valve. Check ventilation valve operation. (1) Blow air into the cylinder head side, and check that air passes through easily. CAUTION: Do not suck air through the valve. Petroleum substances inside the valve are harmful. Cylinder Head Side Clean Hose A59511 (2) Blow air into the intake manifold side, and check that air passes through with difficulty. If the result is not as specified, replace the ventilation valve. (c) Remove the hose from the ventilation valve. Intake Manifold Side Clean Hose A59512 2. (a) INSPECT FUEL TANK CAP ASSY Visually check if the cap and/or gasket are deformed or damaged. If necessary, repair or replace the cap and/or gasket. Gasket A92657 3. (a) INSPECT CHARCOAL CANISTER ASSY Visually check the charcoal canister for cracks or damage. If cracks or damage is found, replace the charcoal canister assy. A81030 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2481 12-24 EMISSION CONTROL Air Vent Port Air Inlet Port - EMISSION CONTROL SYSTEM (3MZ-FE) (b) Check the charcoal canister operation. (1) While holding the purge port closed, blow air (0.39 kPa, 4.0 gf/cm2, 0.06 psi) into the vent port, and check that air flows from the air inlet port. If the result is not as specified, replace the charcoal canister assy. Purge Port A81031 Vent Port (2) While holding the air inlet port closed, blow air (0.39 kPa, 4.0 gf/cm2, 0.06 psi) into the vent port, and check that air flows from the purge port. If the result is not as specified, replace the charcoal canister assy. Air Air Inlet Port Purge Port A81032 (3) While holding the air inlet port closed, apply vacuum (3.43 kPa, 25.7 gf/cm2, 1.01 psi) to the vent port, and check that air is sucked in from the purge port. If the result is not as specified, replace the charcoal canister assy. Vacuum Vent Port Air Inlet Port Purge Port Purge Port A81033 (c) Vacuum Vent Port Air Inlet Port A92672 Vent Port A Vacuum B Purge Port Check air tightness. (1) While holding the vent and air inlet ports closed, apply vacuum (3.43 kPa, 25.7 gf/cm2, 1.01 psi) to the purge port, and check that the vacuum is maintained for 1 minute. HINT: In order to maintain air tightness, the check should be performed while holding the CCV terminal port closed. If the result is not as specified, replace the charcoal canister assy. (d) Check the diaphragm. (1) Remove the air hose between ports A and B. (2) While holding the vent, purge and air inlet ports closed, apply vacuum (1.42 kPa, 11 mmHg, 0.42 in.Hg) into port A, and check that air is sucked in from port B. Air Inlet Port A81035 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2482 12-25 EMISSION CONTROL A Vacuum Vent Port Purge Port Air Inlet Port - EMISSION CONTROL SYSTEM (3MZ-FE) (3) While holding the vent, purge and air inlet ports closed, apply vacuum (1.42 kPa, 11 mmHg, 0.42 in.Hg) into port A, and measure how long it takes for vacuum to drop. Vacuum drop time: 10 seconds or more If the result is not as specified, replace the charcoal canister assy. (4) Reinstall the air hose between ports A and B. A81036 (e) Ohmmeter Measure the VSV resistance for CCV between the terminals. Standard: Condition Specified Condition 20
C (68
F) 25 to 30 Ω 100
C (212
F) 32 to 40 Ω If the result is not as specified, replace the charcoal canister. A74866 (f) Check VSV operation for CCV. (1) Check that air flows from port A to ports B and C. If the result is not as specified, replace the charcoal canister assy. C B Air A A74867 (2) Apply battery positive voltage across the terminals. (3) Check that the valve is closed. If the result is not as specified, replace the charcoal canister assy. Battery Valve C Closed A74868 No Air (4) Check that air does not flow from port A to port B. (5) Check that air flows from port A to port C. If the result is not as specified, replace the charcoal canister assy. B Battery Air A A74869 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2483 12-26 EMISSION CONTROL 4. Ohmmeter (a) 26 to 30 Ω - EMISSION CONTROL SYSTEM (3MZ-FE) INSPECT VACUUM SWITCHING VALVE ASSY FOR EVAP Measure the VSV resistance. Standard: Tester Connection Specified Condition 1-2 26 to 30 Ω at 20
C (68
F) 1 - Body ground 2 - Body ground 10 MΩ or higher If the resistance is not as specified, replace the VSV assy. Ohmmeter 10 MΩ or Higher A92675 (b) Check VSV operation. (1) Check that air does not flow from the port as shown in the illustration. If the result is not as specified, replace the VSV assy. No Air Air A92676 (2) (3) Apply battery positive voltage across the terminals. Check that air flows from the port as shown in the illustration. If the result is not as specified, replace the VSV assy. Air Battery A92681 5. (a) +B AF- HT AF+ INSPECT A/F SENSOR (BANK 1, 2 SENSOR 1) Measure the resistance between terminals 1 (HT) and 2 (+B) and 1 (HT) and 4 (AF-). Standard: Tester Connection Condition Specified Condition 1 (HT) - 2 (+B) 20°C (68°F) 1.8 to 3.4 Ω 1 (HT) - 4 (AF-) - 10 kΩ or higher If the result is not as specified, replace the sensor. A75325 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2484 12-27 EMISSION CONTROL 6. +B HT (a) - EMISSION CONTROL SYSTEM (3MZ-FE) INSPECT HEATED OXYGEN SENSOR (BANK 1 SENSOR 2) Measure the resistance between terminals 1 (HT) and 2 (+B). Standard: Condition E1 OX A82934 (a) HT 20
C (68
F) 11 to 16 Ω 800
C (1,472
F) 23 to 32 Ω If the result is not as specified, replace the sensor. 7. +B INSPECT HEATED OXYGEN SENSOR (BANK 2 SENSOR 2) Measure the resistance between terminals 1 (HT) and 2 (+B). Standard: Condition E1 OX A80122 Specified Condition Specified Condition 20
C (68
F) 11 to 16 Ω 800
C (1,472
F) 23 to 32 Ω If the result is not as specified, replace the sensor. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2485 12-17 EMISSION CONTROL - EMISSION CONTROL SYSTEM (3MZ-FE) 120E6-02 ON-VEHICLE INSPECTION 1. E1 INSPECT AIR-FUEL RATIO COMPENSATION SYSTEM Measure the voltage between the terminals of the ECM connectors. Standard: (a) E7 E8 E6 E9 A2A+ A2A- E5 A1A+ A1A- A59588 Tester Connection Condition Specified Condition E8-22 (A1A+) - E9-1(E1) Ignition switch ON 3.3 V E8-30 (A1A-) - E9-1(E1) Ignition switch ON 3.0 V E8-23 (A2A+) - E9-1(E1) Ignition switch ON 3.3 V E8-31 (A2A-) - E9-1(E1) Ignition switch ON 3.0 V NOTICE: Connect test leads to the connector’s backside. The connectors should not be disconnected from the ECM. HINT: Voltage between the terminals of the ECM is kept constant regardless of the voltage of the A/F sensor. (b) Connect the hand-held tester to the DLC3. (c) Select ”DATA MONITOR”. Then select ”A/FS B1 S1”, ”A/FS B2 S1” and ”O2S B1 S2” to display the monitors. (d) Warm up the A/F sensor with the engine speed at 2,500 rpm for approximately 2 minutes. (e) Keep Engine Speed Lean HINT: (V) Air-fuel 14.6 Ratio 3.3V

Rich Time 2. (a) (b) (c) Keep the engine speed at 2,500 rpm and confirm that the displays of ”A/FS B1 S1” and ”A/FS B2 S1” are as shown in the illustration. A92668 (f) The illustration may differ slightly from the display on the hand held tester. Only the hand-held tester displays the waveform of the A/F sensor. Confirm that the display of ”O2S B1 S2” changes between 0 to 1 V with the engine speed at 2,500 rpm. INSPECT FUEL CUT OFF/RESTART RPM Increase the engine speed to at least 3,500 rpm. Use a sound scope to check for the injector operating noise. When the accelerator pedal is released, injector operating noise stops momentarily and then resumes. Standard: Item Specified Condition Fuel cut off rpm 2,500 rpm Fuel injector restart rpm 1,400 rpm 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2475 12-18 EMISSION CONTROL - EMISSION CONTROL SYSTEM (3MZ-FE) If the result is not as specified, check for DTCs. If a DTC is present, follow the repair procedures according to the DTC. 3. P12931 (a) HINT: Removal or problems with the engine oil dipstick, oil filler cap, PCV hose and other components may cause the engine to run improperly. Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause the engine to run improperly. Be sure to check the areas indicated by the arrow marks. If necessary, replace any damage parts. 4. Vacuum Gauge (a) (b) B06544 Using hand-held tester: INSPECT EVAP SYSTEM LINE Warm up and stop the engine. (1) Warm up the engine to normal operating temperature. Install a vacuum gauge (EVAP control system test equipment vacuum gauge) to the EVAP service port on the purge line. A75352 Hand-Held Tester DLC3 (c) (d) (e) (f) Connect the hand-held tester to the DLC3. Start the engine. Turn the hand-held tester main switch ON. Use the ACTIVE TEST mode on the hand-held tester to operate the VSV for EVAP. (g) Check the vacuum while the engine is idling. Standard: Maintain at 0.368 to 19.713 in.Hg (5 to 268 in.Aq) for over 5 seconds. A80020 Vacuum Gauge B06545 VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS Check for cracks, leaks or damage. A75353 HINT: If the vacuum does not change, the hose connecting the VSV to the service port has come loose or is blocked, or the VSV is malfunctioning. (h) Stop the engine. (i) Disconnect the hand-held tester from the DLC3. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2476 12-19 EMISSION CONTROL - EMISSION CONTROL SYSTEM (3MZ-FE) (j) Disconnect the vacuum gauge from the EVAP service port on the purge line. (k) Connect a pressure gauge to the EVAP service port on the purge line. Pressure Gauge A72589 Hand-held Tester DLC3 A80020 (l) (m) (n) (o) Connect the hand-held tester to the DLC3. Turn the ignition switch ON. Turn the hand-held tester main switch ON. Use the ACTIVE TEST mode on the hand-held tester to operate the VSV for CCV. NOTICE: In step (m), the ignition switch should be ON, but the engine should not be running. HINT: If the check is not completed within 10 minutes, the VSV for CCV will be reset and close automatically. (p) Pressure Gauge Pressure A75354 B06546 Fuel Tank Cap Check the pressure. (1) Add 13.5 to 15.5 in.Aq of pressure from the EVAP service port. Standard: 2 minutes after the pressure is added, the gauge should still read over 7.7 to 8.8 in.Aq. HINT: If you cannot add pressure, the hose connecting the VSV for EVAP canister fuel tank has become disconnected or the VSV is open. (2) Check if the pressure decreases when the fuel tank cap is removed while adding pressure. HINT: If the pressure does not decrease when the fuel tank cap is removed, the hose connecting the service port to the fuel tank is blocked. (q) Turn the ignition switch OFF. (r) Disconnect the hand-held tester from the DLC3. A92656 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2477 12-20 EMISSION CONTROL 5. Vacuum Gauge (a) (b) B06544 - EMISSION CONTROL SYSTEM (3MZ-FE) Not using hand-held tester: INSPECT EVAP SYSTEM LINE Warm up and stop the engine. (1) Warm up the engine to normal operating temperature. Install a vacuum gauge (EVAP control system test equipment vacuum gauge) to the EVAP service port on the purge line. A75352 (c) (d) (e) Disconnect the VSV connector for EVAP. Connect the battery’s positive (+) and negative (-) leads to the VSV terminals for EVAP. Start the engine. Battery A75314 (f) Vacuum Gauge B06545 A75353 HINT: If the vacuum does not change, the hose connecting the VSV to the service port has come loose or is blocked, or the VSV is malfunctioning. (g) Stop the engine. (h) Disconnect the battery’s positive (+) and negative (-) leads from the VSV terminals for EVAP. (i) Reconnect the VSV connector for EVAP. (j) Disconnect the vacuum gauge from the EVAP service port on the purge line. (k) Pressure Gauge Check the vacuum while the engine is idling. Standard: Maintain at 0.368 to 19.713 in.Hg (5 to 268 in.Aq) for over 5 seconds. Connect a pressure gauge to the EVAP service port on the purge line. A72589 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2478 12-21 EMISSION CONTROL - EMISSION CONTROL SYSTEM (3MZ-FE) (l) (m) Disconnect the VSV connector for CCV. Connect the battery’s positive (+) and negative (-) leads to the VSV terminals for CCV. NOTICE: Incorrect electrode connection causes damage to the VSV. Pay due attention when connecting the lead wire. Battery A80147 (n) Pressure Gauge Pressure A75354 B06546 Fuel Tank Cap A92656 Check the pressure. (1) Add 13.5 to 15.5 in.Aq of pressure from the EVAP service port. Standard: 2 minutes after the pressure is added, the gauge should still read over 7.7 to 8.8 in.Aq. HINT: If you cannot add pressure, the hose connecting the VSV for EVAP canister fuel tank has become disconnected or the VSV is open. (2) Check if the pressure decreases when the fuel tank cap is removed while adding pressure. HINT: If the pressure does not decrease when the fuel tank cap is removed, the hose connecting the service port to the fuel tank is blocked. (o) Disconnect the battery’s positive (+) and negative (-) leads from the VSV terminals for CCV. (p) Reconnect the VSV connector for CCV. (q) Disconnect the pressure gauge from the EVAP service port on the purge line. 6. Vent Line Hose A66040 CHECK AIR TIGHTNESS IN FUEL TANK AND FILLER PIPE (a) Disconnect the vent line hose from the fuel tank (see page 12-28 ). (b) Connect the pressure gauge to the fuel tank. (c) Apply pressure to the fuel tank to create an internal pressure of 4 kPa (41 gf/cm2, 0.58 psi). (d) Check that the internal pressure of the fuel tank is maintained for 1 minute. (e) Check the connected portions of each hose and pipe. (f) Check the installed parts on the fuel tank. If malfunctions, damage or other problems are found, replace the fuel tank and filler pipe. (g) Reconnect the vent line hose to the fuel tank. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2479 12-22 EMISSION CONTROL 7. (a) (b) (c) (d) - EMISSION CONTROL SYSTEM (3MZ-FE) INSPECT FUEL CUTOFF VALVE AND FILL CHECK VALVE Disconnect the vent line hose from the fuel tank (see page 12-28 ). Connect the pressure gauge to the fuel tank. Fill the fuel tank with fuel. Apply pressure of 4 kPa (41 gf/cm2, 0.58 psi) to the vent port of the fuel tank. HINT: It is necessary to check the amount of fuel in the fuel tank. When the fuel tank is full, the float valve of the fill check valve is closed and no air can pass through. (e) Remove the fuel tank cap, and check that pressure drops. If pressure does not drop, replace the fuel tank assembly. (f) Reconnect the vent line hose to the fuel tank. Fuel Tank Cap Vent Line Hose A85597 8. (a) CHECK AIR INLET LINE Disconnect the air inlet line hose from the charcoal canister. (b) Check that air can flow freely into the air inlet line. If air cannot flow freely into the air inlet line, repair or replace it. (c) Reconnect the air inlet line hose to the charcoal canister. Air Air Inlet Line Hose A66042 9. (a) VC (+) E2 (-) E7 E8 E6 E5 E9 INSPECT VAPOR PRESSURE SENSOR Measure the power source voltage of the ECM connectors. Standard Tester Connection Condition Specified Condition E7-18 (VC) - E7-28 (E2) Ignition switch ON 4.5 to 5.5 V If the voltage is not as specified, replace the ECM. (b) Measure the power output of the ECM connectors. (1) Remove the fuel tank cap. Standard Tester Connection Condition Specified Condition E5-21 (PTNK) - E7-28 (E2) Ignition switch ON 3.0 to 3.6 V If the voltage is not as specified, replace the ECM. (2) Reinstall the fuel tank cap. PTNK (+) A92658 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2480 12-15 EMISSION CONTROL - EMISSION CONTROL SYSTEM (3MZ-FE) EMISSION CONTROL SYSTEM (3MZ-FE) 120BM-02 LOCATION Ventilation Valve VSV Assy No. 1 Vacuum Surge Tank EVAP Service Port A/F Sensor (Bank 1 Sensor 1) A/F Sensor (Bank 2 Sensor 1) Heated Oxygen Sensor (Bank 1 Sensor 2) Heated Oxygen Sensor (Bank 2 Sensor 2) VSV for CCV Charcoal Canister Filter Charcoal Canister Fuel Tank Cap Fuel Tank Assy A85594 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2473 12-16 EMISSION CONTROL - EMISSION CONTROL SYSTEM (3MZ-FE) 120E5-01 SYSTEM DIAGRAM The emission control system is determined by the ECM based on signals from various sensors. Refueling Valve Vapor Pressure Sensor ECM Restrictor Passage Air Cleaner Carbon Filter Charcoal Canister Purge Valve Fuel Tank EVAP Service Port Purge Line Fresh Air Line Charcoal Canister Filter VSV for CCV A88556 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2474 12-28 EMISSION CONTROL - CHARCOAL CANISTER ASSY (3MZ-FE) CHARCOAL CANISTER ASSY (3MZ-FE) 120E7-01 REPLACEMENT 1. (a) (b) (c) REMOVE EXHAUST PIPE ASSY CENTER Remove the 4 bolts and 4 compression springs. Remove the exhaust pipe center from the 4 exhaust pipe supports. Remove the 2 gaskets from the exhaust pipe front No. 3 and the exhaust pipe center. (b) (a) (a) (b) (a) (b) (a) (b) A81209 2. (a) REMOVE FRONT FLOOR HEAT INSULATOR NO.3 Remove the 4 bolts and heat insulator. 3. (a) (b) (c) REMOVE CHARCOAL CANISTER ASSY Disconnect the VSV connector for CCV. Disconnect the fuel emission hose. Disconnect the air inlet line hose. A92664 (a) (b) (c) A92686 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2486 12-29 EMISSION CONTROL Push Pinch CHARCOAL CANISTER ASSY (3MZ-FE) (d) Disconnect the fuel tank vent hose. (1) Push the connector deeply into the charcoal canister assy to release the locking tab. (2) Pinch portion A. (3) Pull out the connector. (e) Remove the 3 nuts, and then remove the charcoal canister. INSTALL CHARCOAL CANISTER ASSY Install the charcoal canister with the 3 nuts. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) A Pinch - A A92665 4. (a) A81213 5. (a) INSTALL FRONT FLOOR HEAT INSULATOR NO.3 Install the heat insulator with the 4 nuts. Torque: 4.9 N⋅m (50 kgf⋅cm, 43 in.⋅lbf) A92664 6. (a) INSTALL EXHAUST PIPE ASSY CENTER Using a vernier caliper, measure the free length of the compression spring. Minimum length: 41.5 mm (1.634 in.) for center to front No. 3 40.5 mm (1.594 in.) for center to tail If the free length is less than minimum, replace the compression spring. A77857 New Gasket (b) (c) (d) Install 2 new gaskets to the exhaust pipe front No. 3 and the exhaust pipe center as shown in the illustration. Install the exhaust pipe center to the 4 exhaust pipe supports. Install the 4 compression springs and 4 bolts. Torque: 48 N⋅m (489 kgf⋅cm, 35 ft⋅lbf) A78440 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2487 12-30 EMISSION CONTROL - CHARCOAL CANISTER ASSY (3MZ-FE) 7. CHECK EXHAUST LEAKAGE If gas is leaking, tighten the areas necessary to stop the leak. If damaged, replace it. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2488 12-31 EMISSION CONTROL - VENTILATION VALVE SUB-ASSY (3MZ-FE) VENTILATION VALVE SUB-ASSY (3MZ-FE) 120BR-04 REPLACEMENT 1. (a) (b) REMOVE VENTILATION VALVE SUB-ASSY Disconnect the ventilation hose from the ventilation valve. Remove the ventilation valve. 2. (a) Adhesive A92670 (b) INSTALL VENTILATION VALVE SUB-ASSY Install the ventilation valve. (1) Apply adhesive to 2 or 3 threads. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent (2) Install the ventilation valve. Torque: 19 N⋅m (193 kgf⋅cm, 14 ft⋅lbf) Connect the ventilation hose to the ventilation valve. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2489 13-2 INTAKE - INTAKE AIR CONTROL SYSTEM (3MZ-FE) 1308R-01 INSPECTION Lever Valve Actuator Rod A85563 1. (a) INSPECT INTAKE AIR CONTROL VALVE ASSY NO.2 Apply 26.7 kPa (200 mmHg, 7.9 in.Hg) of vacuum to the actuator. Check if the actuator rod pulls the lever and causes the valve to rotate open, as shown in the illustration. (b) One minute after applying the vacuum, check that the actuator rod does not return. If the result is not as specified, replace the IAC valve assy No. 2. 2. (a) C A B A85559 Ohmmeter INSPECT AIR CLEANER CAP SUB-ASSY Cover port C with your finger and blow air into port B. Check that air flows out of port A. (b) Cover port C with your finger and blow air into port A. Check that air does not flow out of port B. (c) Cover ports A and C with your fingers, and apply 60 kPa (450 mmHg, 18 in.Hg) of vacuum to port B. Check that there is no change in the vacuum after one minute. If the result is not as specified, replace the air cleaner cap. 3. 33 to 39 Ω 1 2 (a) INSPECT VACUUM SWITCHING VALVE ASSY FOR IAC VALVE NO. 2 Measure the VSV resistance. Standard: Tester Connection Specified Condition 1-2 33 to 39 Ω at 20
C (68
F) 1 - Body ground 2 - Body ground 10 kΩ or higher If the result is not as specified, replace the VSV assy. Ohmmeter 10 kΩ or higher 1 2 A85555 A85556 Body Ground A85570 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2491 13-3 INTAKE Air - INTAKE AIR CONTROL SYSTEM (3MZ-FE) (b) Check VSV operation. (1) Check that air flows from port E to the filter. If the result is not as specified, replace the VSV assy. Filter E FI6393 (2) Apply battery voltage across the terminals. (3) Check that air flows from port E to port F. If the result is not as specified, replace the VSV assy. Air E F Battery S04523 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2492 13-1 INTAKE - INTAKE AIR CONTROL SYSTEM (3MZ-FE) INTAKE AIR CONTROL SYSTEM (3MZ-FE) 1307N-02 ON-VEHICLE INSPECTION Vacuum Gauge 1. (a) (b) (c) (d) A85554 INSPECT INTAKE AIR CONTROL SYSTEM Using a 3-way connector, connect a vacuum gauge to the actuator hose. Connect the hand-held tester to the DLC3. Start the engine. On the hand-held tester, enter the ACTIVE TEST mode. Standard: Switch Condition Vacuum VSV ON Approx. 27.6 kPa (200 mmHg, 7.9 in.Hg) VSV OFF 0 kPa (0 mmHg, 0 in.Hg) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2490 13-4 INTAKE - INTAKE AIR CONTROL VALVE ASSY NO.2 (3MZ-FE) INTAKE AIR CONTROL VALVE ASSY NO.2 (3MZ-FE) 1307P-03 REPLACEMENT 1. (a) (b) Lever (c) REMOVE INTAKE AIR CONTROL VALVE ASSY NO.2 Remove the 3 bolts and nut. Turn the lever to the closed position as shown in the illustration and pull out the IAC valve. Remove the gasket from the intake air surge tank. A81629 2. (a) (b) INSTALL INTAKE AIR CONTROL VALVE ASSY NO.2 Install a new gasket to the intake air surge tank. Install the IAC valve with the 3 bolts and nut. Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2493 14-1 ENGINE MECHANICAL - ENGINE (2AZ-FE) ENGINE (2AZ-FE) 141P0-02 INSPECTION 1. 2. 3. 4. 5. INSPECT ENGINE COOLANT (See page 16-6 ) INSPECT ENGINE OIL INSPECT BATTERY INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSY INSPECT SPARK PLUG (See page 18-3 ) INCORRECT CORRECT A87787 Hand-held Tester 6. INSPECT V-RIBBED BELT HINT:
After installing the drive belt, check that it fits properly in the ribbed grooves. Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the crank pulley.
”New belt” is a belt which has been used less than 5 minutes on a running engine.
”Used belt” is a belt which has been used on a running engine for 5 minutes or more.
After installing a new belt, run the engine for approximately 5 minutes and then recheck the tension. 7. INSPECT IGNITION TIMING (a) Warm up the engine. (b) When using the hand-held tester: Check the ignition timing. (1) Connect the hand-held tester to the DLC3. (2) Enter DATA LIST MODE on the hand-held tester. Ignition timing: 8 to 12 BTDC @ idle HINT: Please refer to the hand-held tester operator’s manual for help on selecting the DATA LIST. DLC3 A80020 (c) CG DLC3 1 2 3 4 5 6 7 8 9 10 11 1213141516 TC A82779 When not using the hand-held tester: Check the ignition timing. (1) Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3. SST 09843-18040 NOTICE:
Confirm the terminal numbers before connecting them. Connection with a wrong terminal can damage the engine.
Turn off all electrical systems before connecting the terminals.
Perform this inspection after the cooling fan motor is turned off. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2494 14-2 ENGINE MECHANICAL (2) (3) A52004 Hand-held Tester DLC3 A80020 1 2 3 4 5 6 7 8 9 10 11 1213141516 TAC ENGINE (2AZ-FE) Remove the cylinder head cover No. 2. Pull out the wire harness as shown in the illustration. Connect the clip of the timing light to the engine. NOTICE:
Use a timing light which can detect the first signal.
After checking, be sure to tape the wire harness. (4) Check the ignition timing at idle. Ignition timing: 8 to 12 BTDC @ idle NOTICE: When checking the ignition timing, the transmission should be in the neutral position. HINT: After engine rpm is kept at 1,000 to 1,300 rpm for 5 seconds, check that it returns to idle speed. (5) Remove the SST from the DLC3. SST 09843-18040 (6) Check the ignition timing at idle. Ignition timing: 5 to 15 BTDC @ idle (7) Confirm that ignition timing moves to the advanced angle side when the engine rpm is increased. (8) Remove the timing light. 8. INSPECT ENGINE IDLE SPEED (a) Warm up the engine. (b) When using the hand-held tester: Check the idle speed. (1) Connect the hand-held tester to the DLC3. HINT: Please refer to the hand-held tester operator’s manual for further details. (2) Enter DATA LIST MODE on the hand-held tester. Idle speed: 610 to 710 rpm NOTICE:
When checking the idle speed, the transmission should be in the neutral position.
Check idle speed with the cooling fan off.
Switch off all accessories and air conditioning before connecting the hand-held tester. (c) DLC3 - When not using the hand-held tester: Check the idle speed. (1) Using SST, connect tachometer tester probe to terminal 9 (TAC) of the DLC3. (2) Check the idle speed. Idle speed: 610 to 710 rpm SST 09843-18030 A82779 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2495 14-3 ENGINE MECHANICAL - ENGINE (2AZ-FE) 9. (a) (b) (c) (d) (e) A01037 INSPECT COMPRESSION Warm up and stop the engine. Disconnect the injector connectors. Remove the ignition coils. Remove the spark plugs. Check the cylinder compression pressure. (1) Insert a compression gauge into the spark plug hole. (2) Fully open the throttle. (3) While cranking the engine, measure the compression pressure. Compression pressure: 1,360 kPa (13.9 kgf/cm2, 198 psi) Minimum pressure: 0.98 MPa (10 kgf/cm2, 142 psi) Difference between each cylinder: 100 kPa (1.0 kgf/cm2, 14 psi) NOTICE:
Always use a fully charged battery to obtain engine speed of 250 rpm or more.
Check other cylinder’s compression pressure in the same way.
This measurement must be done as quickly as possible. (4) If the cylinder compression is low, pour a small amount of engine oil into the cylinder through the spark plug hole and inspect again. HINT:
If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged.
If pressure stays low, a valve may be stuck or seated improperly, or there may be leakage in the gasket. 10. INSPECT CO/HC (a) Start the engine. (b) Rev the engine at 2,500 rpm for approximately 180 seconds. (c) Insert CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling. (d) Immediately check CO/HC concentration at idle and/or 2,500 rpm. HINT:
Complete the measuring within 3 minutes.
Check regulations and restrictions in your area when performing 2 mode CO/HC concentration testing (engine check at both idle speed and at 2,500 rpm). (e) If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below. (1) Check A/F sensor operation (see page 12-3 ). (2) See the table below for possible causes, and then inspect and repair. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2496 14-4 ENGINE MECHANICAL CO Normal Low High HC High High High - ENGINE (2AZ-FE) Problems Causes Rough idle 1. Faulty ignitions:
Incorrect timing
Fouled, shorted or improperly gapped plugs 2. Incorrect valve clearance 3. Leaky intake and exhaust valves 4. Leaky cylinders Rough idle (fluctuating HC reading) 1. Vacuum leaks:
PCV hoses
Intake manifold
Throttle body
Brake booster line 2. Lean mixture causing misfire Rough idle (black smoke from exhaust) 1. Restricted air filter 2. Plugged PCV valve 3. Faulty SFI system:
Faulty pressure regulator
Defective ECT
Defective MAF meter
Faulty ECM
Faulty injectors
Faulty throttle position sensor 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2497 14-5 ENGINE MECHANICAL - FAN AND GENERATOR V BELT (2AZ-FE) FAN AND GENERATOR V BELT (2AZ-FE) 141P1-02 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. REMOVE FRONT WHEEL RH REMOVE FRONT FENDER SPLASH SHIELD FRONT RH REMOVE FRONT FENDER APRON SEAL RH REMOVE ENGINE MOUNTING STAY NO.2 RH REMOVE ENGINE COVER SUB-ASSY NO.1 REMOVE ENGINE MOVING CONTROL ROD W/BRACKET (See page 14-24 ) REMOVE ENGINE MOUNTING BRACKET NO.2 RH 8. (a) REMOVE FAN AND GENERATOR V BELT Slowly turn the belt tensioner clockwise for more than 3 seconds, and remove the drive belt by using SST. SST 09843-18030 9. (a) INSTALL FAN AND GENERATOR V BELT Slowly turn the belt tensioner clockwise for more than 3 seconds, and install the drive belt by using SST. SST 09249-63010 SST A62240 SST A62240 10. 11. 12. 13. INSTALL ENGINE MOUNTING BRACKET NO.2 RH Torque: 52 N⋅m (531 kgf⋅cm, 38 ft⋅lbf) INSTALL ENGINE MOVING CONTROL ROD W/BRACKET (See page 14-24 ) INSTALL ENGINE MOUNTING STAY NO.2 RH Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) INSTALL FRONT WHEEL RH 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2498 14-6 ENGINE MECHANICAL - VALVE CLEARANCE (2AZ-FE) VALVE CLEARANCE (2AZ-FE) 141P2-01 ADJUSTMENT 1. 2. 3. 4. 5. 6. 7. 8. REMOVE FRONT WHEEL RH REMOVE FRONT FENDER SPLASH SHIELD FRONT RH REMOVE FRONT FENDER APRON SEAL RH REMOVE ENGINE COVER SUB-ASSY NO.1 REMOVE IGNITION COIL ASSY REMOVE SPARK PLUG DISCONNECT VENTILATION HOSE DISCONNECT VENTILATION HOSE NO.2 9. (a) (b) REMOVE CYLINDER HEAD COVER SUB-ASSY Remove the bolt and disconnect the engine wire harness clamp. Remove the 8 bolts, 2 nuts, cylinder head cover and gasket. A94204 10. (a) Timing Marks (b) 11. HINT: Inspect and adjust the valve clearance when the engine is cold. Timing Marks Groove SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with timing mark 0 of the timing chain cover. Check that the timing marks of the camshaft timing gear and sprocket are aligned with the timing marks of the bearing cap No. 1 and No. 2 as shown in the illustration. INSPECT VALVE CLEARANCE A53043 (a) No. 1 Cylinder TDC/Compression IN Check only the valve indicated on the left. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. (2) Record valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed. EX A52469 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2499 14-7 ENGINE MECHANICAL - VALVE CLEARANCE (2AZ-FE) Valve clearance (Cold): No. 4 Cylinder TDC/Compression Paint Mark Timing Mark Timing Mark Groove Exhaust 0.30 to 0.40 mm (0.012 to 0.016 in.) Turn the crankshaft clockwise 1 revolution (360) and set the No.4 cylinder to TDC/compression. (c) Check only the valve indicated on the left. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. (2) Record valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed. Valve clearance (Cold): A52470 Paint Mark Specified Condition 0.19 to 0.29 mm (0.008 to 0.011 in.) (b) IN EX Item Intake Item Specified Condition Intake 0.19 to 0.29 mm (0.008 to 0.011 in.) Exhaust 0.30 to 0.40 mm (0.012 to 0.016 in.) 12. ADJUST VALVE CLEARANCE NOTICE: Be sure not to turn the crankshaft without the chain tensioner. (a) Turn the crankshaft clockwise 1 revolution (360) and set the No. 1 cylinder to the TDC/compression. (b) Place paint marks on the timing chain and camshaft timing gear sprocket. A52471 (c) Remove the 2 bolts and chain tensioner. A13325 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2500 14-8 ENGINE MECHANICAL Loosen - VALVE CLEARANCE (2AZ-FE) (d) Remove the No. 2 camshaft. (1) Fix the camshaft with a wrench and then loosen the sprocket bolt. NOTICE: Be careful not to damage the valve lifter. Fix A52454 1 3 5 4 2 (2) Uniformly loosen and remove the No. 2 camshaft’s 10 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearing caps. (3) Raise the No. 2 camshaft and remove it. Then remove the sprocket bolt. Remove the camshaft timing sprocket and the timing chain from the No. 2 camshaft. Remove the camshaft timing sprocket from the timing chain. A32636 (4) (5) A87614 1 3 5 4 (e) 2 Remove the camshaft. (1) Uniformly loosen and remove the camshaft’s 10 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearing caps. (2) Remove the camshaft. A36526 (f) Tie the timing chain with a string. NOTICE: Be careful not to drop anything inside the timing chain cover. (g) Remove the valve lifters. A52474 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2501 14-9 ENGINE MECHANICAL (h) - VALVE CLEARANCE (2AZ-FE) Adjust the valve clearance. (1) Using a micrometer, measure the thickness of the removed lifter. (2) Calculate the thickness of a new lifter so that the valve clearance comes within the specified value. A A01082 Thickness of new lifter B Thickness of used lifter C Measured valve clearance Valve clearance: Item Specified Condition Intake A = B + (C - 0.24 mm (0.0094 in.)) Exhaust A = B + (C - 0.35 mm (0.0138 in.)) EXAMPLE: (Intake) Measured valve clearance = 0.44 mm (0.0173 in.) 0.44 mm (0.0173 in.) - 0.24 mm (0.0094 in.) = 0.20 mm (0.0079 in.) (Measured - Specification = Excess clearance) Used shim measurement = 5.30 mm (0.2087 in.) 0.20 mm (0.0079 in.) + 5.30 mm (0.2087 in.) = 5.50 mm (0.2165 in.) (Excess clearance + Used shim = Ideal new shim) Closest new shim = 5.50 mm (0.2165 in.) = Shim No. ”50” (3) Select a new lifter with a thickness as close as possible to the calculated values. HINT:
Lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).
Refer to valve lifter selection chart on the following 2 pages. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2502 14-10 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Valve Lifter Selection Chart (Intake) ENGINE MECHANICAL - Author
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: A77296 2503 Intake valve clearance (Cold): 0.19 to 0.29 mm (0.008 to 0.011 in.) EXAMPLE: The 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0157 in.). Replace the 5.250 mm (0.2067 in.) lifter with a new No. 42 lifter. mm (in.) Thickness Lifter No. Thickness 30 5.300 (0.2087) 54 5.540 (0.2181) 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189) 10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197) 12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205) 14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213) 16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220) 18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228) 20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236) 22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244) 24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252) 26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260) 28 5.280 (0.2079) 52 5.520 (0.2173) Lifter No. Thickness Lifter No. 06 5.060 (0.1992) 08 VALVE CLEARANCE (2AZ-FE) New Lifter Thickness 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Valve Lifter Selection Chart (Exhaust) ENGINE MECHANICAL - Author
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: mm (in.) Lifter Thickness No. Thickness 06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181) 08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189) 10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197) 12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205) 14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213) 16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220) 18 5.180 (0.2039) 42 5.420 (0.2134) 66 20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236) 22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244) 24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252) 26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260) 28 5.280 (0.2079) 52 5.520 (0.2173) No. No. Thickness 5.660 (0.2228) 14-1 1 A77297 2504 Exhaust valve clearance (Cold): 0.30 to 0.40 mm (0.012 to 0.016 in.) EXAMPLE: The 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.440 mm (0.0173 in.). Replace the 5.340 mm (0.2102 in.) lifter with a new No. 44 lifter. Lifter VALVE CLEARANCE (2AZ-FE) New lifter thickness Lifter 14-12 ENGINE MECHANICAL (i) Paint Mark - VALVE CLEARANCE (2AZ-FE) Install the camshaft. (1) Install the timing chain on the camshaft timing gear, with the paint mark aligned with the timing marks on the camshaft timing gear. Timing Marks A52456 5 3 1 Bearing Cap No. 1 2 (2) Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration. Torque: 30 N⋅m (301 kgf⋅cm, 22 ft⋅lbf) for bearing cap No. 1 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for bearing cap No. 3 4 Bearing Cap No. 3 A52457 (j) Paint Mark Timing Mark Install the No. 2 camshaft. (1) Put the No. 2 camshaft on the cylinder head with the paint mark of the chain aligned with the timing mark on the camshaft timing sprocket. A53011 (2) Raise the No. 2 camshaft and temporarily tighten the sprocket bolt. A52473 Bearing Cap No. 2 Bearing Cap No. 3 5 3 1 2 4 (3) Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration. Torque: 30 N⋅m (301 kgf⋅cm, 22 ft⋅lbf) for bearing cap No. 2 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for bearing cap No. 3 A52458 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2505 14-13 ENGINE MECHANICAL Tighten - VALVE CLEARANCE (2AZ-FE) (4) Fix the camshaft with a wrench, then tighten the sprocket bolt. Torque: 54 N⋅m (551 kgf⋅cm, 40 ft⋅lbf) NOTICE: Be careful not to damage the valve lifter. Fix A52459 (k) Check that the timing chain paint marks are aligned with the camshaft timing sprocket timing mark and the camshaft timing gear timing mark. Also check the alignment of the pulley groove and chain cover timing mark. (l) Install the chain tensioner. (1) Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out. 7 Links Paint Mark Paint Mark Timing Marks Timing Mark Groove A52460 Raise Push Pin Hook A52461 (2) Install a new gasket and the chain tensioner with the 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) NOTICE: When installing the tensioner, set the hook again if the hook releases the plunger. Engine Front A52462 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2506 14-14 ENGINE MECHANICAL (3) - VALVE CLEARANCE (2AZ-FE) Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook. Disconnect Turn Pin Hook A93972 (4) 13. (a) Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger. INSTALL CYLINDER HEAD COVER SUB-ASSY Remove any old packing (FIPG) material. Plunger Push Turn A93973 (b) Seal Packing A53051 A A A A B A 14. 15. 16. 17. Nut B A Apply seal packing to 2 locations as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 5 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing the cylinder head cover. (c) Install the cylinder head cover with the 8 bolts and 2 nuts. Torque: 11 N⋅m (112 kgf⋅cm, 8 ft⋅lbf) for nut 11 N⋅m (112 kgf⋅cm, 8 ft⋅lbf) for bolt A 14 N⋅m (143 kgf⋅cm, 10 ft⋅lbf) for bolt B Nut A61989 INSTALL SPARK PLUG Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) INSTALL IGNITION COIL ASSY Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) INSTALL FRONT WHEEL RH CHECK FOR ENGINE COOLANT LEAKS (See page 16-6 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2507 14-15 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) PARTIAL ENGINE ASSY (2AZ-FE) 141P3-03 COMPONENTS Front Fender Apron Seal RH Engine Cover Sub-assy No. 1 Fan and Generator V Belt 52 (530, 38) 21 (214, 15) Generator Assy ×3 Compressor and Magnetic Clutch 5.0 (51, 44 in.⋅lbf) 25 (255, 18) Front Fender Splash Shield Front RH Air Cleaner Assy Battery Engine Under Cover No. 1 ×8 Front Fender Splash Shield Front LH N⋅m (kgf⋅cm,ft⋅lbf) : Specified torque A90964 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2508 14-16 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) 64 (653, 47) 64 (653, 47) Engine Moving Control Rod W/Bracket 52 (530, 38) Engine Moving Control Rod Bracket No. 2 64 (653, 47) Front Stabilizer Link Assy LH Engine Mounting Stay No. 2 RH Propeller Shaft Assy (4WD) 35 (357, 26) 74 (755, 55) ×2 Steering Intermediate Shaft Sub-assy ×4 ×2 74 (755, 55) Floor Shift Transmission Control Cable Assy Tie Rod Assy LH 74 (755, 55) 15 (153, 11) 49 (500, 36) 8.0 (82, 71 in.⋅lbf) Front Suspension Member Brace Rear RH Speed Sensor Front LH Front Suspension Member Brace Rear LH Frame Side Plate RH Front Axle Hub LH Nut ×2 127 (1295, 94) 294 (3,000, 217) Front Suspension Arm Sub-assy Lower No. 1 32 (326, 24) Frame Side Plate LH 32 (326, 24) 86 (877, 63) Exhaust Pipe assy Front 86 (877, 63) 56 (571, 41)  Exhaust Pipe Gasket  Exhaust Pipe Gasket 48 (489, 35) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque  Non-reusable part A90965 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2509 14-17 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) Vane Pump Assy Drive Shaft Bearing Bracket (2WD) 64 (653, 47) ×2 43 (438, 31) ×3 54 (551, 40) 64 (653, 47) ×3 95 (969, 70) 75 (765, 55) 34 (347, 25) ×2 Engine Mounting Bracket RH ×3 Engine Mounting Bracket RR (4WD) 64 (653, 47) ×3 95 (696, 70) Stabilizer Bar Front (4WD) 19 (194, 14) 19 (194, 14) 64 (653, 47) 87 (897, 64) 70 (714, 52) Rack & Pinion Power Steering Gear Assy (4WD) Front Frame Assy N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque A90967 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2510 14-18 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) Front Drive Shalt Assy RH Drive Shaft Bearing Bracket Hole Snap Ring 64 (653, 47) 64 (653, 47) Drive Shaft Bearing Bracket Flywheel Housing Under Cover Drive Plate Spacer Front 44 (449, 32) Engine Wire Drive Plate and Ring Gear Sub-assy 98 (1,000, 72) ×8 41 (418, 30) 64 (653, 47) ×6 Drive Plate Spacer Rear 46 (469, 34) Starter Assy 39 (398, 29)  Front Drive Shaft LH Hole Snap Ring Front Drive Shaft Assy LH N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque  Non-reusable part A94363 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2511 14-19 ENGINE MECHANICAL 30 (306, 22) - PARTIAL ENGINE ASSY (2AZ-FE) 9.0 (92, 80 in.⋅lbf) Intake Manifold Sub-assy Ignition Coil Assy ×3  Gasket 30 (306, 22) Engine Wire Intake Manifold Insulator No. 1 Ventilation Hose No. 1 Ventilation Hose No. 2 Manifold Converter Insulator No. 1 V-Ribbed Belt Tensioner Assy 12 (122, 9) 12 (122, 9.0) 59.5 (607, 44) 12 (122, 9.0)  Gasket 37 (337, 27) ×5 Exhaust Manifold Converter Sub-assy Manifold Stay 44 (449, 32) Manifold Stay No. 2 44 (449, 32) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque  Non-reusable part A90966 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2512 14-20 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) Engine Cover Sub-assy No. 1 14 (143,10) ×2 11 (112, 8) Ventilation Valve 11 (112, 8) ×6 19 (194, 14) ×2 Cylinder Head Cover Sub-assy Camshaft Position Sensor Cylinder Head Cover Gasket Spark Plug 19 (194, 14) ×4 9.0 (92, 80 in.⋅lbf) 9.0 (92, 80 in.⋅lbf) 9.0 (92, 80 in.⋅lbf) Water Pump Assy Crankshaft Position Sensor Water Pump Pulley ×4 26 (265, 19) 9.0 (92, 80 in.⋅lbf) ×2 Oil Filter Union 9.0 (92, 80 in.⋅lbf) 30 (306, 22) 180 (1835, 133) Oil Filter Sub-assy Crankshaft Pulley Oil Pan Sub-assy  Gasket Oil Pan Drain Plug 25 (255, 18) N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part × 12 ×2 9.0 (92, 80 in.⋅lbf) 9.0 (92, 80 in.⋅lbf) A90971 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2513 14-21 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) Chain Sub-asy Chain Tensioner Slipper Chain Vibration Damper No. 1 Crankshaft Timing Gear or Sprocket No.2 Chain Sub-assy 19 (194, 14) ×2 Crankshaft Position Sensor Plate No.1 Spring Camshaft Timing Gear Sprocket Chain Tensioner Plate 30 (306, 22) ×2  Gasket 12 (122, 9.0) 9.0 (92, 80 in.⋅lbf) Oil pump Assy Timing Chain Guide ×3 19 (194, 14) 9.0 (92, 80 in.⋅lbf) ×2 9.0 (92, 80 in.⋅lbf) Chain Tensioner Assy No. 1 ×2  Gasket 43 (438, 32) V-Ribbed belt Tensioner Assy ×4 60 (612, 44) Timing Chain or Belt Cover Sub-assy 9.0 (92, 80 in.⋅lbf) Timing Gear Case or Timing Chain Case oil Seal ×8 21 (210, 16) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque  Non-reusable part A92864 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2514 14-22 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) 9.0 (92, 80 in.⋅lbf) × 16 30 (306, 22) ×4 Camshaft Bearing Cap No. 3 Camshaft Bearing Cap No. 1 Camshaft Bearing No. 1 Camshaft Bearing Cap No. 3 Camshaft Bearing Cap No. 2 Camshaft (Intake) Camshaft Timing Gear Assy No. 2 Camshaft (Exhaust) See page (14-41 ) 1st: 79 (806, 58) 2nd: Turn 90
54 (551, 40) 54 (551, 40) × 10 Camshaft Timing Gear or Sprocket Cylinder Head Sub-assy Camshaft Bearing No. 2 9.0 (92, 80 in.⋅lbf) Camshaft Timing Oil Control Valve  O-Ring  Cylinder Head Gasket N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part A92010 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2515 14-23 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE)  Engine Rear Oil Seal Plug 30 (306, 22)  Gasket Oil Control Valve Filter for Camshaft Timing  O-ring Stiffening Crankcase Assy 33 (337, 24) ×5 ×6 Balanceshaft No. 1 33 (337, 24) Balanceshaft No. 2 Balanceshaft Bearing No. 1 Balanceshaft Housing See page (14-41 ) 1st: 22 (220, 15) 2nd: Turn 90
N⋅m (kgf⋅cm, ft⋅lbf) ×8 : Specified torque  Non-reusable part A91573 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2516 14-41 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) 141P5-01 OVERHAUL 1. (a) REMOVE OIL FILTER SUB-ASSY Using SST, remove the oil filter. SST 09228-06501 SST A36541 2. (a) 3. 4. 5. REMOVE OIL FILTER UNION Using a 12 mm hexagon wrench, remove the union. REMOVE OIL FILLER CAP SUB-ASSY REMOVE VENTILATION VALVE SUB-ASSY REMOVE SPARK PLUG 6. REMOVE CYLINDER HEAD COVER SUB-ASSY (a) Remove the 8 bolts, 2 nuts, and cylinder head cover. A94204 7. 8. REMOVE CYLINDER HEAD COVER GASKET REMOVE CRANKSHAFT POSITION SENSOR 9. (a) Timing Marks (b) REMOVE CRANKSHAFT PULLEY Turn the crankshaft pulley and align its groove with timing mark 0 of the timing chain cover. Check that the timing marks of the camshaft timing sprockets are aligned with the timing marks of the No. 1 bearing cap, as shown in the illustration. Timing Marks Groove A53043 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2534 14-42 ENGINE MECHANICAL (c) SST - PARTIAL ENGINE ASSY (2AZ-FE) Remove the crankshaft pulley. (1) Using SST, fix the pulley and loosen the bolt. SST 09213-54015 (91651-60855), 09330-00021 A36684 (2) Using SST, remove the bolt and pulley. SST 09950- 50013 (09951- 05010, 09952- 05010, 09953-05020, 09954-05021) SST A36685 10. REMOVE CHAIN TENSIONER ASSY NO.1 (a) Remove the 2 nuts, chain tensioner and gasket. NOTICE: Do not turn the crankshaft without the chain tensioner. A13325 11. (a) REMOVE WATER PUMP PULLEY Using SST, remove the water pump pulley. SST 09960-10010 (09962-01000, 09963-00700) 12. (a) REMOVE WATER PUMP ASSY Remove the 4 bolts, 2 nuts, bracket and water pump. SST A36335 Bracket A53037 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2535 14-43 ENGINE MECHANICAL 13. - PARTIAL ENGINE ASSY (2AZ-FE) REMOVE OIL PAN DRAIN PLUG 14. (a) REMOVE OIL PAN SUB-ASSY Remove the 12 bolts and 2 nuts. B12056 (b) Insert the blade of SST between the crankcase and oil pan. Cut off the applied sealer and remove the oil pan. SST 09032-00100 NOTICE: Be careful not to damage the contact surface of the cylinder block and oil pan. A00019 15. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSY (a) Remove the 14 bolts and 2 nuts. (b) Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder block and cylinder head. A77251 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2536 14-44 ENGINE MECHANICAL 16. (a) - PARTIAL ENGINE ASSY (2AZ-FE) REMOVE ENGINE REAR OIL SEAL Using a screwdriver and hammer, remove the oil seal. A32626 17. 18. 19. 20. 21. 22. REMOVE REMOVE REMOVE REMOVE REMOVE REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1 TIMING CHAIN GUIDE CHAIN TENSIONER SLIPPER CHAIN VIBRATION DAMPER NO.1 CHAIN SUB-ASSY CRANKSHAFT TIMING GEAR OR SPROCKET 90 23. (a) REMOVE NO.2 CHAIN SUB-ASSY Turn the crankshaft counterclockwise 90, and align the adjusting hole of the oil pump driven sprocket with the groove of the oil pump. (b) Put a bar (φ 4 mm (0.16 in.)) in the adjusting hole of the oil pump driven sprocket to temporarily lock the sprocket in position. then remove the nut. Groove A52508 Groove A52509 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2537 14-45 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) (c) (d) Remove the bolt, chain tensioner plate and spring. Remove the oil pump sprocket gear,driven sprocket and chain. 24. (a) REMOVE OIL PUMP ASSY Remove the 3 bolts, oil pump and gasket. 25. (a) REMOVE NO.2 CAMSHAFT (EXHAUST) Uniformly loosen and remove the No. 2 camshaft (exhaust)’s 10 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearings. Remove the camshaft. B11415 A32684 (b) 1 3 5 4 2 1 3 5 4 2 A36530 26. (a) (b) REMOVE CAMSHAFT (INTAKE) Uniformly loosen and remove the camshaft (intake)’s 10 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearings. Remove the camshaft. A36531 27. REMOVE CAMSHAFT BEARING NO.1 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2538 14-46 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) 28. (a) REMOVE CAMSHAFT TIMING GEAR OR SPROCKET Fix the camshaft with a vise and remove the camshaft timing sprocket. NOTICE: Be careful not to damage the camshaft. A32167 29. (a) Advanced Angle Side (b) REMOVE CAMSHAFT TIMING GEAR ASSY Fix the camshaft with a vise, and make sure that the camshaft timing gear does not move. Cover all the oil ports with vinyl tape except the advanced angle side, as shown in the illustration. A90848 Using an air gun, apply about 150 kPa (1.5 kgf/cm2, 21 psi) of air pressure to the port on the advanced angle side. CAUTION: Some oil spraying will occur. Contain the spray with a shop rag. HINT: This operation releases the lock pin for the extreme retarded angle lock. (d) Under the condition above, check that the camshaft timing gear can be turned by hand to the advanced angle side (counterclockwise), the direction of the arrow shown in the illustration. Standard: Must turn HINT: The camshaft timing gear will turn to the advanced angle side without applying force by hand depending on the force of the air pressure applied. Also, if applying pressure to the oil path is difficult as a result of air leakage from the port, the lock-pin may be difficult to release. (c) A31032 (e) Remove the fringe bolt from the camshaft timing gear. NOTICE:
Be sure not to remove the other 4 bolts.
If planning to reuse the camshaft timing gear, release the straight pin lock first, and then install the gear. A32639 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2539 14-47 ENGINE MECHANICAL 30. 31. 33. 34. 35. (a) 36. - PARTIAL ENGINE ASSY (2AZ-FE) REMOVE CAMSHAFT BEARING NO.2 REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY 3 7 9 6 1 5 10 8 2 4 A94200 32. (a) REMOVE CYLINDER HEAD SUB-ASSY Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers. NOTICE:
Be careful not to drop the washers into the cylinder head.
Head warpage or cracking could result from removing bolts in an incorrect order. REMOVE CYLINDER HEAD GASKET REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY REMOVE OIL CONTROL VALVE FILTER Using a 6 mm socket hexagon wrench, remove the plug and filter. REMOVE W/HEAD TAPER SCREW PLUG NO.1 37. INSPECT BALANCESHAFT THRUST CLEARANCE (a) Using a dial indicator, measure the thrust clearance while moving the balanceshaft back and forth. Standard thrust clearance: 0.050 to 0.090 mm (0.0020 to 0.0035 in.) Maximum thrust clearance: 0.090 mm (0.0035 in.) If the thrust clearance is greater than the maximum, replace the balanceshaft housing and bearings. If necessary, replace the balance shaft. A53071 38. (a) 4 1 8 5 6 7 2 3 A93962 INSPECT BALANCESHAFT OIL CLEARANCE Uniformly loosen and remove the 8 bolts in the sequence shown in the illustration. NOTICE: Be careful not to damage the contact surfaces of the balanceshaft housing and crankcase. HINT: Keep the lower bearing and balanceshaft housing together. (b) Lift out the No. 1 and No. 2 balanceshafts. HINT: Keep the upper bearing with the crankcase. (c) Clean each bearing and journal. (d) Check each bearing and journal for pitting and scratches. If a bearing or journal is damaged, replace the bearings. If necessary, replace the balance shaft. (e) Place the No. 1 and No. 2 balanceshafts on the crankcase. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2540 14-48 ENGINE MECHANICAL (f) (g) Plastigage - PARTIAL ENGINE ASSY (2AZ-FE) Lay a strip of Plastigage across each journal, and install the balanceshaft housing. Apply a light coat of engine oil on the threads and under the heads of the balanceshaft housing bolts. A90849 (h) 5 8 1 4 3 2 7 6 Uniformly tighten the 8 bolts in the sequence shown in the illustration. Torque: 22 N⋅m (220 kgf⋅cm, 16 ft⋅lbf) HINT: The balanceshaft housing bolts are tightened in 2 progressive steps. A93962 90 (i) Paint Mark (j) (k) Engine Front Mark the front side of each balanceshaft housing bolt head with paint. Retighten the bolts 90 as shown in the illustration. Check that the paint marks are now at a 90 angle to the front. A50671 (l) (m) Remove the balanceshaft housing, and measure the Plastigage at its widest point. Standard oil clearance: 0.004 to 0.031 mm (0.0002 to 0.0012 in.) Maximum oil clearance: 0.031 mm (0.0012 in.) Completely remove the Plastigage after the inspection. A13392 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2541 14-49 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) If the clearance is greater than the maximum, replace the bearing. If necessary, replace the balanceshaft. If using a standard bearing, replace it with one of the same number. Balanceshaft housing journal bore diameter: (n) No. 2 Shaft FR No. 2 Shaft RR 26.000 to 26.006 mm (1.0236 to 1.0239 in.) Mark 2 26.007 to 26.012 mm (1.0239 to 1.0241 in.) Mark 3 26.013 to 26.018 mm (1.0241 to 1.0243 in.) Balanceshaft journal diameter: 22.985 to 23.000 mm (0.9049 to 0.9055 in.) Standard bearing center wall thickness: No. 1 Shaft RR No. 1 Shaft FR Mark 1 Mark 1 1.486 to 1.489 mm (0.0585 to 0.0586 in.) Mark 2 1.489 to 1.492 mm (0.0586 to 0.0587 in.) Mark 3 1.492 to 1.495 mm (0.0587 to 0.0589 in.) Completely remove the Plastigage after the inspection. Mark A53040 39. 40. REMOVE BALANCESHAFT REMOVE BALANCESHAFT BEARING NO. 1 41. REMOVE ENGINE REAR OIL SEAL (a) Using a knife, cut off the oil seal lip. (b) Using a screwdriver with its tip taped, pry out the oil seal. NOTICE: After the removal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper. Cut Position A13493 1 5 2 6 9 11 8 4 10 7 3 42. (a) A94192 REMOVE STIFFENING CRANKCASE ASSY Uniformly loosen and remove the 11 bolts in the sequence shown in the illustration. (b) Using a screwdriver, remove the crankcase by prying the portions between the crankcase and cylinder block. NOTICE: Be careful not to damage the contact surfaces of the crankcase and cylinder block. (c) Remove the O-ring from the cylinder block. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2542 14-50 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) 43. (a) (b) A53035 INSPECT OIL PUMP DRIVE SPROCKET Wrap the chain around the drive gear. Using a vernier caliper, measure the sprocket diameter with the chain. Minimum sprocket diameter (w/chain): 48.2 mm (1.898 in.) NOTICE: The vernier caliper must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and sprocket. 44. (a) (b) A53036 A53035 INSPECT OIL PUMP DRIVEN SPROCKET Wrap the chain around the drive shaft gear. Using a vernier caliper, measure the sprocket diameter with the chain. Minimum gear diameter (w/chain): 48.2 mm (1.898 in.) NOTICE: The vernier caliper must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and sprocket. 45. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET (a) Wrap the chain around the timing gear. (b) Using a vernier caliper, measure the timing gear diameter with the chain. Minimum gear diameter (w/ chain): 51.6 mm (2.031 in.) NOTICE: The vernier caliper must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and timing gear. 46. (a) INSPECT CHAIN TENSIONER SLIPPER Measure the tensioner slipper wear. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than the maximum, replace the tensioner slipper. A33838 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2543 14-51 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) 47. (a) INSPECT CHAIN VIBRATION DAMPER NO.1 Measure the vibration damper wear. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than the maximum, replace the vibration damper. A36686 48. (a) INSPECT CYLINDER HEAD SET BOLT Using a vernier caliper, measure the length of the head bolts from the seat to the end. Standard bolt length: 161.3 to 162.7 mm (6.3503 to 6.4055 in.) Maximum bolt length: 164.2 mm (6.4646 in.) If the length is greater than the maximum, replace the bolt. Specified Bolt Length A94201 49. (a) Raise Move (b) Lock INSPECT CHAIN TENSIONER ASSY NO.1 Check that the plunger moves smoothly when the ratchet pawl is raised. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger. A53049 50. (a) 115.4 mm 15 Links A57478 INSPECT CHAIN SUB-ASSY Using a vernier caliper, measure the length of 15 links with the chain fully stretched. Maximum chain elongation: 115.4 mm (4.543 in.) NOTICE: Make the same measurements pulling at 3 or more places selected at random. Average the measurements. If the elongation is greater than the maximum, replace the chain. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2544 14-52 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) 51. (a) (b) A30206 INSPECT CAMSHAFT TIMING GEAR OR SPROCKET Wrap the chain around the timing sprocket. Using a vernier caliper, measure the timing sprocket diameter with the chain. Minimum sprocket diameter (w/chain): 97.3 mm (3.831 in.) NOTICE: The vernier caliper must contact the chain rollers for the measurement. If the diameter is less than the minimum, replace the chain and timing gear. 52. (a) INSPECT CAMSHAFT (INTAKE) Check the camshaft for runout. (1) Place the camshaft on V-blocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than the maximum, replace the camshaft. EM1628 (b) Using a micrometer, measure the cam lobe height. Standard cam lobe height: 46.495 to 46.595 mm (1.8305 to 1.8344 in.) Minimum cam lobe height: 46.385 mm (1.8262 in.) If the cam lobe height is less than the minimum, replace the camshaft. A36687 (c) Using a micrometer, measure the journal diameter. No. 1 journal diameter: 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Other journal diameter: 22.959 to 22.975 mm (0.9039 to 0.9045 in.) If the journal diameter is not as specified, check the oil clearance. A36688 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2545 14-53 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) 53. (a) INSPECT NO.2 CAMSHAFT (EXHAUST) Check the camshaft for runout. (1) Place the camshaft on V-blocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than the maximum, replace the camshaft. EM1628 (b) Using a micrometer, measure the cam lobe height. Standard cam lobe height: 45.983 to 46.083 mm (1.8104 to 1.8143 in.) Minimum cam lobe height: 45.873 mm (1.8060 in.) If the cam lobe height is less than the minimum, replace the camshaft. A36687 (c) Using a micrometer, measure the journal diameter. No. 1 journal diameter: 35.971 to 35.985 mm (1.4162 to 1.4167 in.) Other journal diameter: 22.959 to 22.975 mm (0.9039 to 0.9045 in.) If the journal diameter is not as specified, check the oil clearance. A36688 54. (a) (b) INSTALL BALANCESHAFT BEARING NO.1 Install the bearings in the crankcase and balanceshaft housing. Apply a light coat of engine oil on the bearings. 55. (a) Matchmarks (b) INSTALL BALANCESHAFT NO. 1 AND NO. 2 Rotate the driven gear No. 1 of balanceshaft No. 1 for the rotating direction until it hits the stopper. Confirm that the matchmarks on driven gear No. 1 and No. 2 are matched. Rotating Direction A90850 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2546 14-54 ENGINE MECHANICAL (c) Timing Marks (d) (e) - PARTIAL ENGINE ASSY (2AZ-FE) Align the timing marks of the No. 1 and No. 2 balanceshafts as shown in the illustration. Place the No. 1 and No. 2 balance shafts on the crank case. Apply a light coat of engine oil under the heads of the balance shaft housing bolts. A13508 (f) 5 8 1 4 3 2 7 6 Uniformly tighten the 8 bolts in the sequence shown in the illustration. Torque: 22 N⋅m (224 kgf⋅cm, 16 ft⋅lbf) HINT: The balanceshaft housing bolts are tightened in 2 progressive steps. A93962 90 (g) Paint Mark (h) (i) Engine Front Mark the front side of each balance shaft housing bolt head with paint. Retighten the bolts by 90 as shown in the illustration. Check that the painted marks are now at a 90 angle to the front. A50671 Seal Packing Seal width: 2.5 to 3.0 mm A C D B B 56. (a) INSTALL STIFFENING CRANKCASE ASSY Apply seal packing in a continuous bead (seal width: 2.5 to 3.0 mm (0.098 to 0.118 in.)) to the places shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTICE:
Remove any oil from the contact surface.
Install the crankcase within 3 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing. C,D A A,B: 7.5 mm (0.295 in.) C,D: 4.0 mm (0.1575 in.) A94193 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2547 14-55 ENGINE MECHANICAL O-ring - PARTIAL ENGINE ASSY (2AZ-FE) (b) Place a new O-ring on the cylinder block, as shown in the illustration. (c) With the No. 1 crank pin of the crankshaft placed at 6 o’clock, install the No. 1 and No. 2 balanceshaft and the adjusting hole as shown in the illustration. (d) Uniformly tighten the 11 bolts in the sequence shown in the illustration. Torque: 33 N⋅m (337 kgf⋅cm, 24 ft⋅lbf) (e) Confirm that the timing marks of the balanceshafts are matched when the key groove is placed at 6 o’clock, as shown in the illustration. A53026 No. 1 Crank Pin Timing Marks A91021 11 7 10 6 3 1 4 8 2 5 9 A94192 Timing Marks Key A94194 SST A32658 57. INSTALL ENGINE REAR OIL SEAL (a) Apply MP grease to a new oil seal lip. NOTICE: Keep the lip off the foreign materials. (b) Using SST and a hammer, evenly tap the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-15030, 09950-70010 (09951-07100) NOTICE: Wipe off extra grease on the crankshaft. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2548 14-56 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) 58. (a) INSTALL W/HEAD TAPER SCREW PLUG NO.1 Apply adhesive to the threads of the plug and install it. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Torque: 26 N⋅m (265 kgf⋅cm, 19 ft⋅lbf) 59. INSTALL OIL CONTROL VALVE FILTER FOR CAMSHAFT TIMING Check that no foreign substance is on the mesh part of the filter. Using a 6 mm socket hexagon wrench, install a new gasket and the oil control valve filter with the screw plug. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) A36850 (a) (b) Mesh Part A53039 60. (a) 45 INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY Install the water drain cock within the range shown in the illustration. Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf) 45 A36835 Lot No. 61. (a) INSTALL CYLINDER HEAD GASKET Place a new gasket on the cylinder block surface with the Lot No. stamp upward. NOTICE:
Remove any oil from contact surface.
Be careful of the installation direction.
To avoid damage to the gasket, place the cylinder head on the gasket carefully. INTAKE Engine Front EXHAUST A90968 62. INSTALL CYLINDER HEAD SUB-ASSY HINT: The cylinder head bolts are tightened in 2 progressive steps. (a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. (b) Install the 10 bolts and plate washers to the cylinder head. NOTICE: Do not drop the washers into the cylinder head. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2549 14-57 ENGINE MECHANICAL 8 4 2 5 10 6 1 3 9 7 - PARTIAL ENGINE ASSY (2AZ-FE) (c) Using a 10 mm bi-hexagon wrench, uniformly tighten the 10 bolts in the sequence shown in the illustration. Torque: 79 N⋅m (806 kgf⋅cm, 58 ft⋅lbf) (d) (e) Mark the front side of each cylinder head bolt with paint. Retighten the cylinder head bolts by 90 in the sequence shown in the illustration. Check that the painted marks are now at a 90 angle to the front. A94195 90 (f) Engine Front Paint Mark A00976 63. A53074 INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) 64. INSTALL CAMSHAFT BEARING NO.2 (a) Install the bearing to the camshaft. NOTICE: Clean the contact surfaces of the bearing and the cylinder head. the surfaces should be free of dust and oils. A13383 65. (a) Straight Pin Key Groove A31033 INSTALL CAMSHAFT TIMING GEAR ASSY Put the camshaft timing gear and the camshaft together with the straight pin and key groove. (b) Turn the camshaft timing gear (as shown in the illustration) while pushing it lightly against the camshaft. Push further at the position where the pin enters the groove. CAUTION: Be sure not to turn the camshaft timing gear to the retarded angle side (to the right angle). (c) Check that there is no clearance between the gear’s fringe and the camshaft. (d) Tighten the fringe bolt with the camshaft timing gear fixed. Torque: 54 N⋅m (551 kgf⋅cm, 40 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2550 14-58 ENGINE MECHANICAL (e) - PARTIAL ENGINE ASSY (2AZ-FE) Check that the camshaft timing gear can move to the retarded angle side (the right direction) and is locked at the extreme retarded angle position. HINT:

66. (a) Apply a light coat of engine oil on the threads and under the heads of the bolt. Length of sprocket bolt excluding bolt head: 40 mm (1.57 in.) INSTALL CAMSHAFT TIMING GEAR OR SPROCKET Fix the camshaft with a vise, and install the camshaft No. 2 timing gear. Torque: 54 N⋅m (551 kgf⋅cm, 40 ft⋅lbf) HINT:

A32167 67. Apply a light coat of engine oil on the threads and under the heads of the bolt. Length of sprocket bolt excluding bolt head: 25 mm (0.98 in.) INSTALL CAMSHAFT BEARING NO.1 5 3 1 2 68. (a) 4 Bearing Cap No. 1 Bearing Cap No. 3 A92649 Bearing Cap No. 2 5 3 Bearing Cap No. 3 1 2 4 INSTALL CAMSHAFT (INTAKE) Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) for bearing cap No. 1 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for bearing cap No. 3 NOTICE:
Tighten the bolts after deciding the position for the thrust direction of the camshaft by the bearing cap No. 1.
Install the camshaft with its timing mark of the camshaft timing gear on top. 69. (a) INSTALL NO.2 CAMSHAFT (EXHAUST) Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) for bearing cap No. 2 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for bearing cap No. 3 A94196 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2551 14-59 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) NOTICE:
Tighten the bolts after deciding the position for the thrust direction of the camshaft by the bearing cap No. 2.
Install the camshaft with its timing mark of the camshaft timing gear on top. 70. (a) INSTALL OIL PUMP ASSY Install a new gasket and oil pump with the 3 bolts. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) 71. (a) (b) INSTALL NO.2 CHAIN SUB-ASSY Set the crankshaft key into the left horizontal position. Turn the cutout of the drive shaft to the top. (c) Align the mark links (yellow colored links) with the timing marks of the sprocket as shown in the illustration. Insert the sprocket with chain to the crankshaft and oil pump shaft. Temporarily tighten the oil pump driven sprocket with the nut. A32684 B11424 Mark Link Timing Mark (d) (e) Timing Mark Mark Link A94198 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2552 14-60 ENGINE MECHANICAL Chain Tensioner Plate - PARTIAL ENGINE ASSY (2AZ-FE) (f) Insert the damper spring into the adjusting hole, and install the chain tensioner plate by the bolt. Torque: 12 N⋅m (122 kgf⋅cm, 9.0 ft⋅lbf) (g) Align the adjusting hole of the sprocket with the groove of the oil pump. Put a bar (φ 4 mm (0.16 in.)) into the adjusting hole of the sprocket to temporarily lock the sprocket in position. Install the nut. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) Bolt Spring A90851 (h) Groove A52512 (i) 90 Rotate the crankshaft clockwise 90, and align the crankshaft key with the top. A36525 72. 73. (a) INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET INSTALL CHAIN VIBRATION DAMPER NO.1 Install the chain vibration damper with the 2 bolts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2553 14-61 ENGINE MECHANICAL 74. (a) - PARTIAL ENGINE ASSY (2AZ-FE) INSTALL CHAIN SUB-ASSY Set the No. 1 cylinder to TDC/compression. (1) Align the timing marks of the camshaft timing gear/ sprocket and bearing caps (No. 1 and No. 2). Timing Marks Timing Marks A53018 (2) Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward. A52505 (b) Align the mark link (blue or orange colored link) with the timing mark of the crankshaft timing sprocket. (c) Using SST, tap in the sprocket. SST 09309-37010 Timing Mark Mark Link A52523 SST A13337 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2554 14-62 ENGINE MECHANICAL (d) Mark Links Timing Mark Timing Marks - PARTIAL ENGINE ASSY (2AZ-FE) Align the mark links (gold or yellow colored links) with the timing marks of the camshaft timing gear and camshaft timing sprocket. Then install the chain. A52513 75. 76. INSTALL CHAIN TENSIONER SLIPPER Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) INSTALL TIMING CHAIN GUIDE Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) 77. (a) INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 Install the sensor plate with the F mark facing forward. A53064 78. SST A13767 B A Seal Cylinder Head Packing Gasket Cylinder Head A Seal Packing Cylinder Seal Block Packing Seal Width: 2.0 mm B Seal Packing INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (a) Using SST, tap in a new oil seal until its surface is flush with the timing chain cover edge. SST 09223-22010 (b) Apply a light coat of MP grease to the lip of the oil seal. NOTICE: Keep the gap between the timing chain cover edge and the oil seal free of foreign matter. 79. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSY NOTICE:
Remove any oil from the contact surface.
Install the chain cover within 3 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing. (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block. (b) Apply seal packing in a continuous bead (seal width: 2.0 mm (0.079 in.)) as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent A90970 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2555 14-63 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) (c) Apply seal packing in a continuous bead (seal width: 3.0 to 4.0 mm (0.12 to 0.16 in.)) as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent (d) Install the timing chain cover with the 14 bolts and 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for bolt A 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) for bolt B 43N⋅m (438 kgf⋅cm, 32 ft⋅lbf) for bolt C 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for nut Install the stud bolt to the drive belt tensioner. Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) 4.0 mm (0.16 in.) A A 2.5 mm (0.098 in.) A Seal Width: 3.0 to 4.0 mm A A94199 C Nut Nut C C C B (e) C A B B B B B B B A77251 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2556 14-64 ENGINE MECHANICAL 6.0 mm (0.236 in.) Seal Width: 3.0 to 4.0 mm Seal Packing A94202 9 11 1 8 12 7 PARTIAL ENGINE ASSY (2AZ-FE) 80. INSTALL OIL PAN SUB-ASSY NOTICE:
Remove any oil from the contact surface.
Install the oil pan within 3 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing. (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan. (b) Apply seal packing in a continuous bead (seal width: 3.0 to 4.0 mm (0.12 to 0.16 in.)) as shown in the illustration, and install the oil pan. Seal packing: Part No. 08826-00080 or equivalent (c) 10 - Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) 13 6 14 5 81. (a) 4 3 2 A64641 INSTALL OIL PAN DRAIN PLUG Install a new gasket and the drain plug. Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf) 82. (a) (b) 0.5 to 1.0 mm (0.020 to 0.039 in.) Seal Width: 2.2 to 2.5 mm A94203 INSTALL WATER PUMP ASSY Clean the contact surface of the cylinder block. Apply seal packing in a continuous bead (seal width: 2.2 to 2.5 mm (0.087 to 0.098 in.)) to the outside edge of the water pump. Seal packing: Part No. 08826-00100 or equivalent NOTICE:
Remove any oil from the contact surface.
Install the water pump within 5 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2557 14-65 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) (c) Install the water pump with the 4 bolts and 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) NOTICE: Tighten the outside bolts and nuts with the clamp. B12052 83. (a) INSTALL WATER PUMP PULLEY Using SST, install the water pump pulley with the 4 bolts. SST 09960-10010 (09962-01000, 09963-00700) Torque: 26 N⋅m (265 kgf⋅cm, 19 ft⋅lbf) 84. (a) INSTALL CRANKSHAFT POSITION SENSOR Install the sensor with the 2 bolts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) Confirm that the wire harness of the sensor is placed as shown in the illustration. SST A36335 Wire Harness (b) Clamp Rib A52071 85. (a) (b) SST INSTALL CRANKSHAFT PULLEY Install the pulley. Using SST,tighten the bolt. SST 09213-54015 (91651-60855), 09330-00021 Torque: 180 N⋅m (1,835 kgf⋅cm, 133 ft⋅lbf) HINT: Apply a light coat of engine oil to the bolt threads and the area beneath the bolt head that come in contact with the washer. A36684 86. (a) Raise INSTALL CHAIN TENSIONER ASSY NO.1 Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out. Push Pin Hook A52461 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2558 14-66 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) (b) Install a new gasket and the chain tensioner with the 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) NOTICE: If the hook is released while inserting, apply the hook again, and insert the chain tensioner. Engine Front A52462 (c) Turn the crankshaft counterclockwise and check that the plunger knock pin is disconnected from the hook. (d) Turn the crankshaft clockwise and check that the slipper is pushed by the plunger. Disconnect Turn Pin Hook A93972 Plunger Push Turn 87. 88. 89. (a) A93973 INSPECT VALVE CLEARANCE (See page 14-6 ) ADJUST VALVE CLEARANCE (See page 14-6 ) INSTALL CYLINDER HEAD COVER GASKET Install the gasket to the cylinder head cover. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2559 14-67 ENGINE MECHANICAL 90. (a) Seal Packing A A94205 A A B A 91. 92. (a) 93. 94. (a) Nut PARTIAL ENGINE ASSY (2AZ-FE) INSTALL CYLINDER HEAD COVER SUB-ASSY Remove any old packing (FIPG) material. (b) Seal Packing A - B Apply seal packing to the 2 locations shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 5 minutes after applying seal packing.
Do not apply engine oil for at least 2 hours after installing. (c) Install the cylinder head cover with the 8 bolts and 2 nuts. Torque: 11 N⋅m (112 kgf⋅cm, 8 ft⋅lbf) for nut 11 N⋅m (112 kgf⋅cm, 8 ft⋅lbf) for bolt A 14 N⋅m (143 kgf⋅cm, 10 ft⋅lbf) for bolt B Nut A A94204 INSTALL SPARK PLUG Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) INSTALL VENTILATION VALVE SUB-ASSY Apply adhesive on the threads of the ventilation valve. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) Adhesive: Part No. 08833-00070 THREE BOND 1324 or equivalent INSTALL OIL FILLER CAP SUB-ASSY INSTALL OIL FILTER UNION Using a 12 mm hexagon wrench, install the oil filter union. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) 95. INSTALL OIL FILTER SUB-ASSY (a) Check and clean the oil filter installation surface. (b) Apply clean engine oil to the gasket of a new oil filter. (c) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. (d) Using SST, tighten it an additional 3/4 turn. SST 09228-06501 SST A36541 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2560 14-24 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) 141P4-03 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. (a) (b) 9. 10. 11. 12. 13. 14. 15. 16. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See page 11-1 ) REMOVE FRONT WHEEL REMOVE ENGINE UNDER COVER NO.1 REMOVE FRONT FENDER SPLASH SHIELD FRONT RH REMOVE FRONT FENDER SPLASH SHIELD FRONTR LH REMOVE FRONT FENDER APRON SEAL RH DRAIN COOLANT (See page 16-6 ) DRAIN AUTOMATIC TRANSAXLE FLUID Using a 10 mm hexagon wrench, remove the drain plug and gasket. Drain automatic transaxle fluid. Install a new gasket and the drain plug. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) DRAIN TRANSFER OIL (4WD TYPE) REMOVE BATTERY REMOVE AIR CLEANER ASSY DISCONNECT RADIATOR HOSE INLET DISCONNECT RADIATOR HOSE OUTLET DISCONNECT OIL COOLER INLET HOSE DISCONNECT OIL COOLER OUTLET HOSE REMOVE ENGINE MOUNTING STAY NO.2 RH 17. (a) REMOVE ENGINE MOVING CONTROL ROD W/BRACKET Remove the 3 bolts and engine moving control rod. A92861 18. 19. 20. REMOVE ENGINE MOUNTING BRACKET NO.2 RH REMOVE FAN AND GENERATOR V BELT (See page 14-5 ) DISCONNECT VANE PUMP OIL RESERVOIR ASSY 21. (a) DISCONNECT RETURN TUBE SUB-ASSY Remove the 2 bolts and disconnect the return tube. A52493 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2517 14-25 ENGINE MECHANICAL 22. 23. 24. 25. 26. DISCONNECT DISCONNECT DISCONNECT DISCONNECT DISCONNECT - PARTIAL ENGINE ASSY (2AZ-FE) UNION TO CHECK VALVE HOSE TRANSMISSION CONTROL CABLE ASSY (See page 40-34 ) HEATER INLET WATER HOSE HEATER OUTLET WATER HOSE FUEL TUBE SUB-ASSY (See page 11-1 ) 27. DISCONNECT ENGINE ROOM MAIN WIRE (a) Disconnect the engine wire from the ECM and J/B. (b) Disconnect the engine wire from the engine room J/B. (1) Remove the nut fixing the wire harness. (2) Using a screwdriver, unlock the engine room J/B. Disconnect the engine wire by pulling it upward. (3) Disconnect the connectors. (4) Remove the body ground. A53014 28. REMOVE EXHAUST PIPE ASSY FRONT (See page 15-2 ) 29. (a) (b) REMOVE PROPELLER SHAFT (4WD TYPE) Place the matchmarks on both of the flanges. Remove the 4 nuts, 4 bolts and 4 washers. (c) Insert SST after removing the propeller shaft. SST 09325-20010 Matchmark A52514 SST A53068 30. REMOVE FRONT STABILIZER LINK ASSY LH (a) Using a 6 mm socket hexagon wrench, fix the stud bolt. (b) Remove the nut and disconnect the stabilizer link. 31. REMOVE FRONT STABILIZER LINK ASSY RH HINT: Use the same procedures described for the LH side. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2518 14-26 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) 32. (a) REMOVE FRONT AXLE HUB RH NUT Using SST and a hammer, strike the lock nut covering to remove it. SST SST 09930-00010 NOTICE:
Set the drive shaft’s groove so that it faces up. Then use the SST and a hammer.
Remove the covering from the lock nut completely or the screw of the drive shaft may be damaged. C65981
Do not sharpen the tip of the SST. (b) Using a 30 mm socket wrench, remove the lock nut. REMOVE FRONT AXLE HUB LH NUT 33. HINT: Use the same procedures described for the LH side. 34. DISCONNECT SPEED SENSOR FRONT LH (a) Remove the bolt and disconnect the speed sensor from the steering knuckle. NOTICE: Keep the speed sensor tip and connection free from a foreign matter. 35. DISCONNECT SPEED SENSOR FRONT RH HINT: Use the same procedures described for the LH side. 36. (a) (b) DISCONNECT TIE ROD ASSY LH Remove the cotter pin and castle nut. Using SST, disconnect the tie rod end from the steering knuckle. SST 09628-6201 1 NOTICE: Be careful not to damage the cover of the ball joint. SST C65311 37. DISCONNECT TIE ROD ASSY RH HINT: Use the same procedures described for the LH side. 38. (a) DISCONNECT FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH Fix the crankshaft and remove the 6 setting bolts. C65935 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2519 14-27 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) 39. DISCONNECT FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH HINT: Use the same procedures described for the LH side. 40. (a) REMOVE DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT Fix the crankshaft and remove the 6 setting bolts. A62253 41. (a) DISCONNECT STEERING INTERMEDIATE SHAFT SUB-ASSY Loosen the sliding yoke bolt. A52332 (b) Matchmark (c) Place matchmarks on the intermediate shaft and control valve shaft. Remove the bolt and the steering intermediate shaft. A52331 (d) To prevent the steering wheel from rotating, fix the wheel with the seat belt. NOTICE: If the steering wheel is not fixed, the spiral cable will be damaged. A52334 42. DISCONNECT COMPRESSOR AND MAGNETIC CLUTCH HINT: Hung up the hoses instead of detaching. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2520 14-28 ENGINE MECHANICAL B B B B A - PARTIAL ENGINE ASSY (2AZ-FE) 43. (a) (b) REMOVE ENGINE ASSEMBLY WITH TRANSAXLE Set the engine lifter. Remove the 6 bolts and frame side rail plate RH and LH. (c) Remove the 6 bolts and front suspension member brace rear RH and LH. Carefully remove the engine assembly from the vehicle. A A52335 C (d) C D D D D Engine Hanger No. 1 A52336 (e) Engine Hanger No. 2 Install the 2 engine hangers as shown in the illustration. Parts No.: Engine hanger No. 1 12281-28010 Engine hanger No. 2 12282-28010 Bolt 91512-61020 (f) Torque: 38 N⋅m (387 kgf⋅cm, 28 ft lbf) Using a chain block and an engine sling device, hang the engine assembly. 44. (a) (b) REMOVE VANE PUMP ASSY Disconnect the PS oil pressure switch connector. Remove the 2 bolts and vane pump from the engine. A90847 A13317 45. 46. REMOVE STABILIZER BAR FRONT (4WD TYPE) REMOVE RACK & PINION POWER STEERING GEAR ASSY (4WD TYPE) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2521 14-29 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) 47. (a) REMOVE FRONT FRAME ASSY Remove the nut installing the engine mounting insulator LH. (b) Remove the nut installing the engine mounting insulator RH. (c) Remove the nut installing the engine mounting insulator FR. A52490 A52482 A52441 48. REMOVE FRONT DRIVE SHAFT ASSY RH (4WD TYPE) (See page 30-21 ) 49. (a) REMOVE ENGINE MOUNTING BRACKET RR (4WD TYPE) Remove the 6 bolts and engine mounting bracket RR. A52503 50. 51. 52. 53. 54. REMOVE TRANSFER ASSY (4WD TYPE) (See page 31-9 ) REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30-21 ) REMOVE FRONT DRIVE SHAFT ASSY RH (2WD TYPE) (See page 30-21 ) REMOVE STARTER ASSY (See page 19-4 ) REMOVE AUTOMATIC TRANSAXLE ASSY (See page 40-12 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2522 14-30 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) 55. (a) REMOVE DRIVE PLATE & RING GEAR SUB-ASSY Using SST, fix the crankshaft. SST 09213-54015 (91651-60855), 09330-00021 (b) Remove the 8 bolts, rear spacer, drive plate and front spacer. SST A36684 A91018 56. 57. INSTALL ENGINE STAND REMOVE ENGINE COVER SUB-ASSY NO.1 58. (a) REMOVE INTAKE MANIFOLD Remove the 5 bolts, 2 nuts, intake manifold and gasket. A61987 59. (a) INSPECT INTAKE MANIFOLD Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 2.0 mm (0.079 in.) If the warpage is greater than the maximum, replace the manifold. A85564 60. 61. 62. 63. 64. REMOVE REMOVE REMOVE REMOVE REMOVE VENTILATION HOSE No.1 VENTILATION HOSE NO.2 ENGINE WIRE INTAKE MANIFOLD INSULATOR NO.1 GENERATOR ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2523 14-31 ENGINE MECHANICAL 65. 66. 67. - PARTIAL ENGINE ASSY (2AZ-FE) REMOVE OIL LEVEL GAGE SUB-ASSY REMOVE OIL LEVEL GAGE GUIDE REMOVE MANIFOLD CONVERTER INSULATOR NO.1 68. (a) REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY Remove the 3 bolts, 2 nuts, and the No. 1 and No. 2 exhaust manifold stays. A52499 (b) Remove the 5 nuts, exhaust manifold converter and gasket. A92868 69. INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSY (a) Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.70 mm (0.0276 in.) If the warpage is greater than the maximum, replace the manifold. A85567 70. 71. 72. 73. REMOVE WATER INLET REMOVE THERMOSTAT REMOVE IGNITION COIL ASSY REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY 74. (a) REMOVE V-RIBBED BELT TENSIONER ASSY Remove the bolt, nut and belt tensioner. A32676 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2524 14-32 ENGINE MECHANICAL 75. 76. 77. 78. 79. 80. - PARTIAL ENGINE ASSY (2AZ-FE) REMOVE DRIVE SHAFT BEARING BRACKET (2WD TYPE) REMOVE ENGINE MOUNTING BRACKET RH REMOVE FUEL DELIVERY PIPE W/INJECTOR (See page 11-10 ) REMOVE WATER BY-PASS PIPE NO.1 REMOVE OIL COOLER PIPE (W/ OIL COOLER) REMOVE OIL COOLER HOSE (W/ OIL COOLER) Oil Pressure Switch 81. (a) REMOVE ENGINE OIL PRESSURE SWITCH ASSY Remove the oil pressure switch. 82. (a) REMOVE KNOCK SENSOR Remove the nut and the sensor. B11410 A85381 83. 84. 85. (a) (b) REMOVE ENGINE COOLANT TEMPERATURE SENSOR REPLACE PARTIAL ENGINE ASSY INSTALL ENGINE COOLANT TEMPERATURE SENSOR Install a new gasket to the sensor. Install the sensor. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) 86. (a) Upper 10 Engine Front 10 INSTALL KNOCK SENSOR Install the sensor with the nut. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) HINT: Angling the knock sensor below the horizontal (below 0) is recommended. A78436 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2525 14-33 ENGINE MECHANICAL 87. (a) (b) 88. (a) 89. (a) 90. 91. 92. - PARTIAL ENGINE ASSY (2AZ-FE) INSTALL ENGINE OIL PRESSURE SWITCH ASSY Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833-00080 THREE BOND 1344 or equivalent Install the oil pressure switch. Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf) INSTALL OIL COOLER PIPE (W/ OIL COOLER) Install a new gasket and the oil cooler pipe with the bolt and 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) INSTALL WATER BY-PASS PIPE NO.1 Install a new gasket and the by-pass pipe with the bolt and 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) INSTALL FUEL DELIVERY PIPE W/INJECTOR (See page 11-10 ) INSTALL ENGINE MOUNTING BRACKET RH Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) INSTALL DRIVE SHAFT BEARING BRACKET (2WD TYPE) Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) 93. (a) INSTALL V-RIBBED BELT TENSIONER ASSY Install the belt tensioner with the bolt and nut. Torque: 60 N⋅m (612 kgf⋅cm, 44 ft⋅lbf) A32676 94. 95. 96. 97. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) INSTALL IGNITION COIL ASSY Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) INSTALL THERMOSTAT (See page 16-1 1) INSTALL WATER INLET Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) 98. 2 3 (a) 4 1 INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY Install a new gasket and the exhaust manifold converter. Uniformly tighten the 5 nuts in the sequence shown in the illustration. Torque: 37 N⋅m (377 kgf⋅cm, 27 ft⋅lbf) 5 A92868 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2526 14-34 ENGINE MECHANICAL (b) - PARTIAL ENGINE ASSY (2AZ-FE) Install the No. 1 and No. 2 exhaust manifold stays with the 2 bolts and 2 nuts. Torque: 44 N⋅m (449 kgf⋅cm, 32 ft⋅lbf) A52499 99. 100. (a) (b) INSTALL MANIFOLD CONVERTER INSULATOR NO.1 INSTALL OIL LEVEL GAGE GUIDE Apply a light coat of the engine oil to the O-ring and install it to the guide. Install the oil level gage and guide with the bolt. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) 101. INSTALL GENERATOR ASSY (See page 19-40 ) 102. INSTALL INTAKE MANIFOLD (a) Install a new gasket and the intake manifold with the 5 bolts and 2 nuts. Uniformly tighten the bolts in several passes. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) A61987 103. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY (a) Using SST, fix the crankshaft. SST 09213-54015 (91651-60855), 09330-00021 (b) Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Part No. 08833-00070, THREE BOND or equivalent. SST A36684 (c) 1 6 3 7 8 4 Install the front spacer, drive plate and rear spacer with 8 bolts. Uniformly tighten the 8 bolts in the sequence shown in the illustration. Torque: 98 N⋅m (1,000 kgf⋅cm, 72 ft⋅lbf) 2 5 A61988 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2527 14-35 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) 104. INSTALL AUTOMATIC TRANSAXLE ASSY (See page 40-12 ) 105. INSTALL STARTER ASSY (See page 19-4 ) Torque: 39 N⋅m (398 kgf⋅cm, 29 ft⋅lbf) 106. INSTALL FRONT DRIVE SHAFT ASSY RH (2WD TYPE) (See page 30-21 ) 107. INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30-21 ) 108. INSTALL TRANSFER ASSY (4WD TYPE) (See page 31-9 ) A 109. INSTALL ENGINE MOUNTING BRACKET RR (4WD TYPE) (a) Install the mounting bracket with the 6 bolts. Torque: 34 N⋅m (347 kgf⋅cm, 25 ft⋅lbf) for bolt A 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) for bolt B A B A B B A53010 110. INSTALL FRONT DRIVE SHAFT ASSY RH (4WD TYPE) (See page 30-21 ) 111. INSTALL FRONT FRAME ASSY (a) Install the engine mounting insulator LH with the nut. Torque: 95 N⋅m (969 kgf⋅cm, 70 ft⋅lbf) A52490 (b) Install the engine mounting insulator RH with the nut. Torque: 95 N⋅m (969 kgf⋅cm, 70 ft⋅lbf) A52482 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2528 14-36 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) (c) Install the engine mounting insulator FR with the nut. Torque: 87 N⋅m (887 kgf⋅cm, 64 ft⋅lbf) (d) 4WD type: Install the engine mounting insulator RR with 2 nuts. Torque: 75 N⋅m (765 kgf⋅cm, 55 ft⋅lbf) A52441 A52340 112. INSTALL RACK & PINION POWER STEERING GEAR ASSY (4WD TYPE) Torque: 70 N⋅m (714 kgf⋅cm, 52 ft⋅lbf) 113. INSTALL STABILIZER BAR FRONT (4WD TYPE) Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) 114. INSTALL VANE PUMP ASSY (a) Install the vane pump to the engine with the 2 bolts. (b) Connect the PS oil pressure switch connector. Torque: 43 N⋅m (438 kgf⋅cm, 31 ft⋅lbf) A13317 B A B B B A 115. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (a) Set the engine assembly with transaxle on the engine lifter. (b) Install the engine assembly to the vehicle. (c) Install the frame side plate LH and RH with the 6 bolts. Torque: 86 N⋅m (877 kgf⋅cm, 63 ft⋅lbf) for bolt A 32 N⋅m (326 kgf⋅cm, 24 ft⋅lbf) for bolt B and nut A52335 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2529 14-37 ENGINE MECHANICAL (d) C C D - PARTIAL ENGINE ASSY (2AZ-FE) Install the front suspension member brace rear RH and LH with the 6 bolts. Torque: 86 N⋅m (877 kgf⋅cm, 63 ft⋅lbf) for bolt C 32 N⋅m (326 kgf⋅cm, 24 ft⋅lbf) for bolt D and nut D D D A52336 116. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (See page 55-45 ) 117. INSTALL STEERING INTERMEDIATE SHAFT SUB-ASSY (a) Align the matchmarks on the intermediate shaft and control valve shaft. Torque: 35 N⋅m (357 kgf⋅cm, 26 ft⋅lbf) Matchmark A52331 (b) Tighten the bolt. Torque: 35 N⋅m (357 kgf⋅cm, 26 ft⋅lbf) A52332 118. INSTALL BOLT, W/WASHER (a) Fix the crankshaft, and install the 6 setting bolts. Torque: 41 N⋅m (418 kgf⋅cm, 30 ft⋅lbf) A62253 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2530 14-38 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) 119. INSTALL FRONT SUSPENSION ARM SUB- ASSY LOWER NO.1 LH (a) Install the drive shaft to the steering knuckle. (b) Install the suspension lower arm with the bolt and the 2 nuts. Torque: 127 N⋅m (1,295 kgf⋅cm, 94 ft⋅lbf) C65935 120. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH HINT: Use the same procedures described for the LH side. 121. INSTALL TIE ROD ASSY LH (a) Connect the tie rod end to the steering knuckle and install a new castle nut. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) NOTICE:
Prevent any lubricant from contacting the thread and the taper portions.
After tightening the castle nut, tighten it to the additional direction within 60 to put into a cotter pin. (b) Insert a new cotter pin. 122. INSTALL TIE ROD ASSY RH HINT: Use the same procedures described for the LH side. 123. INSTALL SPEED SENSOR FRONT LH Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 124. INSTALL SPEED SENSOR FRONT RH Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 125. INSTALL FRONT AXLE HUB LH NUT (a) Using a 30 mm socket wrench, install a new hub nut. Torque: 294 N⋅m (3,000 kgf⋅cm, 217 ft⋅lbf) (b) Using a chisel and hammer, tapped the front axle hub LH nut. C65982 126. INSTALL FRONT AXLE HUB RH NUT HINT: Use the same procedures described for the LH side. 127. INSTALL FRONT STABILIZER LINK ASSY LH (a) Using a 5 mm socket hexagon wrench, fix the stud bolt and install the nut. Torque: 74 N⋅m (755 kgf⋅cm, 55 ft⋅lbf) 128. INSTALL FRONT STABILIZER LINK ASSY RH HINT: Use the same procedures described for the LH side. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2531 14-39 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (2AZ-FE) 129. INSTALL PROPELLER SHAFT (4WD TYPE) (a) Align the matchmarks on both the flanges of the front propeller shaft and intermediate shaft, then install and tighten the 4 bolts, 4 washers and 4 nuts. Torque: 74 N⋅m (755 kgf⋅cm, 55 ft⋅lbf) Matchmark A52514 130. INSTALL EXHAUST PIPE ASSY FRONT (See page 15-2 ) 131. CONNECT FUEL TUBE SUB-ASSY (See page 11-1 ) 132. INSTALL RETURN TUBE SUB-ASSY (a) Install the return tube with 2 bolts. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) A52493 133. INSTALL FAN AND GENERATOR V BELT (See page 14-5 ) 134. INSTALL ENGINE MOUNTING BRACKET NO.2 RH Torque: 52 N⋅m (530 kgf⋅cm, 38 ft⋅lbf) 135. INSTALL ENGINE MOVING CONTROL ROD W/BRACKET (a) Install the engine mounting control rod with the 3 bolts. Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) HINT: First, loosely install bolts (1) and (2) with your hand. Then use a wench to install bolt (3). Finally, tighten bolt (2) and (1), in that order. 1 2 3 A92861 136. INSTALL ENGINE MOUNTING STAY NO.2 RH Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) 137. INSTALL AIR CLEANER ASSY Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) 138. ADD TRANSFER OIL (a) Install a new gasket and the filler plug. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) 139. ADD AUTOMATIC TRANSAXLE FLUID 140. ADD ENGINE OIL 141. ADD COOLANT (See page 16-6 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2532 14-40 ENGINE MECHANICAL 142. 143. 144. 145. 146. 147. 148. 149. - PARTIAL ENGINE ASSY (2AZ-FE) CHECK FOR ENGINE OIL LEAKS CHECK FOR ENGINE COOLANT LEAKS (See page 16-6 ) INSPECT FOR FUEL LEAKS (See page 11-1 ) INSTALL FRONT WHEEL ADJUST FRONT WHEEL ALIGNMENT (See page 26-7 ) CHECK IDLE SPEED AND IGNITION TIMING (See page 14-1 ) INSPECT CO/HC (See page 14-1 ) CHECK ABS SPEED SENSOR SIGNAL (See page 05-765 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2533 14-91 ENGINE MECHANICAL - CYLINDER HEAD ASSY (2AZ-FE) CYLINDER HEAD ASSY (2AZ-FE) 141P6-02 COMPONENTS Valve Lifter Valve Retainer Lock Retainer Inner Compression Spring
Valve Stem Oil O Seal or Ring Valve Spring Seat Intake Valve Guide Bush Valve Lifter Valve Retainer Lock Retainer Inner Compression Spring
Valve Stem Oil O Seal or Ring Valve Spring Seat Exhaust Valve Guide Bush Stud Bolt 10 (102, 7.0) 5.0 (51, 44 in.⋅lbf) Ring w/ Head Pin Cylinder Head Assy 5.0 (51, 44 in.⋅lbf) 10 (102, 7.0) Exhaust Valve Intake Valve N⋅m (kgf⋅cm,ft⋅lbf) : Specified torque
Non-reusable part A77366 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2584 14-92 ENGINE MECHANICAL - CYLINDER HEAD ASSY (2AZ-FE) 141P7-02 OVERHAUL 1. REMOVE VALVE LIFTER HINT: Arrange the valve lifters in the correct order. 2. (a) SST REMOVE INTAKE VALVE Using SST and wooden blocks, compress and remove the 8 valve spring retainer locks. SST 09202-70020 (09202-00010) Remove the retainer, valve spring and valve. (b) HINT: Arrange the removed parts in the correct order. Wooden Blocks A52444 3. (a) SST REMOVE EXHAUST VALVE Using SST and wooden blocks, compress and remove the 8 valve spring retainer locks. SST 09202-70020 (09202-00010) Remove the retainer, valve spring and valve. (b) HINT: Arrange the removed parts in the correct order. Wooden Blocks A52472 4. (a) REMOVE VALVE STEM OIL O SEAL OR RING Using needle-nose pliers, remove the oil seals. A13356 5. 6. REMOVE VALVE SPRING SEAT REMOVE STUD BOLT 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2585 14-93 ENGINE MECHANICAL 7. (a) Cylinder Block Side - CYLINDER HEAD ASSY (2AZ-FE) INSPECT CYLINDER HEAD FOR FLATNESS Using a precision straight edge and a feeler gauge, measure the surface contacting the cylinder block and the manifolds for warpage. Maximum warpage: Item Specified Condition Cylinder block side 0.05 mm (0.0020 in.) Intake manifold side 0.08 mm (0.0031 in.) Exhaust manifold side 0.08 mm (0.0031 in.) If the warpage is greater than the maximum, replace the cylinder head. Intake Manifold Side Exhaust Manifold Side A52445 8. (a) INSPECT CYLINDER HEAD FOR CRACKS Using a dye penetrate, check the intake ports, exhaust ports and cylinder surface for cracks. If cracked, replace the cylinder head. A13365 9. (a) (b) (c) Width EM0183 A52446 INSPECT VALVE SEATS Apply a light coat of prussian blue (or white lead) to the valve face. Lightly press the valve face against the valve seat. Check the valve face and valve seat according to the following procedure. (1) If blue appears 360
around the valve face, the valve face is concentric. If not, replace the valve. (2) If blue appears 360
around the valve seat, the guide and valve face are concentric. If not, resurface the valve seat. (3) Check that the valve seat contact is in the middle of the valve face with the width between 1.0 to 1.4 mm (0.039 to 0.055 in.). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2586 14-94 ENGINE MECHANICAL - CYLINDER HEAD ASSY (2AZ-FE) 10. REPAIR VALVE SEATS NOTICE: Keep the lip free from a foreign matter. (a) If the seating is too high on the valve face, use 30
and 45
cutters to correct the seat. (b) If the seating is too low on the valve face, use 75
and 45
cutters to correct the seat. Hand-lap the valve and valve seat with an abrasive compound. Check the valve seating position. 45
30
1.0 to 1.4 mm (0.039 to 0.055 in.) A94213 75
45
(c) (d) 1.0 to 1.4 mm (0.039 to 0.055 in.) A94214 11. (a) (b) A36626 INSPECT CAMSHAFT THRUST CLEARANCE Install the camshafts. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: Intake 0.040 to 0.095 mm (0.0016 to 0.0037 in.) Exhaust 0.080 to 0.135 mm (0.0032 to 0.0053 in.) Maximum thrust clearance: Intake 0.11mm (0.0043 in.) Exhaust 0.15 mm (0.0059 in.) If the thrust clearance is greater than the maximum, replace the cylinder head. If the thrust surface is damaged, replace the camshaft. 12. (a) (b) (c) INSPECT CAMSHAFT OIL CLEARANCE Clean the bearing caps and camshaft journals. Place the camshafts on the cylinder head. Lay a strip of Plastigage across each of the camshaft journal. A36627 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2587 14-95 ENGINE MECHANICAL - CYLINDER HEAD ASSY (2AZ-FE) (d) Install the bearing caps. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) for No. 1 bearing cap 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) for No. 2 bearing cap 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for No. 3 bearing cap NOTICE: Do not turn the camshaft. A32645 (e) A36628 Remove the bearing cap, and measure the Plastigage at its widest point. Standard oil clearance: Intake No. 1 journal bearing mark 1 0.007 to 0.038 mm (0.0028 to 0.00150 in.) Intake No. 1 journal bearing mark 2 0.008 to 0.038 mm (0.0031 to 0.00150 in.) Intake No. 1 journal bearing mark 3 0.008 to 0.038 mm (0.0031 to 0.00150 in.) Other journals 0.025 to 0.062 mm (0.00098 to 0.00244 in.) Exhaust No. 1 journal 0.040 to 0.079 mm (0.00157 to 0.00311 in.) Other journals 0.025 to 0.062 mm (0.00098 to 0.00244 in.) Maximum oil clearance: Intake No. 1 journal 0.07 mm (0.0028 in.) Other journals 0.10 mm (0.0039 in.) NOTICE: Completely remove the Plastigage after the inspection. If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the cylinder head. If the oil clearance on the No.1 journal is greater than the maximum, choose a new bearing and install it. HINT: Cylinder head journal bore diameter Number Mark Mark 1 40.000 to 40.008 mm (1.57480 to 1.57511 in.) Mark 2 40.009 to 40.017 mm (1.57515 to 1.57547 in.) Mark 3 40.018 to 40.025 mm (1.57551 to 1.57578 in.) Standard bearing center wall thickness Number Mark A13530 Mark 1 2.000 to 2.004 mm (0.07874 to 0.07890 in.) Mark 2 2.005 to 2.008 mm (0.07894 to 0.07905 in.) Mark 3 2.009 to 2.012 mm (0.07909 to 0.07921 in.) Camshaft journal diameter: 35.971 to 35.985 mm (1.41618 to 1.41673 in.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2588 14-96 ENGINE MECHANICAL - CYLINDER HEAD ASSY (2AZ-FE) 13. (a) INSPECT INNER COMPRESSION SPRING Using a vernier caliper, measure the free length of the valve spring. Free length: 45.7 mm (1.799 in.) If the free length is not as specified, replace the valve spring. EM0801 (b) Using steel squares, measure the deviation of the valve spring. Maximum deviation: 1.6 mm (0.063 in.) If the deviation is greater than the maximum, replace the valve spring. Deviation EM0988 14. (a) INSPECT INTAKE VALVE Using a vernier caliper, measure the valve overall length. Standard overall length: 101.71 mm (4.0043 in.) Minimum overall length: 101.21 mm (3.9846 in.) If the overall length is less than the minimum, replace the valve. EM2534 (b) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 5.470 to 5.485 mm (0.2154 to 0.2159 in.) A32770 (c) Using a vernier caliper, measure the valve head margin thickness. Standard margin thickness: 1.05 to 1.45 mm (0.0413 to 0.0571 in.) Minimum margin thickness: 0.5 mm (0.0197 in.) If the margin thickness is less than the minimum, replace the valve. Margin Thickness EM0181 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2589 14-97 ENGINE MECHANICAL - CYLINDER HEAD ASSY (2AZ-FE) 15. (a) INSPECT EXHAUST VALVE Using a vernier caliper, measure the valve overall length. Standard overall length: 101.15 mm (3.9823 in.) Minimum overall length: 100.70 mm (3.9646 in.) If the overall length is less than the minimum, replace the valve. EM2534 (b) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 5.465 to 5.480 mm (0.2152 to 0.2157 in.) Z00052 (c) Using a vernier caliper, measure the valve head margin thickness. Standard margin thickness: 1.20 to 1.60 mm (0.0470 to 0.0630 in.) Minimum margin thickness: 0.5 mm (0.020 in.) If the margin thickness is less than the minimum, replace the valve. Margin Thickness EM0181 16. (a) A13367 INSPECT INTAKE VALVE GUIDE BUSH Using a caliper gauge, measure the inside diameter of the guide bush. Bush inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 in.) (b) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement. Standard oil clearance: 0.025 to 0.060 mm (0.0010 to 0.0024 in.) Maximum oil clearance: 0.08 mm (0.0031 in.) If the clearance is greater than the maximum, replace the valve and guide bush (see steps 18 and 20). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2590 14-98 ENGINE MECHANICAL - CYLINDER HEAD ASSY (2AZ-FE) 17. (a) A13367 INSPECT EXHAUST VALVE GUIDE BUSH Using a caliper gauge, measure the inside diameter of the guide bush. Bush inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 in.) (b) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement. Standard oil clearance: 0.030 to 0.065 mm (0.0012 to 0.0026 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) If the clearance is greater than the maximum, replace the valve and guide bush (see steps 19 and 21). 18. (a) REMOVE INTAKE VALVE GUIDE BUSH Using SST and a hammer, tap out the guide bush. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) 19. (a) REMOVE EXHAUST VALVE GUIDE BUSH Using SST and a hammer, tap out the guide bush. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) SST A36632 SST 20. (a) A36633 INSTALL INTAKE VALVE GUIDE BUSH Using a caliper gauge, measure the bush bore diameter of the cylinder head. Diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.) (b) Install the STD bush if the diameter is within the specified diameter. Standard diameter: 10.333 to 10.344 mm (0.4068 to 0.4072 in.) If the diameter is not as specified, replace the STD bush. (c) SST Using SST and a hammer, tap in a new guide bush to the specified protrusion height. Protrusion height: 9.6 to 10.0 mm (0.3780 to 0.3937 in.) SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) A36634 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2591 14-99 ENGINE MECHANICAL (d) 21. (a) (b) (c) SST (d) A36635 - CYLINDER HEAD ASSY (2AZ-FE) Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and valve stem. Standard oil clearance: 0.025 to 0.060 mm (0.00098 to 0.00236 in.) INSTALL EXHAUST VALVE GUIDE BUSH Using a caliper gauge, measure the bush bore diameter of the cylinder head. Diameter: 10.285 to 10.306 mm (0.4049 to 0.4057 in.) Install the STD bush if the diameter is within the specified diameter. Standard diameter: 10.333 to 10.344 mm (0.4068 to 0.4072 in.) Using SST and a hammer, tap in a new guide bush to the specified protrusion height. Protrusion height: 9.6 to 10.0 mm (0.3780 to 0.3937 in.) Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and valve stem. SST 09201- 10000 (09201- 01050), 09950- 70010 (09951-07100), 23801 Standard oil clearance: 0.030 to 0.065 mm (0.00118 to 0.00256 in.) 22. (a) INSPECT VALVE LIFTER Using a micrometer, measure the lifter diameter. Lifter diameter: 30.966 to 30.976 mm (1.2191 to 1.2195 in.) (b) Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31.009 to 31.025 mm (1.2208 to 1.2215 in.) P16860 A13374 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2592 14-100 ENGINE MECHANICAL - CYLINDER HEAD ASSY (2AZ-FE) (c) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.033 to 0.059 mm (0.0013 to 0.0023 in.) Maximum oil clearance: 0.07 mm (0.0028 in.) If the oil clearance is greater than the maximum, replace the lifter. If necessary, replace the cylinder head. 23. (a) Upper Side INSTALL RING W/HEAD PIN Using a plastic-faced hammer, tap in a new ring pin to the specified protrusion height. Protrusion height: 5.5 mm (0.22 in.) 11 mm (0.43 in.) 5.5 mm 8 mm (0.31 in.) [mm] A62971 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2593 14-101 ENGINE MECHANICAL 24. - CYLINDER HEAD ASSY (2AZ-FE) INSTALL STUD BOLT Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) for bolt A 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) for bolt B 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) for bolt C 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) for bolt D Front Upper A A Intake Side Exhaust Side C C B B 12 mm (0.47 in.) D D D D D 18 mm (0.71 in.) 14 mm (0.55 in.) 24 mm (0.94 in.) 46.5 mm (1.83 in.) 31.5 mm (1.24 in.) (M6) (M6) 9 mm (0.35 in.) 12 mm (0.47 in.) 49.5 mm (1.95 in.) (M8) 38.7 mm (1.52 in.) (M8) 13 mm (0.51 in.) 13 mm (0.51 in.) A90852 25. INSTALL VALVE SPRING SEAT 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2594 14-102 ENGINE MECHANICAL Intake Side Exhaust Side Gray Black A52449 - CYLINDER HEAD ASSY (2AZ-FE) 26. INSTALL VALVE STEM OIL O SEAL OR RING (a) Apply a light coat of engine oil on a new oil seal. NOTICE: Pay close attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust or installing the exhaust oil seal to the intake can cause installation problems later. HINT: The intake valve oil seal is gray and the exhaust valve oil seal is black. (b) Using SST, push in the oil seal. SST 09201-41020 SST A36639 27. (a) (b) SST Wooden Blocks A52444 (c) Using a plastic-faced hammer and a discarded valve with its tip wrapped in tape, lightly tap the installed valve to ensure that it is securely fit. NOTICE: Be careful not to damage the valve stem tip. Vinyl Tape Valve Stem INSTALL INTAKE VALVE Install the valve, spring and retainer to the cylinder head. Using SST and wooden blocks, compress the spring and install the 2 retainer locks. SST 09202-70020 (09202-00010) A13888 28. (a) (b) SST INSTALL EXHAUST VALVE Install the valve, spring and retainer to the cylinder head. Using SST and wooden blocks, compress the spring and install the 2 retainer locks. SST 09202-70020 (09202-00010) Wooden Blocks A52472 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2595 14-103 ENGINE MECHANICAL CYLINDER HEAD ASSY (2AZ-FE) (c) Using a plastic-faced hammer and a discarded valve with its tip wrapped in vinyl tape, lightly tap the installed valve to ensure that it is securely fit. NOTICE: Be careful not to damage the valve stem tip. Vinyl Tape Valve Stem - A13888 29. INSTALL VALVE LIFTER (a) Assemble the valve lifter and the tip of the valve stem with a light coat of engine oil applied. NOTICE: Install the valve lifters in their original places. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2596 14-104 ENGINE MECHANICAL - CYLINDER BLOCK ASSY (2AZ-FE) CYLINDER BLOCK ASSY (2AZ-FE) 141P8-02 COMPONENTS Piston Ring Set Piston  Snap Ring  Snap Ring Piston Pin Connecting Rod Connecting Rod Bearing Cylinder Block Assy Crankshaft Thrust Washer Crankshaft Bearing Crankshaft Connecting Rod Bearing Crankshaft Bearing Connecting Rod Cap Connecting Rod Bearing Cap Bolt See page 14-105 1st: 25 (250, 18) 2nd: Turn 90
Crankshaft Bearing Cap Crankshaft Bearing Cap Bolt See page 14-105 1st: 20 (204, 15) 2nd: Turn 90
N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque  Non-reusable part A88217 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2597 14-105 ENGINE MECHANICAL - CYLINDER BLOCK ASSY (2AZ-FE) 141P9-02 OVERHAUL 1. (a) A36642 A13397 INSPECT CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.160 to 0.362 mm (0.0063 to 0.0143 in.) Maximum thrust clearance: 0.362 mm (0.0143 in.) If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft. 2. INSPECT CONNECTING ROD OIL CLEARANCE HINT: The connecting rod cap bolts are tightened in 2 progressive steps. (a) Check that the matchmarks on the connecting rod and cap are aligned to ensure the correct reassembly. HINT: The matchmarks on the connecting rods and caps are for ensuring the correct reassembly. (b) Using a 12 mm socket wrench, remove the 2 connecting rod cap bolts. (c) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. HINT: Keep the lower bearing inserted to the connecting rod cap. (d) Clean the crank pin and bearing. (e) Check the crank pin and bearing for pitting and scratches. (f) Lay a strip of Plastigage on the crank pin. A13400 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2598 14-106 ENGINE MECHANICAL - CYLINDER BLOCK ASSY (2AZ-FE) (g) Check that the front mark of the connecting rod cap is facing in the correct direction. (h) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. (i) Install the connecting cap (see step 37). NOTICE: Do not turn the crankshaft. (j) Remove the 2 bolts and connecting rod cap. Front Mark A52515 (k) Measure the Plastigage at its widest point. Standard oil clearance: 0.024 to 0.048 mm (0.0009 to 0.0019 in.) Maximum oil clearance: 0.08 mm (0.0031 in.) If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. A36644 Mark 1, 2 or 3 Mark 1, 2 or 3 A13840 HINT: If replacing a bearing, replace it with one that has the same number as the connecting rod. There are 3 sizes of standard bearings: 1, 2 and 3. Standard bearing center wall thickness: Mark 1 1.485 to 1.488 mm (0.05854 to 0.05858 in.) Mark 2 1.489 to 1.491 mm (0.05862 to 0.05870 in.) Mark 3 1.492 to 1.494 mm (0.05874 to 0.05881 in.) (l) Completely remove the Plastigage. 3. (a) REMOVE PISTON SUB-ASSY W/CONNECTING ROD Using a ridge reamer, remove all the carbon from the top of the cylinder. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. (b) HINT:

A13469 4. Keep the bearing, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order. REMOVE CONNECTING ROD BEARING 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2599 14-107 ENGINE MECHANICAL 5. (a) - CYLINDER BLOCK ASSY (2AZ-FE) (b) REMOVE PISTON RING SET Using a piston ring expander, remove the 2 compression rings. Remove the 2 side rails and oil ring by hand. 6. (a) REMOVE PISTON PIN HOLE SNAP RING Using a small screwdriver, pry out the 2 snap rings. 7. (a) REMOVE PISTON Gradually heat the piston to approximately 80 to 90C (176 to 194F). (b) Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. A36647 A13478 A01178 HINT:

The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. A01179 8. (a) A36645 INSPECT CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.040 to 0.240 mm (0.0016 to 0.0094 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than the maximum, replace the thrust washers as a set. Thrust washer thickness: 1.930 to 1.980 mm (0.0760 to 0.0780 in.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2600 14-108 ENGINE MECHANICAL 4 8 10 6 2 3 7 9 5 1 9. (a) - CYLINDER BLOCK ASSY (2AZ-FE) INSPECT CRANKSHAFT OIL CLEARANCE Uniformly loosen and remove the 10 main bearing cap bolts, in the sequence shown in the illustration. A87780 (b) A87781 Use 2 removed main bearing cap bolts to remove the 5 main bearing caps and 5 lower bearings. NOTICE: Insert the bolts into one of the caps. Ease the cap out by gently pulling up and applying force toward the front and back side of the cylinder block, as shown in the illustration. Take care not to damage the contact surfaces of the cap and cylinder block. HINT:
Keep the lower bearing and main bearing cap together.
Arrange the main bearing caps in correct order. (c) Lift out the crankshaft. HINT: Keep the upper bearings together with the cylinder block. (d) Clean each main journal and bearing. (e) Check each main journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. (f) Place the crankshaft on the cylinder block. (g) Lay a strip of Plastigage across each journal. (h) Install the main bearing caps (see step 36). NOTICE: Do not turn the crankshaft. (i) Remove the main bearing cap (see steps (a) to (b) above). Plastigage A87782 (j) Measure the Plastigage at its widest point. Standard oil clearance: 0.024 to 0.048 mm (0.00094 to 0.00189 in.) If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft. A87783 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2601 14-109 ENGINE MECHANICAL (k) Number Mark No. 3 No. 4 CYLINDER BLOCK ASSY (2AZ-FE) If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, and then select the bearing according to the chart below. There are 4 sizes of standard bearings: 1, 2, 3, and 4. Cylinder block (A) + Crankshaft (B) 0 to 2 3 to 5 6 to 8 9 to 11 Use bearing 1 2 3 4 HINT: EXAMPLE Cylinder block 4 (A) + Crankshaft 3 (B) = Total number 7 (Use bearing 3) No. 1 No. 2 - No. 5 Number Mark A87784 Reference: Item Mark Specified Condition Cylinder block main journal bore diameter (A) 0 1 2 3 4 5 6 59.000 to 59.002 mm (2.32283 to 2.32291 in.) 59.003 to 59.004 mm (2.32294 to 2.32299 in.) 59.005 to 59.006 mm (2.32303 to 2.32307 in.) 59.007 to 59.009 mm (2.32311 to 2.32318 in.) 59.010 to 59.011 mm (2.32322 to 2.32326 in.) 59.012 to 59.013 mm (2.32330 to 2.32334 in.) 59.014 to 59.016 mm (2.32338 to 2.32346 in.) Crankshaft main journal diameter (B) 0 1 2 3 4 5 54.999 to 55.000 mm (2.16531 to 2.16535 in.) 54.997 to 54.998 mm (2.16523 to 2.16527 in.) 54.995 to 54.996 mm (2.16515 to 2.16519 in.) 54.993 to 54.994 mm (2.16507 to 2.16511 in.) 54.991 to 54.992 mm (2.16500 to 2.16504 in.) 54.989 to 54.990 mm (2.16489 to 2.16496 in.) Standard bearing center wall thickness 1 2 3 4 1.993 to 1.996 mm (0.07846 to 0.07858 in.) 1.997 to 1.999 mm (0.07862 to 0.07870 in.) 2.000 to 2.002 mm (0.07874 to 0.07882 in.) 2.003 to 2.005 mm (0.07886 to 0.07894 in.) (l) Completely remove the Plastigage. 10. REMOVE CRANKSHAFT (a) Lift out the crankshaft. (b) Remove the 5 upper main bearings and 2 thrust washers from the cylinder block. HINT: Arrange the main bearings and thrust washers in the correct order. 11. REMOVE CRANKSHAFT THRUST WASHER UPPER 12. REMOVE CRANKSHAFT BEARING HINT: Arrange the bearings in the correct order. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2602 14-1 10 ENGINE MECHANICAL - CYLINDER BLOCK ASSY (2AZ-FE) 13. REMOVE CRANKSHAFT BEARING NO.2 HINT: Arrange the main bearings and thrust washers in the correct order. 14. REMOVE STUD BOLT 15. CLEAN CYLINDER BLOCK NOTICE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block. Always wash the cylinder block at a temperature of 45C (113F) or less. 16. (a) INSPECT CYLINDER BLOCK FOR FLATNESS Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Maximum warpage: 0.05 mm (0.0020 in.) If the warpage is greater than the maximum, replace the cylinder block. A36648 17. (a) INSPECT CYLINDER BORE Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions. Standard diameter: 88.500 to 88.513 mm (3.4842 to 3.4848 in.) Maximum diameter: 88.633 mm (3.4895 in.) If the measured diameters is greater than the standard, replace the cylinder block. Thrust Direction Front Axial Direction A B 10 mm (0.39 in.) A88899 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2603 14-1 11 ENGINE MECHANICAL 18. (a) - CYLINDER BLOCK ASSY (2AZ-FE) INSPECT PISTON DIAMETER Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 30.3 mm (1.193 in.) from the piston head. Piston diameter: 88.439 to 88.449 mm (3.4818 to 3.4822 in.) 30.3 mm (1.193 in.) A13486 19. (a) INSPECT PISTON CLEARANCE Subtract the piston diameter measurement from the cylinder bore diameter measurement. Specified oil clearance: 0.051 to 0.100 mm (0.0020 to 0.0039 in.) If the clearance is greater than the maximum, replace all the 4 pistons. If necessary, replace the cylinder block. 20. INSPECT RING GROOVE CLEARANCE (a) Using a feeler gauge, measure the clearance between the piston ring and the wall of the ring groove. Ring groove clearance: 0.030 to 0.070 mm (0.0012 to 0.0028 in.) If the clearance is not as specified, replace the piston. A36650 21. (a) INSPECT PISTON RING END GAP Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block. 110 mm Piston Ring A53017 (b) EM2552 Using a feeler gauge, measure the end gap. Standard end gap: No. 1 0.22 to 0.32 mm (0.0087 to 0.0126 in.) No. 2 0.50 to 0.60 mm (0.0197 to 0.0236 in.) Oil (side rail) 0.10 to 0.35 mm (0.0039 to 0.0138 in.) Maximum end gap: No. 1 0.89 mm (0.0350 in.) No. 2 1.35 mm (0.0531 in.) Oil (side rail) 0.73 mm (0.0287 in.) If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum even with a new piston ring, replace the cylinder block. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2604 14-1 12 ENGINE MECHANICAL 22. (a) A13490 (b) - CYLINDER BLOCK ASSY (2AZ-FE) INSPECT PISTON PIN OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the piston bushing. Pin hole bush diameter: 22.001 to 22.010 mm (0.8662 to 0.8665 in.) Pin hole bush diameter (Reference): Mark Specified Condition A 22.001 to 22.004 mm (0.86618 to 0.86630 in.) B 22.005 to 22.007 mm (0.86634 to 0.86612 in.) C 22.008 to 22.010 mm (0.86645 to 0.86653 in.) Using a micrometer, measure the piston pin diameter. Piston pin diameter: 21.997 to 22.009 mm (0.8660 to 0.8665 in.) Piston pin diameter (Reference): Mark Specified Condition A 21.997 to 22.000 mm (0.86602 to 0.86614 in.) B 22.001 to 22.003 mm (0.86618 to 0.86626 in.) C 22.004 to 22.006 mm (0.86630 to 0.86638 in.) EM0227 (c) A01185 Using a caliper gauge, measure the inside diameter of the connecting rod bush. Bush inside diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 in.) Bush inside diameter: Mark Specified Condition A 22.005 to 22.008 mm (0.8663 to 0.8665 in.) B 22.008 to 22.011 mm (0.8665 to 0.8666 in.) C 22.011 to 22.014 mm (0.8666 to 0.8667 in.) (d) Subtract the piston pin diameter measurement from the piton pin bush hole diameter measurement. Standard oil clearance: 0.001 to 0.007 mm (0.00004 to 0.00028 in.) Maximum oil clearance: 0.010 mm (0.0020 in.) If the oil clearance is greater than maximum, replace the connecting rod. If necessary, replace the piston and piston pin as a set. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2605 14-1 13 ENGINE MECHANICAL Piston Bushing Inside Diameter Mark Front Mark - CYLINDER BLOCK ASSY (2AZ-FE) If the oil clearance is greater than the maximum, replace the connecting rod. If necessary, replace the piston and piston pin as a set. (e) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 in.) Maximum oil clearance: 0.010 mm (0.0020 in.) If the oil clearance is greater than the maximum, replace the connecting rod. If necessary, replace the connecting rod and piston pin as a set. Front Mark Connecting Rod Bushing Inside Diameter Mark A62247 23. (a) INSPECT CONNECTING ROD SUB-ASSY Using a rod aligner and feeler gauge, check the connecting rod alignment. (1) Check for out-of-alignment. Maximum out-of-alignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If the out-of-alignment is greater than the maximum, replace the connecting rod assembly. Z00064 (2) Check for twist. Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If the twist is greater than the maximum, replace the connecting rod assembly. Z00065 24. (a) INSPECT CONNECTING ROD BOLT Using a vernier caliper, measure the tension portion diameter of the bolt. Standard diameter: 7.2 to 7.3 mm (0.283 to 0.287 in.) Maximum diameter: 7.0 mm (0.276 in.) If the diameter is less than the minimum, replace the bolt. A01470 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2606 14-1 14 ENGINE MECHANICAL - CYLINDER BLOCK ASSY (2AZ-FE) 25. (a) INSPECT CRANKSHAFT Using a dial indicator and V-blocks, measure the circle runout, as shown in the illustration. Maximum circle runout: 0.03 mm (0.0012 in.) If the circle runout is greater than the maximum, replace the crankshaft. A13491 (b) Using a micrometer, measure the diameter of each main journal. Diameter: 54.988 to 55.000 mm (2.16488 to 2.16535 in.) If the diameter is not as specified, check the oil clearance (see step 26). If necessary, replace the crankshaft. (c) Check each main journal for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round: 0.003 mm (0.0001 in.) If the taper and out-of-round is greater than the maximum, replace the crankshaft. Diameter (Reference): A36653 Mark Specified Condition 0 54.999 to 55.000 mm (2.16531 to 2.16535 in.) 1 54.997 to 54.998 mm (2.16523 to 2.16527 in.) 2 54.995 to 54.996 mm (2.16515 to 2.16519 in.) 3 54.993 to 54.994 mm (2.16507 to 2.16511 in.) 4 54.991 to 54.992 mm (2.16499 to 2.16504 in.) 5 54.989 to 54.990 mm (2.16491 to 2.16495 in.) (d) ZF6928 Using a micrometer, measure the diameter of each crank pin. Diameter: 47.990 to 48.000 mm (1.8894 to 1.8898 in.) If the diameter is not as specified, check the oil clearance (see step 2). If necessary, replace the crankshaft. (e) Check each crank pin for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round: 0.003 mm (0.0001 in.) If the taper and out-of-round is greater than the maximum, replace the crankshaft. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2607 14-1 15 ENGINE MECHANICAL - CYLINDER BLOCK ASSY (2AZ-FE) 26. (a) INSPECT CRANKSHAFT BEARING CAP SET BOLT Using a vernier caliper, measure the tension portion diameter of the bolt. Standard diameter: 7.3 to 7.6 mm (0.287 to 0.299 in.) Minimum diameter: 7.2 mm (0.283 in.) If the diameter is less than the minimum, replace the bolt. 27. INSTALL RING PIN A01194 (a) Using a plastic-faced hammer, tap into the ring pin. Bottom Side Upper Side A A A 14 mm (0.55 in.) A 13 mm (0.51 in.) B B 6.0 mm (0.24 in.) for Ring Pin A 5.0 mm (0.20 in.) for Ring Pin B 12 mm (0.47 in.) 12 mm (0.47 in.) A92404 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2608 14-1 16 ENGINE MECHANICAL 28. (a) (b) - CYLINDER BLOCK ASSY (2AZ-FE) INSTALL TIGHT PLUG Apply adhesive around the tight plugs. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent. Using SST, install new tight plugs as shown in the illustration. SST 09950- 60010 (09951- 00200), 09950- 70010 (09951-07100) Standard depth: Engine front 1.7 to 2.7 mm (0.067 to 0.106 in.) Engine rear 2.2 to 3.2 mm (0.087 to 0.126 in.) A62239 29. (a) INSTALL STUD BOLT Install the stud bolts as shown in the illustration. Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) for stud bolt A 10 N⋅m (102 kgf⋅cm, 7 ft.lbf) for stud bolt B 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) for stud bolt C Front Side C A Exhaust Side 16 mm (0.63 in.) A B 18 mm (0.71 in.) 14 mm (0.55 in.) 84 mm (3.31 in.) 31.5 mm (1.24 in.) 27.5 mm (1.08 in.) 20 mm (0.79 in.) 9.0 mm (0.35 in.) A (M16) B (M10) 9.0mm (0.35 in.) C (M6) A92178 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2609 14-1 17 ENGINE MECHANICAL 30. (a) Rear Side - CYLINDER BLOCK ASSY (2AZ-FE) INSTALL STRAIGHT PIN Using a plastic-faced hammer, tap into the straight pin. Bottom Side Front Side A A B A B A 10 mm (0.39 in.) 8.0 mm (0.31 in.) 15 mm (0.59 in.) A 7.5 mm (0.30 in.) for Pin A 12 mm (0.47 in.) for Pin B 22 mm (0.87 in.) B A92406 31. (a) (b) INSTALL PISTON Using a small screwdriver, install a new snap ring at one end of the piston pin hole. Gradually heat the piston to approximately 80 to 90C (176 to 194F). A32958 P12418 (c) (d) Front Mark Align the front marks of the piston and connecting rod, and push in the piston with your thumb. Using a small screwdriver, install a new snap ring on the other end of the piston pin hole. Front Mark A13497 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2610 14-1 18 ENGINE MECHANICAL - CYLINDER BLOCK ASSY (2AZ-FE) 32. (a) (b) INSTALL PISTON RING SET Install the oil ring expander and 2 side rails by hand. Using a piston ring expander, install the 2 compression rings with the painted mark as shown in the illustration. NOTICE: Install the compression ring No. 2 with the code mark (2N) facing upward. Upward No. 1 Painted Mark No. 2 Code Mark (2N) A52526 No. 1 and Expander (c) Side Rail Lower Position the piston rings so that the ring ends are as shown in the illustration. Front Side Rail Upper No. 2 Compression A52527 33. (a) INSTALL CRANKSHAFT BEARING Install the upper bearing with an oil groove on the cylinder block. NOTICE: Clean the contact surfaces of the bearing and the cylinder block. The surfaces should be free of dust and oils. A53029 34. INSTALL CRANKSHAFT BEARING NO.2 (a) Install the lower bearing on bearing cap. NOTICE: Clean the contact surfaces of the bearing and the bearing cap. The surfaces should be free of dust and oils. A33379 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2611 14-1 19 ENGINE MECHANICAL 35. (a) 36. (a) (b) A13501 (c) 7 3 1 5 9 8 4 2 6 10 - CYLINDER BLOCK ASSY (2AZ-FE) INSTALL CRANKSHAFT THRUST WASHER UPPER Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward. INSTALL CRANKSHAFT Apply engine oil to upper bearing and install the crankshaft on the cylinder block. Examine the front marks and numbers and install the bearing caps on the cylinder block. Apply a light coat of engine oil on the threads and under the head of bearing cap bolts. (d) Install and uniformly tighten 10 main bearing cap bolts in several passes,in the sequence shown. Torque: 40 N⋅m (408 kgf⋅cm, 30 ft⋅lbf) (e) (f) Mark the front side of the bearing cap bolts with paint. Retighten the bearing cap bolts 90in the sequence shown. Check that the painted mark is now at a 90angle to the front. Check that the crankshaft turns smoothly. A87780 90 Paint Mark Engine Front (g) (h) A50671 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2612 14-120 ENGINE MECHANICAL - CYLINDER BLOCK ASSY (2AZ-FE) 37. (a) Claw A50672 INSTALL CONNECTING ROD BEARING Align the bearing claw with the groove of the connecting rod or connecting cap. NOTICE: Clean the backside of the bearing and the bearing surface of the connecting rod. The surface should be free of dust and oil. 38. INSTALL PISTON NOTICE: The connecting rod cap bolts are tightened in 2 progressive steps. (a) Apply engine oil to the cylinder walls, the pistons, and the surfaces of connecting rod bearings. (b) Check the position of the piston ring ends. (c) Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. NOTICE: Match the numbered connecting rod cap with the connecting rod. Front Mark Front A52528 (d) Front Mark (e) (f) (g) Check that the protrusion of the connecting rod cap is facing in the correct direction. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. Using a 12 mm socket wrench, uniformly tighten the 2 bolts. Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf) Mark the front of the connecting cap bolts with paint. A52515 90 (h) (i) Paint Mark Engine Front Retighten the cap bolts 90 as shown in the illustration. Check that the crankshaft turns smoothly. SST 09011-38121 A50671 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2613 14-84 ENGINE MECHANICAL - CYLINDER HEAD GASKET (2AZ-FE) CYLINDER HEAD GASKET (2AZ-FE) 141PA-02 REPLACEMENT 1. 2. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See page 11-1 ) REMOVE FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER) DRAIN COOLANT (See page 16-6 ) DRAIN TRANSFER OIL (4WD TYPE) DISCONNECT RADIATOR HOSE OUTLET DISCONNECT UNION TO CONNECTOR TUBE HOSE DISCONNECT HEATOR INLET WATER HOSE DISCONNECT FUEL TUBE SUB-ASSY (See page 11-10 ) SEPARATE FRONT DRIVE SHAFT ASSY RH (4WD TYPE) (See page 30-21 ) 3. 4. 5. 6. 7. 8. 9. 10. (a) SEPARATE ENGINE MOUNTING INSULATOR ASSY RR (4WD TYPE) Remove the 2 bolts and disconnect the engine mounting insulator. A52340 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. REMOVE ENGINE MOUNTING BRACKET RR (4WD TYPE) (See page 14-24 ) REMOVE INTAKE MANIFOLD (See page 14-24 ) DISCONNECT ENGINE WIRE REMOVE INTAKE MANIFOLD INSULATOR NO.1 REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1 REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY (See page 14-24 ) REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY REMOVE CHAIN SUB-ASSY (See page 14-68 ) REMOVE NO.2 CAMSHAFT (See page 14-41 ) REMOVE CAMSHAFT (See page 14-41 ) REMOVE CAMSHAFT BEARING NO.2 REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY 3 7 9 6 1 5 10 8 2 4 23. (a) REMOVE CYLINDER HEAD SUB-ASSY Using a 10 mm Bi-hexagon wrench, uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers. NOTICE:
Be careful not to drop washers into the cylinder head.
Head warpage or cracking could result from removing bolts in an incorrect order. A94200 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2577 14-85 ENGINE MECHANICAL 24. 25. - CYLINDER HEAD GASKET (2AZ-FE) REMOVE CYLINDER HEAD GASKET INSPECT CYLINDER HEAD SET BOLT (See page 14-41 ) Lot No. 26. (a) INSTALL CYLINDER HEAD GASKET Place a new gasket on the cylinder block surface with the Lot No. stamp upward. NOTICE:
Remove any oil from contact surface.
Be careful of the installation direction.
To avoid damage to the gasket, place the cylinder head on the gasket carefully. INTAKE Engine Front EXHAUST A90968 27. INSTALL CYLINDER HEAD SUB-ASSY HINT: The cylinder head bolts are tightened in 2 progressive steps. (a) Apply a light coat of engine oil to the bolt threads and the area beneath the bolt heads that come in contact with the washers. (b) Install the bolts and plate washers to the cylinder head. NOTICE: Do not drop the washers into the cylinder head. 8 4 2 5 10 6 1 3 9 7 (c) Using a 10 mm bi-hexagon wrench, uniformly tighten the 10 bolts in the sequence shown in the illustration. Torque: 79 N⋅m (806 kgf⋅cm, 58 ft⋅lbf) (d) (e) Mark the front side of the cylinder head bolt with paint. Retighten the cylinder head bolts 90 in the sequence shown in the illustration. Check that the painted mark is now at a 90 angle to the front. A94195 90 (f) Engine Front Paint Mark A00976 28. 29. 30. 31. A53074 INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) INSTALL CAMSHAFT BEARING NO.2 INSTALL CAMSHAFT (See page 14-41 ) INSTALL NO.2 CAMSHAFT (See page 14-41 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2578 14-86 ENGINE MECHANICAL 32. 33. - CYLINDER HEAD GASKET (2AZ-FE) INSTALL CHAIN SUB-ASSY (See page 14-68 ) INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY 34. 2 3 (a) 4 1 INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY Install a new gasket and the exhaust manifold convert with the 5 nuts. Uniformly tighten the nuts in the sequence shown in the illustration. Torque: 37 N⋅m (337 kgf⋅cm, 27 ft⋅lbf) 5 A92868 (b) Install the No. 1 and No. 2 exhaust manifold stays with the 2 bolts and 2 nuts. Torque: 44 N⋅m (449 kgf⋅cm, 32 ft⋅lbf) A52499 35. 36. 37. 38. 39. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 Torque: 12 N⋅m (122 kgf⋅cm, 9 ft⋅lbf) INSTALL INTAKE MANIFOLD INSULATOR NO.1 INSTALL ENGINE WIRE INSTALL INTAKE MANIFOLD (See page 14-24 ) INSTALL ENGINE MOUNTING BRACKET RR (4WD TYPE) (See page 14-24 ) 40. (a) INSTALL ENGINE MOUNTING INSULATOR ASSY RR (4WD TYPE) Install the mounting insulator with bolts. Torque: 75 N⋅m (765 kgf⋅cm, 55 ft⋅lbf) A52340 41. 42. 43. INSTALL FRONT DRIVE SHAFT ASSY RH (4WD TYPE) (See page 30-21 ) INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) CONNECT FUEL TUBE SUB-ASSY (See page 11-10 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2579 14-87 ENGINE MECHANICAL 44. 45. 46. 47. (a) 48. 49. 50. 51. 52. 53. 54. - CYLINDER HEAD GASKET (2AZ-FE) INSTALL FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER Torque: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf) ADD ENGINE OIL ADD COOLANT (see page 16-6 ) ADD TRANSFER OIL (4WD TYPE) Install a new gasket and the filler plug. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) CHECK FOR OIL LEAKS CHECK FOR ENGINE COOLANT LEAKS (See page 16-6 ) INSPECT FOR FUEL LEAKS (See page 11-4 ) CHECK IDLE SPEED AND IGNITION TIMING (See page 14-1 ) INSPECT CO/HC (See page 14-1 ) CHECK ABS SPEED SENSOR SIGNAL INSPECT FRONT WHEEL ALIGNMENT (See page 26-7 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2580 14-79 ENGINE MECHANICAL - CAMSHAFT (2AZ-FE) CAMSHAFT (2AZ-FE) 141PC-02 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. REMOVE FRONT WHEEL RH REMOVE FRONT FENDER SPLASH SHIELD FRONT RH REMOVE FRONT FENDER APRON SEAL RH REMOVE ENGINE COVER SUB-ASSY NO.1 REMOVE IGNITION COIL ASSY REMOVE SPARK PLUG DISCONNECT VENTILATION HOSE DISCONNECT VENTILATION HOSE NO.2 DISCONNECT ENGINE WIRE REMOVE CYLINDER HEAD COVER SUB-ASSY (See page 14-41 ) SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14-6 ) REMOVE CHAIN TENSIONER ASSY NO.1 (See page 14-41 ) Loosen 13. (a) REMOVE NO.2 CAMSHAFT (EXHAUST) Fix the camshaft with a wrench, and then loosen the sprocket bolt. NOTICE: Be careful not to damage the valve lifter. Fix A52454 1 3 5 4 2 (b) Loosen and remove the bearing cap bolts on No. 2 camshaft (exhaust) in the sequence shown in the illustration in several passes, and remove the 5 bearing caps. (c) Raise the No. 2 camshaft (exhaust) and remove it. Then remove the sprocket bolt. Disconnect the camshaft timing sprocket (with the timing chain) from the No. 2 camshaft (exhaust). Remove the camshaft timing sprocket from the timing chain. A36530 (d) (e) A86659 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2572 14-80 ENGINE MECHANICAL 1 3 5 4 14. (a) 2 (b) - CAMSHAFT (2AZ-FE) REMOVE CAMSHAFT (INTAKE) Loosen the bearing cap bolts on camshaft (intake) in the sequence shown in the illustration in several passes, and remove the caps. Remove the camshaft. A36531 (c) Tie the timing chain with a string. NOTICE: Do not drop anything inside the timing chain cover. A52474 15. (a) Advanced Angle Side (b) REMOVE CAMSHAFT TIMING GEAR ASSY Fix the camshaft (intake) with a vise, and make sure that the camshaft timing gear does not rotate. Cover all the paths with vinyl tape except the advanced side path shown in the illustration. A90848 Using an air gun, apply about 150 kPa (1.5 kgf/cm2, 21 psi) of air pressure to the port on the advanced angle side. CAUTION: Some oil spraying will occur. Contain the spray with a shop rag. HINT: This operation releases the lock pin for the extreme retarded angle lock. (d) Under the condition above, check that the camshaft timing gear can be turned by hand to the advanced angle side (counterclockwise), the direction of the arrow in the illustration. Standard: Must turn HINT: The camshaft timing gear will turn to the advanced angle side without applying force by hand depending on the force of the air pressure applied. Also, if applying pressure to the oil path is difficult as a result of air leakage from the port, the lock pin may be difficult to be released. (c) A31032 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2573 14-81 ENGINE MECHANICAL - CAMSHAFT (2AZ-FE) (e) Remove the fringe bolt from the camshaft timing gear. NOTICE:
Be sure not to remove the other 4 bolts.
If planning to reuse the camshaft timing gear assembly, release the straight pin lock first, and then install the gear. A32639 16. (a) Straight Pin Key Groove A31033 INSTALL CAMSHAFT TIMING GEAR ASSY Put the camshaft timing gear and the camshaft (intake) together with the straight pin and key groove. (b) Turn the camshaft timing gear (as shown in the illustration) while pushing it lightly against the camshaft (intake).Push further at the position where the pin gets into the groove. NOTICE: Be sure not to turn the camshaft timing gear to the retarded angle side (to the right direction). (c) Check that there is no clearance between the gear’s fringe and the camshaft (intake). (d) Tighten the fringe bolt with the camshaft timing gear fixed. Torque: 54 N⋅m (551 kgf⋅cm, 40 ft⋅lbf) HINT:
Apply a light coat of engine oil on the threads and under the head of the bolt.
Length of sprocket bolt excluding bolt head: 40 mm (1.57 in.) (e) Check that the camshaft timing gear can move to the retarded angle side (to the right direction) and is locked at the extreme retarded angle. 17. (a) Paint Mark INSTALL CAMSHAFT (INTAKE) Install the timing chain on the camshaft timing gear, with the painted mark of the link aligned with the timing marks of the camshaft timing sprocket. Timing Marks A52456 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2574 14-82 ENGINE MECHANICAL 5 3 1 2 (b) 4 Bearing Cap No. 1 Bearing Cap No. 3 A92649 Paint Mark Timing Mark - CAMSHAFT (2AZ-FE) Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) for bearing cap No. 1 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for bearing cap No. 3 HINT: Apply a light coat of engine oil on the threads and under the heads of the bolts. 18. INSTALL NO.2 CAMSHAFT (EXHAUST) (a) Put the camshaft on the cylinder head with the painted mark of the link of chain aligned with the timing mark of the camshaft timing sprocket. A53011 (b) Raising the camshaft, temporarily tighten the sprocket bolt. (c) Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) for bearing cap No. 2 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for bearing cap No. 3 A52473 Bearing Cap No. 2 5 3 Bearing Cap No. 3 1 Tighten 2 4 A94196 Fix A52459 HINT: Apply a light coat of engine oil on the threads and under the heads of the bolts. (d) Fix the camshaft with a wrench, and then tighten the sprocket bolt. Torque: 54 N⋅m (551 kgf⋅cm, 40 ft⋅lbf) HINT:
Apply a light coat of engine oil on the threads and under the head of the bolt.
Length of sprocket bolt excluding bolt head: 25 mm (0.98 in.) NOTICE: Be careful not to damage the valve lifter. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2575 14-83 ENGINE MECHANICAL (e) 7 Links Paint Mark Timing Marks - CAMSHAFT (2AZ-FE) As shown in the illustration, check the paint marks of the timing chain, camshaft timing gear and camshaft timing sprocket and the alignment of the pulley groove with timing mark of the chain cover. Paint Mark Timing Mark Groove A52460 19. 20. 21. 22. 23. 24. 25. INSTALL CHAIN TENSIONER ASSY NO.1 (See page 14-68 ) INSTALL CYLINDER HEAD COVER SUB-ASSY (See page 14-41 ) CONNECT ENGINE WIRE INSTALL IGNITION COIL ASSY Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) INSTALL SPARK PLUG Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) INSTALL FRONT WHEEL RH CHECK FOR ENGINE OIL LEAKS 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2576 14-89 ENGINE MECHANICAL - ENGINE REAR OIL SEAL (2AZ-FE) ENGINE REAR OIL SEAL (2AZ-FE) 141PE-03 REPLACEMENT 1. REMOVE AUTOMATIC TRANSAXLE ASSY (See page 40-12 ) HINT: Remove and install the transaxle after removing the engine assy w/ transaxle. 2. (a) REMOVE DRIVE PLATE & RING GEAR SUB-ASSY Using SST, fix the crankshaft. SST 09213-54015 (91651-60855), 09330-00021 (b) Remove the 8 bolts, rear spacer, drive plate and front spacer. SST A36684 A91018 Cut Position 3. REMOVE ENGINE REAR OIL SEAL (a) Using a knife, cut through the oil seal lip. (b) Using a screwdriver with its tip taped, pry out the oil seal. NOTICE: After the removal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper. A53052 SST A32658 4. INSTALL ENGINE REAR OIL SEAL (a) Apply MP grease to a new oil seal lip. NOTICE: Keep the lip free from foreign matter. (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-15030, 09950-70010 (09951-07100) NOTICE: Wipe off extra grease from the crankshaft. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2582 14-90 ENGINE MECHANICAL - ENGINE REAR OIL SEAL (2AZ-FE) 5. (a) INSTALL DRIVE PLATE & RING GEAR SUB-ASSY Using SST, fix the crankshaft. SST 09213-54015 (91651-60855), 09330-00021 (b) (c) Clean the bolt and the bolt hole. Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Part No. 08833-00070, THREE BOND or equivalent Install the front spacer, drive plate and rear spacer with the 8 bolts. Uniformly tighten the bolts in the sequence shown in the illustration. Torque: 98 N⋅m (1,000 kgf⋅cm, 72 ft⋅lbf) SST A36684 1 6 3 (d) 7 8 4 2 5 A61988 6. INSTALL AUTOMATIC TRANSAXLE ASSY (See page 40-12 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2583 14-88 ENGINE MECHANICAL - TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (2AZ-FE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (2AZ-FE) 141PD-02 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. REMOVE FRONT WHEEL RH REMOVE FRONT FENDER SPLASH SHIELD FRONT RH REMOVE FRONT FENDER APRON SEAL RH REMOVE ENGINE COVER SUB-ASSY NO.1 REMOVE ENGINE MOUNTING STAY NO.2 RH REMOVE ENGINE MOVING CONTROL ROD W/BRACKET (See page 14-24 ) REMOVE ENGINE MOUNTING STAY NO.2 RH REMOVE ENGINE MOUNTING BRACKET NO.2 RH REMOVE FAN AND GENERATOR V BELT (See page 14-5 ) REMOVE CRANKSHAFT PULLEY (See page 14-41 ) 11. (a) SST REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL Using SST, remove the oil seal. SST 09308-10010, 09950-60010 (09951-00200) SST A87778 12. 13. 14. 15. 16. 17. 18. 19. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL (a) Apply MP grease to a new oil seal lip. NOTICE: Keep the lip free from a foreign matter. (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-22010 SST NOTICE: A94207 Wipe off extra grease from the crankshaft. INSTALL CRANKSHAFT PULLEY (See page 14-41 ) INSTALL FAN AND GENERATOR V BELT (See page 14-5 ) Torque: 52 N⋅m (531 kgf⋅cm, 38 ft⋅lbf) INSTALL ENGINE MOUNTING BRACKET NO.2 RH Torque: 52 N⋅m (531 kgf⋅cm, 38 ft⋅lbf) INSTALL ENGINE MOUNTING STAY NO.2 RH Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) INSTALL ENGINE MOVING CONTROL ROD W/BRACKET (See page 14-24 ) INSTALL FRONT WHEEL RH CHECK FOR ENGINE OIL LEAKS 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2581 14-68 ENGINE MECHANICAL - CHAIN (2AZ-FE) CHAIN (2AZ-FE) 141PB-01 REPLACEMENT 1. 2. 3. 4. 5. 6. (a) REMOVE HOOD SUB-ASSY REMOVE FRONT WHEEL RH REMOVE ENGINE UNDER COVER NO.1 REMOVE FRONT FENDER SPLASH SHIELD FRONT RH REMOVE FRONT FENDER APRON SEAL RH DRAIN ENGINE OIL Install a new gasket and the drain plug after draining engine oil. Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf) 7. REMOVE EXHAUST PIPE ASSY FRONT 8. REMOVE ENGINE MOVING CONTROL ROD W/BRACKET (See page 14-24 ) 9. REMOVE ENGINE MOUNTING STAY NO.2 RH 10. REMOVE ENGINE MOUNTING BRACKET NO.2 RH 11. REMOVE FAN AND GENERATOR V BELT (See page 14-5 ) 12. REMOVE ENGINE COVER SUB-ASSY NO.1 13. DISCONNECT ENGINE WIRE 14. REMOVE GENERATOR ASSY 15. REMOVE VANE PUMP ASSY (See page 51-8 ) NOTICE: Do not disconnect the hose. 16. REMOVE IGNITION COIL ASSY 17. DISCONNECT VENTILATION HOSE No.1 18. DISCONNECT VENTILATION HOSE NO.2 19. REMOVE ENGINE COVER SUB-ASSY NO.1 20. REMOVE CYLINDER HEAD COVER SUB-ASSY (Seepage 14-41 ) 21. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14-6 ) 22. SST REMOVE CRANKSHAFT PULLEY (1) Using SST, fix the pulley and loosen the bolt. SST 09213-54015 (91651-60855), 09330-00021 A36684 (2) Using SST, remove the bolt and pulley. SST 09950- 50013 (09951- 05010, 09952- 05010, 09953-05020, 09954-05021) SST A36685 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2561 14-69 ENGINE MECHANICAL 23. 24. 25. 26. REMOVE REMOVE REMOVE REMOVE - CHAIN (2AZ-FE) CRANKSHAFT POSITION SENSOR OIL PAN SUB-ASSY (Seepage 14-41 ) CHAIN TENSIONER ASSY NO.1 (See page 14-41 ) V-RIBBED BELT TENSIONER ASSY (See page 14-24 ) Engine Hanger No.1 27. (a) Engine Hanger No.2 INSTALL ENGINE HANGER NO.1 Install the engine hanger No. 1 and No. 2 with the bolts as shown in the illustration. Parts No.: Engine hanger No. 1 12281-28010 Engine hanger No. 2 12282-28010 Bolt 91512-61020 Torque: 38 N⋅m (387 kgf⋅cm, 30 ft⋅lbf) A52507 28. REMOVE ENGINE MOUNTING INSULATOR (a) Attach the engine chain hoist to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part. (b) Remove the bolt and disconnect the engine mounting insulator FR. A52441 (c) Remove the bolt and disconnect the steering gear return hose clamp from the frame. (d) Remove the 4 nuts from the engine mounting insulator RH. Raise the engine and remove the engine mounting insulator RH. A59901 (e) A59900 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2562 14-70 ENGINE MECHANICAL 29. (a) - CHAIN (2AZ-FE) REMOVE ENGINE MOUNTING BRACKET RH Remove the 3 bolts and engine mounting bracket. A52481 30. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSSY (a) Remove the stud bolt for the drive belt tensioner from the cylinder block. (b) Remove the 14 bolts and 2 nuts. (c) Pry out the timing chain cover with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder block and cylinder head. A77251 31. 32. 33. 34. 35. REMOVE REMOVE REMOVE REMOVE REMOVE Groove CRANKSHAFT POSITION SENSOR PLATE NO.1 CHAIN TENSIONER SLIPPER CHAIN VIBRATION DAMPER NO.1 CHAIN SUB-ASSY CRANKSHAFT TIMING GEAR OR SPROCKET 36. REMOVE NO.2 CHAIN SUB-ASSY 90 (a) Turn the crankshaft counterclockwise 90, and align an adjusting hole of the oil pump driven sprocket with the groove of the oil pump. A52508 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2563 14-71 ENGINE MECHANICAL - CHAIN (2AZ-FE) (b) Put a bar (φ 4.0 mm (0.16 in.)) in the adjusting hole of the oil pump driven sprocket to temporarily lock the sprocket in position. Remove the nut. (c) (d) Remove the bolt, chain tensioner plate and spring. Remove the chain tensioner, oil pump driven sprocket and chain. 37. (a) (b) INSTALL NO.2 CHAIN SUB-ASSY Set the crankshaft key into the left horizontal position. Turn the cutout of the drive shaft to the top. (c) Align the mark links (yellow colored links) with the timing marks of the sprocket as shown in the illustration. Insert the sprockets with chain to the crankshaft and oil pump shaft. Temporarily tighten the oil pump driven sprocket with the nut. Groove A52509 B11415 B11424 Mark Link Timing Mark (d) (e) Timing Mark Mark Link A94198 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2564 14-72 ENGINE MECHANICAL Chain Tensioner Plate - CHAIN (2AZ-FE) (f) Insert the damper spring into the adjusting hole, and install the chain tensioner plate with the nut. Torque: 12 N⋅m (122 kgf⋅cm, 9.0 ft⋅lbf) (g) Align the adjusting hole of the oil pump driven sprocket with the groove of the oil pump. Put a bar (φ 4 mm (0.16 in.)) in the adjusting hole of the oil pump driven sprocket to temporarily lock the sprocket in position. Install the nut. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) Bolt Spring A90851 (h) Groove A52512 (i) 90 Rotate the crankshaft counterclockwise 90, and align the crankshaft key to the top. A36525 38. INSTALL CHAIN VIBRATION DAMPER NO.1 Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2565 14-73 ENGINE MECHANICAL 39. (a) - CHAIN (2AZ-FE) INSTALL CHAIN SUB-ASSY Set the No.1 cylinder to TDC/compression. (1) Align the timing marks of the camshaft timing sprockets and bearing caps (No. 1 and No. 2). Timing Marks Timing Marks A53018 (2) Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward. A52505 (b) Align the mark link (gold or orange colored link) with the timing mark of the crankshaft timing sprocket. (c) Using SST, tap in the sprocket. SST 09309-37010 Timing Mark Mark Link A52523 SST A13337 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2566 14-74 ENGINE MECHANICAL (d) Mark Links Timing Mark Timing Marks - CHAIN (2AZ-FE) Align the mark links (gold or yellow colored links) with the timing marks of the camshaft timing gear and camshaft timing sprocket. Install the chain. A52513 40. 41. INSTALL CHAIN TENSIONER SLIPPER Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14-41 ) 42. B A Seal Cylinder Head Packing Gasket Cylinder Head A Seal Packing B Cylinder Seal Block Seal Packing Packing Seal Width: 2.0 mm A90970 INSTALL TIMING CHAIN OR BELT COVER SUB-ASSSY NOTICE:
Remove any oil from the contact surface.
Install the chain cover within 3 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing. (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block. (b) Apply seal packing in a continuous bead (seal width: 2.0 mm (0.079 in.)) as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent (c) Apply seal packing in a continuous bead (seal width: 3.0 to 4.0 mm (0.12 to 0.16 in.)) as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent 4.0 mm (0.16 in.) A A 2.5 mm (0.098 in.) A Seal Width: 3.0 to 4.0 mm A A94199 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2567 14-75 ENGINE MECHANICAL (d) C Nut Nut C C C (e) C A B - CHAIN (2AZ-FE) Install the timing chain cover with the 14 bolts and 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for bolt A 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) for bolt B 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) for bolt C 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) for nut Install the stud bolt to the drive belt tensioner. Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) B B B B B B B A77251 43. 44. INSTALL CHAIN TENSIONER ASSY NO.1 INSTALL V-RIBBED BELT TENSIONER ASSY (See page 14-24 ) 45. (a) INSTALL ENGINE MOUNTING BRACKET RH Install the engine mounting bracket with the 3 bolts. Torque: 54 N⋅m (551 kgf⋅cm, 40 ft⋅lbf) 46. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Raise the engine and install the engine mounting insulator RH. Install the engine mounting insulator RH with the 4 nuts. Torque: 95 N⋅m (969 kgf⋅cm, 70 ft⋅lbf) for bolt A 87 N⋅m (887 kgf⋅cm, 64 ft⋅lbf) for bolt B A52481 A (a) (b) B B B A59900 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2568 14-76 ENGINE MECHANICAL - CHAIN (2AZ-FE) (c) Install the steering gear return hose clamp to the frame with the bolt. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) (d) Install the engine mounting insulator FR with the bolt. Torque: 87 N⋅m (887 kgf⋅cm, 64 in.⋅lbf) A59901 A52441 47. 48. INSTALL OIL PAN SUB-ASSY (See page 14-41 ) INSTALL CRANKSHAFT POSITION SENSOR (See page 14-41 ) 49. (a) SST A53034 Raise INSTALL CRANKSHAFT PULLEY Install the crankshaft pulley. (1) Align the pulley set key with the key groove of the pulley, and side on the pulley. (2) Using SST, install the pulley bolt. SST 09213-54015 (91651-60855), 09330-00021 Torque: 180 N⋅m (1,835 kgf⋅cm, 133 ft lbf) HINT: Apply a light coat of engine oil to the bolt threads and the area beneath the bolt heads that come in contact with the washers. 50. INSTALL CHAIN TENSIONER ASSY NO.1 (a) Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out. Push Pin Hook A52461 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2569 14-77 ENGINE MECHANICAL - CHAIN (2AZ-FE) (b) Install a new gasket and the chain tensioner with the 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) NOTICE: If the hook is released while inserting, apply the hook again, and insert the chain tensioner. Engine Front A52462 (c) Turn the crankshaft counterclockwise and check that the plunger knock pin is disconnected from the hook. (d) Turn the crankshaft clockwise and check that the slipper is pushed by the plunger. Disconnect Turn Pin Hook A93972 Plunger Push Turn 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. A93973 INSTALL CYLINDER HEAD COVER SUB-ASSY (See page 14-79 ) INSTALL IGNITION COIL ASSY Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) INSTALL VANE PUMP ASSY (See page 51-8 ) INSTALL GENERATOR ASSY (See page 19-16 ) INSTALL ENGINE WIRE INSTALL FAN AND GENERATOR V BELT (See page 14-5 ) INSTALL ENGINE MOUNTING BRACKET NO.2 RH Torque: 52 N⋅m (531 kgf⋅cm, 38 ft⋅lbf) INSTALL ENGINE MOUNTING STAY NO.2 RH Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) INSTALL ENGINE MOVING CONTROL ROD W/BRACKET (See page 14-24 ) INSTALL EXHAUST PIPE ASSY FRONT (See page 15-2 ) INSTALL FRONT WHEEL RH 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2570 14-78 ENGINE MECHANICAL 62. 63. 64. - CHAIN (2AZ-FE) INSTALL HOOD SUB-ASSY Torque: 13 N⋅m (133 kgf⋅cm, 10 ft⋅lbf) ADD ENGINE OIL CHECK FOR ENGINE OIL LEAKS 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2571 14-121 ENGINE MECHANICAL - ENGINE (3MZ-FE) ENGINE (3MZ-FE) 141PF-02 INSPECTION 1. 2. 3. 4. 5. INSPECT ENGINE COOLANT (See page 16-20 ) INSPECT ENGINE OIL INSPECT BATTERY (See page 19-36 ) INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSY INSPECT SPARK PLUG (See page 18-9 ) 6. (a) A87786 INSPECT V-RIBBED BELT Using a belt tension gauge, check the belt tension. Belt tension gauge: DENSO BTG-20 (95506-00020) Borroughs No. BT-33-73F Drive belt tension: Item Specified Condition Cooler compressor to crankshaft pulley New belt 143 to 165 lbf Cooler compressor to crankshaft pulley Used belt 80 to 132 lbf Vane pump New belt 132 to 154 lbf Vane pump Used belt 55 to 88 lbf HINT:
CORRECT INCORRECT A87787


7. (a) (b) Hand-held Tester After installing the drive belt, check that it fits properly in the ribbed grooves. Check that the belt has not slipped out of the groove on the bottom of the crank pulley with your hand. ”New belt” is a belt which has been used for less than 5 minutes on a running engine. ”Used belt” is a belt which has been used on a running engine for 5 minutes or more. After installing a new belt, run the engine for approximately 5 minutes and then recheck the tension. INSPECT IGNITION TIMING Warm up the engine. When using the hand-held tester: Check the ignition timing. (1) Connect the hand-held tester to the DLC3. (2) Enter DATA LIST MODE on the hand-held tester. Ignition timing: 8 to 12 BTDC @ idle HINT: Please refer to the hand-held tester operator’s manual for further details. A80020 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2614 14-122 ENGINE MECHANICAL - ENGINE (3MZ-FE) (c) CG DLC3 1 2 3 4 5 6 7 8 9 10 11 1213141516 TC A82779 When not using the hand-held tester: Check the ignition timing. (1) Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3. SST 09843-18040 NOTICE:
Confirm the terminal numbers before connecting them. Connection with a wrong terminal can damage the engine.
Turn off all electrical systems before connecting the terminals.
Perform this inspection after the cooling fan motor is turned off. (2) Remove the V-bank cover (see page 14-149 ). (3) (4) Tester Terminal Black Lead Wire A82935 Hand-held Tester A80020 Pull out the black lead wire harness as shown in the illustration. Connect the tester terminal of the timing light to the engine. NOTICE: Use a timing light which detects the first signal. (5) Check the ignition timing at idle. Ignition timing: 8 to 12 BTDC @ idle NOTICE: When checking the ignition timing, the transmission should be in the neutral position. HINT: Run the engine at 1,000 to 1,300 rpm for 5 seconds, and then check that the engine rpm returns to idle speed. (6) Remove the SST from the DLC3. (7) Check the ignition timing at idle. Ignition timing: 7 to 24 BTDC @ idle (8) Confirm that the ignition timing moves to the advanced angle side when the engine rpm is increased. (9) Remove the timing light. 8. INSPECT ENGINE IDLE SPEED (a) Warm up the engine. (b) When using the hand-held tester: Check the idle speed. (1) Connect the hand-held tester to the DLC3. (2) Enter DATA LIST MODE on the hand-held tester. Idle speed: 650 to 750 rpm NOTICE:
When checking the idle speed, the transmission should be in the neutral position.
Check the idle speed with the cooling fan off. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2615 14-123 ENGINE MECHANICAL
ENGINE (3MZ-FE) Switch off all accessories and air conditioning before connecting the hand-held tester. HINT: Please refer to the hand-held tester operator’s manual for further details. (c) When not using the hand-held tester: Check the idle speed. (1) Using SST, connect tachometer tester probe to terminal 9 (TAC) of the DLC3. SST 09843-18030 (2) Check the idle speed. Idle speed: 650 to 750 rpm DLC3 1 2 3 4 5 6 7 8 9 10 11 1213141516 TAC - A82779 9. (a) (b) (c) (d) (e) INSPECT COMPRESSION Warm up and stop the engine. Disconnect the injector connectors. Remove the intake air surge tank (see page 10-20 ). Remove the 6 ignition coils. Remove the 6 spark plugs. (f) P19471 Check the cylinder compression pressure. SST 09992-00500 (1) Insert a compression gauge into the spark plug hole. (2) Fully open the throttle. (3) While cranking the engine, measure the compression pressure. Compression pressure: 1.5 MPa (15.3 kgf/cm2, 218 psi) Minimum pressure: 1.0 MPa (10.2 kgf/cm2, 145 psi) Difference between each cylinder: 100 kPa (1.0 kgf/cm2, 15 psi) NOTICE:
Always use a fully charged battery to obtain engine speed of 250 rpm or more.
Check other cylinder’s compression pressure in the same way.
This measurement must be done as quickly as possible. (4) If the cylinder compression is low, pour a small amount of engine oil into the cylinder through the spark plug hole and inspect again. HINT:
If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2616 14-124 ENGINE MECHANICAL
- ENGINE (3MZ-FE) If pressure stays low, a valve may be stuck or seated improperly, or there may be leakage in the gasket. 10. INSPECT CO/HC (a) Start the engine. (b) Rev the engine at 2,500 rpm for approximately 180 seconds. (c) Insert CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling. (d) Check CO/HC concentration at idle and/or 2,500 rpm. HINT: Check regulations and restrictions in your area when performing 2 mode CO/CH concentration testing (engine check at both idle speed and at 2,500 rpm). If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below. (1) Check A/F sensor operation (see page 05-649 ). (2) See the table below for possible causes, and then inspect and repair. CO Normal Low High HC High High High Problems Causes Rough idle 1. Faulty ignitions:
Incorrect timing
Fouled, shorted or improperly gapped plugs 2. Incorrect valve clearance 3. Leaks in intake and exhaust valves 4. Leaks in cylinders Rough idle (fluctuating HC reading) 1. Vacuum leaks:
PCV hoses
Intake manifold
Throttle body
Brake booster line 2. Lean mixture causing misfire Rough idle (black smoke from exhaust) 1. Restricted air filter 2. Plugged PCV valve 3. Faulty SFI system:
Faulty fuel pressure regulator
Defective ECT sensor
Defective MAF meter
Faulty ECM
Faulty injectors
Faulty throttle position sensor 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2617 14-125 ENGINE MECHANICAL - DRIVE BELT (3MZ-FE) DRIVE BELT (3MZ-FE) 141PG-01 REPLACEMENT 1. 2. 3. REMOVE FRONT WHEEL RH REMOVE ENGINE UNDER COVER NO.1 REMOVE FRONT FENDER APRON SEAL RH 4. (a) (b) REMOVE V (COOLER COMPRESSOR CRANKSHAFT PULLEY) BELT NO.1 Loosen bolts A and B. Loosen adjusting bolt C and remove the belt. 5. (a) REMOVE VANE PUMP V BELT Loosen bolts A and B, and remove the belt. 6. (a) (b) INSTALL VANE PUMP V BELT Install the belt on each pulley. Using a bar, adjust the belt tension and tighten bolt B. Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) Tighten bolt A. Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) A C TO B A62387 A B A62382 A (c) B A62382 7. A C B (a) (b) (c) INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 Install the belt on each pulley. Tighten adjusting bolt C, and adjust the belt tension. First tighten bolt A, and then B. Torque: 58 N⋅m (591 kgf⋅cm, 43 ft⋅lbf) for bolt A 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) for bolt B A62387 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2618 14-126 ENGINE MECHANICAL 8. 9. - DRIVE BELT (3MZ-FE) INSPECT DRIVE BELT TENSION (See page 14-121 ) INSTALL FRONT WHEEL RH 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2619 14-127 ENGINE MECHANICAL - VALVE CLEARANCE (3MZ-FE) VALVE CLEARANCE (3MZ-FE) 141PH-01 ADJUSTMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. DRAIN ENGINE COOLANT (See page 16-26 ) REMOVE FR WIPER ARM LH (See page 66-7 ) REMOVE FR WIPER ARM RH (See page 66-7 ) REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See page 66-7 ) REMOVE WINDSHIELD WIPER LINK ASSY (See page 66-7 ) REMOVE COWL PANEL SUB-ASSY REMOVE FRONT FENDER APRON SEAL RH REMOVE FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER REMOVE V-BANK COVER SUB-ASSY (See page 14-149 ) REMOVE AIR CLEANER CAP SUB-ASSY REMOVE EMISSION CONTROL VALVE SET (See page 14-149 ) REMOVE INTAKE AIR SURGE TANK (See page 14-149 ) REMOVE RADIATOR HOSE INLET REMOVE IGNITION COIL ASSY REMOVE CYLINDER HEAD COVER SUB-ASSY (See page 14-173 ) REMOVE CYLINDER HEAD COVER SUB-ASSY LH (See page 14-173 ) 17. (a) INSPECT VALVE CLEARANCE Turn the crankshaft pulley, and align the timing notch with timing mark 0 of the No. 1 timing belt cover. (b) Check that the valve lifters on the No. 1 (IN and EX) are both loose. If not, turn the crankshaft 1 revolution (360) and align the mark as above. P18805 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2620 14-128 ENGINE MECHANICAL (c) RH Bank 3 3 EX IN - Check the valves indicated in the illustration on the left. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (Cold): Item Specified Condition Intake 0.15 to 0.25 mm (0.006 to 0.010 in.) Exhaust 0.25 to 0.35 mm (0.010 to 0.014 in.) (2) 1 1 Front LH Bank VALVE CLEARANCE (3MZ-FE) 6 6 Record valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed. IN EX 2 2 A78666 (d) RH Bank 5 5 EX IN 3 3 LH Bank Turn the crankshaft 2/3 of a revolution (240), and check the valves indicated in the illustration on the left. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (Cold): Item Specified Condition Intake 0.15 to 0.25 mm (0.006 to 0.010 in.) Exhaust 0.25 to 0.35 mm (0.010 to 0.014 in.) (2) Front 2 2 Record valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed. IN EX 4 4 A78667 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2621 14-129 ENGINE MECHANICAL (e) RH Bank 1 1 EX IN Front 4 4 VALVE CLEARANCE (3MZ-FE) Turn the crankshaft 2/3 of a revolution (240), and check the valves indicated in the illustration on the left. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Valve clearance (Cold): Item Specified Condition Intake 0.15 to 0.25 mm (0.006 to 0.010 in.) Exhaust 0.25 to 0.35 mm (0.010 to 0.014 in.) (2) 5 5 LH Bank - Record valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed. IN EX 6 6 A78668 Upward 18. (a) (b) ADJUST VALVE CLEARANCE Turn the camshaft so that the cam lobe faces upward. Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft. (c) Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A). SST 09248-55040 (09248-05410, 09248-05420) Notch A78669 Front of No. 1 and No. 2 Cylinders SST (A) HINT:
SST (B)
7 Apply SST (B) at a slight angle on the side marked with ”9” or ”7” at the position shown in the illustration. When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake side at a slight angle. Others SST (A) SST (B) 9 A78670 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2622 14-130 ENGINE MECHANICAL - VALVE CLEARANCE (3MZ-FE) (d) Using a small screwdriver and magnetic finger, remove the adjusting shim. (e) Using a micrometer, measure the thickness of the removed shim. Calculate the thickness of a new shim so that the valve clearance comes within the specified value. SST (B) Magnetic Finger A78671 (f) EM0494 (g) A Thickness of new shim B Thickness of used shim C Measured valve clearance Specified value (Cold): Intake A = B + (C - 0.20 mm (0.0079 in.)) Exhaust A = B + (C - 0.30 mm (0.0118 in.)) Select a new shim with a thickness as close as possible to the calculated values. EXAMPLE (Intake): Measured valve clearance = 0.45 mm (0.0177 in.) 0.45 mm (0.0177 in.) - 0.20 mm (0.0079 in.) = 0.25 mm (0.0098 in.) (Measured - Specification = Excess clearance) Used shim measurement = 2.80 mm (0.1102 in.) 0.25 mm (0.0098 in.) + 2.80 mm (0.1102 in.) = 3.05 mm (0.1201 in.) (Excess clearance + Used shim = Ideal new shim) Closest new shim = 3.05 mm (0.1201 in.) Select No. 12 shim HINT:

Shims are available in 17 sizes in increments of 0.05 mm (0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.). Refer to adjusting shim selection chart on the following 2 pages. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2623 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Adjusting Shim Selection Chart (Intake) Installed shim thickness mm (in.) Measured clearance mm (in.) ENGINE MECHANICAL
- Author
: Shim No. Thickness Shim No. mm (in.) Thickness VALVE CLEARANCE (3MZ-FE) New shim thickness Date
: HINT: A shim’s thickness is written on its face in millimeters. 14-131 V00719 2624 Intake valve clearance (Cold): 0.15 to 0.25 mm (0.006 to 0.010 in.) EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and the measured clearance is 0.450 mm (0.0177 in.). Replace the 2.800 mm (0.1102 in.) shim with a new No. 12 shim. 14-132 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Adjusting Shim Selection Chart (Exhaust) Installed shim thickness mm (in.) Measured clearance mm (in.) ENGINE MECHANICAL
- Author
: Shim No. Thickness Shim No. mm (in.) Thickness Date
: V00720 2625 Exhaust valve clearance (Cold): 0.25 to 0.35 mm (0.010 to 0.014 in.) EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and the measured clearance is 0.450 mm (0.0177 in.). Replace the 2.800 mm (0.1102 in.) shim with a new No. 10 shim. HINT: A shim’s thickness is written on its face in millimeters. VALVE CLEARANCE (3MZ-FE) New shim thickness 14-133 ENGINE MECHANICAL SST (A) (h) (i) SST (B) (j) - VALVE CLEARANCE (3MZ-FE) Place a new adjusting shim on the valve lifter with the imprinted number facing down. Press down the valve lifter with SST (A), and remove SST (B). SST 09248-55040 (09248-05410, 09248-05420) Recheck the valve clearance. A78672 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. INSTALL CYLINDER HEAD COVER SUB-ASSY (See page 14-173 ) INSTALL CYLINDER HEAD COVER SUB-ASSY LH (See page 14-173 ) INSTALL IGNITION COIL ASSY Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) INSTALL RADIATOR HOSE INLET INSTALL INTAKE AIR SURGE TANK (See page 14-149 ) INSTALL EMISSION CONTROL VALVE SET (See page 14-149 ) INSTALL AIR CLEANER CAP SUB-ASSY CONNECT VACUUM HOSES (See page 14-149 ) INSTALL V-BANK COVER SUB-ASSY (See page 14-149 ) INSTALL FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER Torque: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf) INSTALL COWL PANEL SUB-ASSY INSTALL WINDSHIELD WIPER LINK ASSY (See page 66-7 ) INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSY (See page 66-7 ) INSTALL FR WIPER ARM LH (See page 66-7 ) INSTALL FR WIPER ARM RH (See page 66-7 ) ADD ENGINE COOLANT (See page 16-26 ) CHECK FOR ENGINE COOLANT LEAKS (See page 16-20 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2626 14-134 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) PARTIAL ENGINE ASSY (3MZ-FE) 141PI-02 COMPONENTS Front Fender Apron Seal RH Front Fender Apron Seal LH Front Fender Splash Shield Sub-assy RH Front Fender Splash Shield Sub-assy LH Engine Under Cover No. 1 A91354 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2627 14-135 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) Front Wiper Arm LH Front Wiper Arm RH 24 (245, 18) Cowl Top Ventilator Louver Sub-assy 7.0 (71, 62 in.⋅lbf) Windshield Wiper Link Assy Cowl Panel Sub-assy N·m (kgf·cm, ft·lbf) : Specified torque A91356 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2628 14-136 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) Front Suspension Brace Sub-assy Upper Center 8.0 (82, 71 in.⋅lbf) 6.0 (61, 53 in.⋅lbf) Battery Clamp Sub-assy Air Cleaner Cap Sub-assy Air Cleaner Filter Element Sub-assy V-Bank Cover Sub-assy 5.0 (51, 44 in.⋅lbf) Battery Battery Tray Air Cleaner Case N·m (kgf·cm, ft·lbf) : Specified torque A91357 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2629 14-137 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) Engine Moving Control Rod V-Belt No. 1 64 (653, 47) 23 (235, 17) 8.0 (82, 71 in.⋅lbf) 58 (591, 43) Generator Bracket No. 2 Condenser 28 (286, 21) 10 (102, 7) 43 (438, 32) Engine Mounting Stay No. 2 RH Generator Assy 18 (184, 13) Generator Belt Adjusting Bar Oil Reservoir to Pump Hose No. 1 Union to Check Valve Hose Fuel Vapor Feed Hose Heater Outlet Water Hose Radiator Hose Outlet Heater Inlet Water Hose Fuel Pipe Sub-assy No. 1 Fuel Pipe Clamp Steering Gear Outlet Return Tube Radiator Hose Inlet Transmission Control Cable Assy Oil Cooler Inlet Tube No. 1 Oil Cooler Outlet Tube No. 1 Fan Belt Adjusting Bar Bracket 15 (152, 11) 25 (255, 18) Compressor and Magnetic Clutch 26 (265, 19) 25 (255, 18) N·m (kgf·cm, ft·lbf) : Specified torque A91358 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2630 14-138 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) Steering Intermediate Shaft Sub-assy 35 (357, 26) 35 (357, 26) Front Stabilizer Link Assy LH Power Steering Link Assy Tie Rod End Sub-assy LH 49 (500, 36) 74 (755, 55) Front Drive Shaft Assy LH  Cotter Pin Speed Sensor Front LH 8.0 (82, 71 in.⋅lbf)   Front Axle Hub LH Nut Front Suspension Arm Sub-assy Lower No. 1 LH 294 (2,998, 217) 127 (1,295, 217) 74 (755, 55) Exhaust Pipe Support Bracket No. 1  Gasket  Gasket Exhaust Pipe Sub-assy Front No. 3  21 (214, 15) 4WD: Propeller Shaft Assy 56 (571, 41) 56 (571, 41)  Gasket 48 (490, 35) Exhaust Pipe Assy Front 56 (571, 41) N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part A91359 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2631 14-139 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) Exhaust Manifold Heat Insulator No. 1 Vane Pump V-Belt 8.0 (82, 71 in.⋅lbf) 9.0 (92, 80 in.⋅lbf) 43 (438, 32) 49 (500, 36) Exhaust Manifold Converter Sub-assy ×6 Vane Pump Assy 95 (969, 70) 34 (347, 25)  Gasket Manifold Stay 87 (887, 64) 95 (969, 70) Stabilizer Bar Front 29 (296, 21) 75 (765, 55) Front Frame Assy 70 (714, 52) Power Steering Link Assy Front Side Rail Plate Sub-assy RH Front Suspension Member Brace Rear RH 85 (867, 63) Front Suspension Member Brace Rear LH 32 (326, 24) Front Side Rail Plate Sub-assy LH 85 (867, 63) 32 (326, 24) N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part A91361 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2632 14-140 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 69 (704, 51) 4WD: Front Drive Shaft Assy RH Transfer Assy  Snap Ring 34 (347, 25) 64 (653, 47) 34 (347, 25) 4WD: Engine Mounting Bracket RR Transfer Stiffener Plate RH 2WD: Engine Mounting Bracket RR 2WD: Front Drive Shaft Assy RH 64 (653, 47)  Snap Ring  Snap Ring 32 (326, 24) Front Drive Shaft Assy LH Flywheel Housing Under Cover ×6 64 (653, 47) 41 (418, 30) 37 (377, 27) Automatic Transaxle Assy 8 (82, 71 in.⋅lbf) 37 (377, 27) 64 (653, 47) Engine Mounting Bracket FR Starter Assy N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part A91363 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2633 14-141 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 8.0 (82, 71 in.⋅lbf) Emission Control Valve Set Engine Hanger No. 1 20 (204, 15) Emission Control Valve Bracket 28 (286, 21) 20 (204, 15) Surge Tank Stay No. 2 20 (204, 15) 20 (204, 15) Intake Air Surge Tank Surge Tank Stay No. 1 28 (286, 21)  Gasket 15 (153, 11) 8.0 (82, 71 in.⋅lbf) 15 (153, 11) 15 (153, 11) 15 (153, 11) Intake Manifold Water Outlet  Gasket 8.0 (82, 71 in.⋅lbf) Ignition Coil Assy 83 (846, 61) ×8 Drive Plate Spacer Rear Drive Plate Spacer Front N·m (kgf·cm, ft·lbf) Drive Plate & Ring Gear Sub-assy : Specified torque  Non-reusable part A81803 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2634 14-142 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 20 (204, 15) Knock Sensor 8.0 (82, 71 in.⋅lbf) Thermostat 32 (326, 24) Water Inlet  O-Ring Pump Bracket Water Inlet Pipe 9.0 (92, 80 in.⋅lbf) 20 (204, 15) 15 (153, 11) Engine Oil Pressure Switch Assy Exhaust Manifold Heat Insulator No. 2 54 (551, 40)  Gasket Engine Mounting Bracket RH 58 (591, 43) Generator Bracket No. 1 ×6 49 (500, 36) 25 (255, 18) Compressor Mounting Bracket No. 1 Exhaust Manifold Converter Sub-assy No. 2 Manifold Stay No. 2 9.0 (92, 80 in.⋅lbf) Manifold Converter Insulator No. 3 N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part 49 (500, 36) A91371 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2635 14-143 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) Spark Plug 27 (275, 20) Oil Filler Cap Sub-assy 18 (184, 13) Ventilation Valve Sub-assy Spark Plug 18 (184, 13) ×9 8.0 (82, 71 in.⋅lbf) 8.0 (82, 71 in.⋅lbf) ×9 Oil Filler Cap Gasket Gasket Gasket Cylinder Head Cover Sub-assy Cylinder Head Cover Sub-assy LH  Spark Plug Tube Gasket VVT Sensor 8.0 (82, 71 in.⋅lbf)  Spark Plug Tube Gasket Camshaft Timing Oil Control Valve Assy  O-Ring 8.0 (82, 71 in.⋅lbf) 8.0 (82, 71 in.⋅lbf) Camshaft Timing Oil Control Valve Assy VVT Sensor 8.0 (82, 71 in.⋅lbf) Oil Level Gage Guide Oil Level Gage Sub-assy  O-Ring 8.0 (82, 71 in.⋅lbf) N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part A78304 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2636 14-144 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 9.0 (92, 80 in.⋅lbf) Timing Belt Timing Belt No. 2 Cover Timing Belt Guide No. 2 9.0 (92, 80 in.⋅lbf) Engine Mounting Bracket RH 220 (2,243, 162) 28 (286, 21) Timing Belt No. 1 Cover Crankshaft Pulley Timing Belt Tensioner Assy 27 (275, 20) N·m (kgf·cm, ft·lbf) : Specified torque A78305 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2637 14-145 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) Timing Belt No. 3 Cover Collar Gasket Camshaft Timing Pulley Timing Belt Idler Bracket Bushing 125 (1,275, 92) 28 (286, 21) 9.0 (92, 80 in.⋅lbf) Camshaft Timing Pulley 43 (438, 32) 125 (1,275, 92) Timing Belt Idler Sub-assy No. 2 Water Pump Assy  Water Pump Gasket 8.0 (82, 71 in.⋅lbf) Timing Belt Idler Sub-assy No. 1 34 (347, 25) Crankshaft Timing Pulley Timing Belt Plate 8.0 (82, 71 in.⋅lbf) Crankshaft Position Sensor N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part 8.0 (82, 71 in.⋅lbf) A78306 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2638 14-146 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) Camshaft Bearing Cap No. 4 RH Bank Camshaft Timing Gear Bolt Washer Camshaft Bearing Cap No. 2 Camshaft Sub Gear Camshaft Sub Gear Wave Washer × 10 16 (163, 12) Camshaft Sub Gear Shaft Snap Ring Camshaft Bearing Cap No. 1 Camshaft Bearing Cap No. 5 Camshaft Bearing Cap No. 2 Camshaft Bearing Cap No. 3 Camshaft Bearing Cap No. 6 No. 2 Camshaft 16 (163, 12) × 10 150 (1,530, 111) Camshaft Bearing Cap No. 2 Camshaft Timing Gear Assy Camshaft See page 14-235 1st: 54 (551, 40) 2nd: Turn 90
×8 19 (194, 14)  Gasket 10 (102, 7) Cylinder Head Sub-assy Cylinder Head Cover Rear 45 (459, 33)  Gasket  Camshaft Setting Oil Seal Oil Control Valve Filter  Cylinder Head Gasket N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part A78307 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2639 14-147 ENGINE MECHANICAL LH Bank Camshaft Bearing Cap No. 5 × 10 16 (163, 12) - PARTIAL ENGINE ASSY (3MZ-FE) Camshaft Bearing Cap No. 2 Camshaft Bearing Cap No. 3 Camshaft Bearing Cap No. 6 Camshaft Sub Camshaft Timing Gear Assy Gear Wave Washer 150 (1,530, 110) Camshaft Bearing Cap No. 2 No. 3 Camshaft Sub-assy × 10 Camshaft Bearing Cap No. 2 Camshaft Bearing Cap No. 4 Camshaft Sub Gear Camshaft Sub Gear Shaft Snap Ring 16 (163, 12) Oil Control Valve Filter Camshaft Bearing Cap No. 1  Gasket Camshaft Timing Gear Bolt Washer No. 4 Camshaft Sub-assy 45 (459, 33) See page 14-240 ×8 1st: 54 (551, 40) 2nd: Turn 90
10 (102, 7) 19 (194, 14) Cylinder Head LH  Gasket  Camshaft Setting Oil Seal Cylinder Head Cover Rear Engine Hanger No. 2 20 (204, 15)  Cylinder Head Gasket No. 2 N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part A78308 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2640 14-148 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 8.0 (82, 71 in.⋅lbf) Water Inlet Housing Engine Rear Oil Seal Retainer Cylinder Block Sub-assy 20 (204, 15) Oil Pump Assy 43 (438, 32) ×6 8.0 (82, 71 in.⋅lbf) Engine Rear Oil Seal Retainer  O-Ring 30 (306, 22) Oil Filter Union  Oil Filter Sub-assy 8.0 (82, 71 in.⋅lbf) Oil Pan Baffle Plate  Oil Pump Seal Oil Pan Sub-assy 8.0 (82, 71 in.⋅lbf) 20 (204, 15) 8.0 (82, 71 in.⋅lbf) 20 (204, 15)  Gasket Oil Strainer Sub-assy 8.0 (82, 71 in.⋅lbf) 8.0 (82, 71 in.⋅lbf) Oil Pan Sub-assy No. 2 Oil Pan Drain Plug 45 (459, 33)  Gasket 8.0 (82, 71 in.⋅lbf) N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part A78309 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2641 14-173 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 141PK-02 OVERHAUL 1. 2. 3. 4. 5. DRAIN ENGINE OIL REMOVE SPARK PLUG REMOVE VENTILATION VALVE SUB-ASSY REMOVE OIL FILLER CAP SUB-ASSY REMOVE OIL FILLER CAP GASKET 6. (a) (b) (b) (b) (a) (a) (c) REMOVE CYLINDER HEAD COVER SUB-ASSY Remove the 2 engine wire harness clamps. Remove the 3 nuts and disconnect the engine wire harness. Remove the 9 bolts and cylinder head cover. (b) A78541 7. REMOVE CYLINDER HEAD COVER GASKET 8. (a) (b) REMOVE CYLINDER HEAD COVER SUB-ASSY LH Using an E6 torx socket wrench, remove the 2 bolts and disconnect the engine wire harness protector. Remove the 9 bolts and cylinder head cover. A36719 9. 10. 11. (a) (b) 12. 13. REMOVE CYLINDER HEAD COVER GASKET NO.2 REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY REMOVE VVT SENSOR Remove the sensor. Remove the O-ring from the sensor. REMOVE OIL LEVEL GAGE SUB-ASSY REMOVE OIL LEVEL GAGE GUIDE 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2666 14-174 ENGINE MECHANICAL 14. (a) - PARTIAL ENGINE ASSY (3MZ-FE) REMOVE CRANKSHAFT PULLEY Using SST, loosen the pulley bolt. SST 09213-54015 (91651-60855), 09330-00021 SST A78700 (b) Using SST and the pulley bolt, remove the pulley. SST 09950- 50013 (09951- 05010, 09952- 05010, 09953-05020, 09954-05031) NOTICE: Before using SST, apply lubricating oil to the threads and tip of the center bolt 150. SST A78701 15. REMOVE TIMING BELT NO.1 COVER 16. (a) Clamp Clamp (b) REMOVE TIMING BELT NO.2 COVER Disconnect the engine wire protector clamps from the timing belt No. 3 cover. Remove the 5 bolts and timing belt cover. A05050 17. 18. REMOVE ENGINE MOUNTING BRACKET RH REMOVE TIMING BELT GUIDE NO.2 19. (a) REMOVE TIMING BELT Set the No. 1 cylinder to TDC/compression. (1) Temporarily install the crankshaft pulley bolt and washer to the crankshaft. (2) Turn the crankshaft clockwise, and align the timing mark of the crankshaft timing pulley with the oil pump body. Turn A78326 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2667 14-175 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) (3) Check that timing marks of the camshaft timing pulleys and No. 3 timing belt cover are aligned. If not, turn the crankshaft 1 revolution (360). (4) Remove the crankshaft pulley bolt. A05052 (b) If planning to reuse the timing belt, check that there are 4 installation marks on the timing belt, as shown in the illustration. (1) If the installation marks have disappeared, put new installation marks on the timing belt before removing. A52840 (c) Approx. 60 Turn A78327 Set the No. 1 cylinder to approximately 60 BTDC/ compression. (1) Turn the crankshaft counterclockwise by approximately 60. NOTICE: With the timing belt removed: The crankshaft pulley must be at the correct angle to avoid damage in later steps. If the crankshaft pulley is at the wrong angle and the camshaft timing pulley and the camshaft are removed, the piston head and valve head may come in contact and damaged. (d) Remove the timing belt tensioner. NOTICE: Do not reinstall the tensioner with its plunger extended. (e) (3) (5) (2) (4) (1) Remove the timing belt in this order. 1st No. 1 idler pulley 2nd RH camshaft timing pulley 3rd No. 2 idler pulley 4th LH camshaft timing pulley 5th Water pump pulley 6th Crankshaft timing pulley (6) A78702 20. (a) 21. 22. REMOVE TIMING BELT IDLER SUB-ASSY NO.1 Using a socket hexagon wrench 10, remove the pivot bolt, timing belt idler No. 1 and plate washer. REMOVE TIMING BELT IDLER SUB-ASSY NO.2 REMOVE CRANKSHAFT POSITION SENSOR 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2668 14-176 ENGINE MECHANICAL RH - PARTIAL ENGINE ASSY (3MZ-FE) 23. (a) REMOVE CAMSHAFT TIMING PULLEY Using SST, remove the bolt and RH timing pulley. SST 09960- 10010 (09962- 01000, 09963- 01000), 09249-63010 (b) Using SST, remove the bolt and LH timing pulley. SST 09960-10010 (09962-01000, 09963-01000) SST A90211 LH HINT: Arrange the camshaft timing pulleys (RH and LH sides) so that they can be returned to the original locations when reassembling. SST A90212 24. (a) Clamp Clamp (b) REMOVE TIMING BELT NO.3 COVER Disconnect the 3 engine wire harness clamps from the timing belt No. 3 cover. Remove the 6 bolts and the timing belt cover. Clamp A05077 25. REMOVE TIMING BELT IDLER BRACKET 26. (a) (b) (c) SST A15128 A32939 REMOVE CRANKSHAFT TIMING PULLEY Remove the bolt and the timing belt plate. Install the pulley bolt to the crankshaft. Using SST, remove the crankshaft timing pulley. SST 09950- 50013 (09951- 05010, 09952- 05010, 09953-05020, 09954-05011) NOTICE:
Do not scratch the sensor part of the crankshaft timing pulley.
Before using SST, apply lubricating oil to the threads and tip of the center bolt 150. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2669 14-177 ENGINE MECHANICAL 27. (a) - PARTIAL ENGINE ASSY (3MZ-FE) REMOVE WATER PUMP ASSY Remove the 3 bolts and 3 nuts, then remove the water pump and the gasket. A78535 28. REMOVE CAMSHAFT NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps must be carried out. (a) Align the camshaft drive and driven gear’s timing marks (2 dot marks each) by turning the camshaft with a wrench. (b) Secure the exhaust camshaft sub gear to the main gear with a service bolt. Recommended service bolt: Align A78706 Main Gear Sub Gear Service Bolt A78707 Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16 to 20 mm Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) HINT: When removing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2670 14-178 ENGINE MECHANICAL 10 6 - PARTIAL ENGINE ASSY (3MZ-FE) (c) 2 8 1 5 4 9 7 3 Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps and the camshaft. NOTICE:
Do not pry out the camshaft.
Be careful not to damage the portion of the cylinder head receiving the shaft thrust. A78708 5 29. (a) 1 9 7 2 6 3 10 8 4 A78709 REMOVE NO.2 CAMSHAFT Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps and the No. 2 camshaft. NOTICE:
Do not pry out the camshaft.
Be careful not to damage the portion of the cylinder head receiving the shaft thrust. (b) Remove the oil seal from the No. 2 camshaft. 30. REMOVE NO.3 CAMSHAFT SUB-ASSY NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out. (a) Align Align the camshaft drive and driven gear’s timing marks (1 dot mark each) by turning the camshaft with a wrench. A78710 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2671 14-179 ENGINE MECHANICAL (b) Service Bolt - PARTIAL ENGINE ASSY (3MZ-FE) Secure the exhaust camshaft sub gear to the main gear with a service bolt. Recommended service bolt: Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16 to 20 mm Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) Main Gear Sub Gear A78711 (c) 1 5 2 9 6 7 10 8 3 HINT: When removing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt. 4 Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps and the No. 3 camshaft. NOTICE:
Do not pry out the camshaft.
Be careful not to damage the portion of the cylinder head receiving the shaft thrust. A78712 6 31. (a) 2 10 1 8 5 9 4 7 3 A78713 REMOVE NO.4 CAMSHAFT SUB-ASSY Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps and the No. 4 camshaft. NOTICE:
Do not pry out the camshaft.
Be careful not to damage the portion of the cylinder head receiving the shaft thrust. (b) Remove the oil seal from the No. 4 camshaft. 32. (a) (b) INSPECT CAMSHAFT TIMING GEAR ASSY Clamp the camshaft in a vise on the hexagonal lobe. Check that the VVT-i does not turn. A05739 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2672 14-180 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) (c) Convex Portion A78714 Cover all the oil ports with vinyl tape except the port on the advanced angle side (nearest to the convex portion) shown in the illustration. (d) Using an air gun, apply about 100 kPa (1 kgf/cm2, 14 psi) of air pressure to the port on the advanced angle side. NOTICE: Some oil will spill out. Contain the oil with a shop rag. HINT: This operation releases the lock pin for the extreme retarded angle lock. (e) Under the condition above, check that the VVT-i can be turned by hand to the advanced angle side, the direction of the white arrow in the illustration. Standard: Must turn HINT: The VVT-i will turn to the advanced angle side without applying force by hand depending on the force of the air pressure applied. Also, if applying pressure to the oil path is difficult as a result of air leakage from the port, the lock-pin may be difficult to release. (f) Check that the VVT-i moves freely within a 30 range. Avoid moving the VVT-i unit to the extreme retarded angle position as the lock-pin will re-engage. Standard: Smooth movable range is about 30 (g) Turn the VVT-i by hand and lock it at the extreme retarded angle position. 33. REMOVE CAMSHAFT TIMING GEAR ASSY NOTICE: Do not remove or install the timing gear (VVT-i) unless you are replacing the VVT-i or the camshaft. (a) Clamp the camshaft in a vise on the hexagonal lobe. NOTICE: Do not damage the camshaft. A05739 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2673 14-181 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) (b) A05740 Using a 46 mm socket wrench, remove the lock nut by turning it clockwise. NOTICE:
Remove it with the lock-pin engaged and locked at the extreme retarded angle position.
The lock nut has LH threads.
Only use the socket wrench. Other tools will deform the cam angle rotor. (c) Remove the timing gear (VVT-i). NOTICE: Never remove the 3 bolts on the gear. If it is difficult to remove the VVT-i, tap it lightly using a plasticfaced hammer and then remove it. 34. REMOVE CAMSHAFT SUB GEAR (a) Clamp the camshaft in a vise on the hexagonal lobe. NOTICE: Be careful not to damage the camshaft. P12596 (b) Using SST, turn the sub gear counterclockwise and remove the service bolt. SST 09960-10010 (09962-01000, 09963-00500) (c) (d) Using snap ring pliers, remove the snap ring. Remove the wave washer, camshaft sub gear and camshaft gear bolt washer. SST A78715 Snap Ring Pliers HINT: Arrange the camshaft sub gears and gear bolt washers (RH and LH sides) so that they can be returned to their original location when reassembled. A52353 35. 36. REMOVE ENGINE HANGER NO.2 REMOVE CYLINDER HEAD COVER REAR 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2674 14-182 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 37. (a) REMOVE OIL CONTROL VALVE FILTER Remove the plug, gasket and valve filter. 38. (a) REMOVE CYLINDER HEAD SUB-ASSY Using a socket hexagon wrench 8, remove the hexagon bolt. A05275 Front A78716 (b) Uniformly loosen the 8 cylinder head bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers. NOTICE:
Be careful not to drop washers into the cylinder head.
Head warpage or cracking could result from removing bolts in an incorrect order. Front 2 7 5 3 4 6 8 1 A78717 39. REMOVE CYLINDER HEAD GASKET 40. (a) Front REMOVE CYLINDER HEAD LH Using a socket hexagon wrench 8, remove the hexagon bolt. A78718 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2675 14-183 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) (b) Uniformly loosen the 8 cylinder head bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers. NOTICE:
Be careful not to drop washers into the cylinder head.
Head warpage or cracking could result from removing bolts in an incorrect order. Front 4 6 8 1 2 7 5 3 A78719 41. REMOVE CYLINDER HEAD GASKET NO.2 8 2 42. (a) REMOVE WATER INLET HOUSING Uniformly loosen and remove the 8 bolts and 2 nuts in the sequence shown in the illustration. Remove the water inlet housing. 43. (a) REMOVE OIL FILTER SUB-ASSY Using SST, remove the oil filter. SST 09228-07501 Using a socket hexagon wrench 12, remove the oil filter union. 10 5 3 4 6 7 9 1 A78314 SST (b) B06486 44. REMOVE OIL PAN DRAIN PLUG 45. (a) REMOVE OIL PAN SUB-ASSY NO.2 Remove the 10 bolts and 2 nuts. A36750 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2676 14-184 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) (b) SST SST A00019 46. (a) Insert the blade of SST between the oil pan No. 1 and oil pan No. 2. Cut through the sealer and remove the oil pan No. 2. SST 09032-00100 NOTICE:
Do not damage the contact surface of oil pan No. 1 and oil pan No. 2.
Do not damage the flange portion of the oil pan No. 2 during removal. REMOVE OIL STRAINER SUB-ASSY Remove the bolt and 2 nuts. Then remove the oil strainer and the gasket. 47. (a) REMOVE OIL PAN SUB-ASSY Uniformly loosen and remove the 15 bolts and 2 nuts, as shown in the illustration. B04136 (b) Using a screwdriver, remove the oil pan by prying between the cylinder block and the oil pan. NOTICE: Be careful not to damage the contact surfaces of the oil pan and cylinder block. B04137 48. REMOVE OIL PAN BAFFLE PLATE 49. (a) (b) REMOVE ENGINE REAR OIL SEAL RETAINER Uniformly loosen and remove the 6 bolts. Using a screwdriver, remove the oil seal retainer by prying between the oil seal retainer and the main bearing cap. P12508 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2677 14-185 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 50. (a) REMOVE ENGINE REAR OIL SEAL Using a screwdriver and a hammer, tap out the oil seal. 51. (a) (b) (c) REMOVE OIL PUMP ASSY Remove the 9 bolts. Using a screwdriver, remove the oil pump by prying between the oil pump and the main bearing cap. Remove the O-ring. 52. (a) REMOVE OIL PUMP SEAL Using a screwdriver, pry out the oil seal. P12589 A51990 A62375 53. (a) REMOVE SPARK PLUG TUBE GASKET Bend up the tab on the ventilation baffle plate which prevents the gasket from slipping out. NOTICE: Be careful not to damage the baffle plate of the cylinder head cover. (b) Using a screwdriver and a hammer, tap out the gasket. A05245 (c) Using needle-nose pliers, pry out the gasket. NOTICE: Be careful not to damage the cylinder head cover. A05243 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2678 14-186 ENGINE MECHANICAL EM3336 - PARTIAL ENGINE ASSY (3MZ-FE) 54. INSPECT TIMING BELT NOTICE:
Do not bend, twist or turn the timing belt inside out.
Do not allow the timing belt to come into contact with oil, water or steam.
Do not utilize timing belt tension when installing or removing the mounting bolt of the camshaft timing pulley. Check the belt for any defects, as shown in the illustrations. Also, check these points below. (a) If there is premature parting:
Check for proper installation.
Check the timing cover gasket for no damage and proper installation. (b) If the belt teeth are cracked or damaged, check to see if either camshaft is locked. (c) If there is noticeable wear or cracks on the belt, check to see if there are nicks on the side of the idler pulley lock and water pump. (d) If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley. (e) If there is noticeable wear on the belt teeth:
Check the timing cover for damage.
Check that the gasket has been installed correctly.
Check for foreign objects on the pulley teeth. If there is any doubt about the belt condition, replace the timing belt. 55. (a) INSPECT CAMSHAFT Inspect the camshaft for runout. (1) Place the camshaft on V-blocks. (2) Using a dial indicator, measure the runout at the center journal. Maximum circle runout: 0.06 mm (0.0024 in.) If the runout is greater than the maximum, replace the camshaft. EM1628 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2679 14-187 ENGINE MECHANICAL (b) - PARTIAL ENGINE ASSY (3MZ-FE) Inspect the cam lobes. (1) Using a micrometer, measure the cam lobe height. Standard cam lobe height: Item Specified Condition Intake 43.132 to 43.232 mm (1.6981 to 1.7020 in.) Exhaust 43.010 to 43.110 mm (1.6933 to 1.6972 in.) Minimum cam lobe height: A51428 Item Specified Condition Intake 42.98 mm (1.6921 in.) Exhaust 42.86 mm (1.6874 in.) If the cam lobe height is less than the minimum, replace the camshaft. (c) Inspect the camshaft journals. (1) Using a micrometer, measure the journal diameter. Journal diameter: 26.959 to 26.975 mm (1.0614 to 1.0620 in.) If the journal diameter is not as specified, check the oil clearance. A51429 56. (a) INSPECT CYLINDER HEAD SET BOLT Using a vernier caliper, measure the tension portion diameter of the bolt. Standard outside diameter: 8.95 to 9.05 mm (0.3524 to 0.3563 in.) Minimum outside diameter: 8.75 mm (0.3445 in.) If the diameter is less than the minimum, replace the bolt. Tension Portion A78721 57. (a) SST (b) (c) INSTALL SPARK PLUG TUBE GASKET Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover. SST 09950- 60010 (09951- 00430), 09950- 70010 (09951-07100) Return the ventilation plate tab to its original position. Apply a light coat of MP grease to the gasket lip. A78722 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2680 14-188 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 58. (a) SST A78723 INSTALL ENGINE REAR OIL SEAL Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-15030, 09950-70010 (09951-07100) NOTICE:
Be careful not to tap the oil seal at an angle.
Keep the gap between the rear oil seal retainer edge and the oil seal free of foreign matter. (b) Apply MP grease to the oil seal lip. 59. (a) Seal Width: 2 to 3 mm A INSTALL ENGINE REAR OIL SEAL RETAINER Remove any old packing material from the contact surface. (b) A B B A78724 Apply a continuous bead of seal packing (seal width: 2 to 3 mm (0.08 to 0.12 in.)), as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTICE:
Remove any oil from the contact surface.
Install the oil seal retainer within 3 minutes after applying seal packing.
Do not expose the seal to engine oil for at least 2 hours after installing. (c) Install the oil seal retainer. Tighten the 6 bolts uniformly. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 60. (a) SST A78754 INSTALL OIL PUMP SEAL Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge. SST 09223-00010 NOTICE:
Be careful not to tap the oil seal at an angle.
Keep the gap between the oil pump body edge and the oil seal free of foreign matter. (b) Apply MP grease to the oil seal lip. 61. (a) (b) INSTALL OIL PUMP ASSY Remove any old packing material from the contact surface. Apply a light coat of engine oil to a new O-ring and place it on the cylinder block. A36784 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2681 14-189 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) (c) Apply a continuous bead of seal packing (seal width: 2 to 3 mm (0.08 to 0.12 in.)), as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTICE:
Remove any oil from the contact surface.
Apply seal packing to the inner side of the bolt holes.
Install the oil pump within 3 minutes after applying seal packing.
Do not expose the seal to engine oil for at least 2 hours after installing the oil pump. B A C Seal Packing A Seal Width: 2 to 3 mm B C A78725 (d) Align the key of the oil pump drive gear with the keyway located on the crankshaft, and slide the oil pump into place. (e) Install the oil pump with the 9 bolts. Tighten the bolts uniformly in several steps. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) for bolt A 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) for bolt B 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) for bolt C A36785 A B C A A B A A A A51990 62. INSTALL OIL PAN BAFFLE PLATE Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2682 14-190 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 63. (a) (b) INSTALL OIL PAN SUB-ASSY Remove any old seal packing from the contact surface. Apply a continuous bead of seal packing (seal width: 3 to Region ”X” Region ”Y” 4 mm (0.12 to 0.16 in.)), as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTICE:
Remove any oil from the contact surface.
Apply seal packing to the outer side of the bolt holes in region ”X”.
Apply seal packing to the inner side of the bolt holes in region ”Y”. B A
Install the oil pan within 3 minutes after applying seal packing. Seal Packing B A
Do not expose the seal to engine oil for at least 2 hours after installing. (c) Install the oil pan No. 1 with the 15 bolts and 2 nuts. Tighten the bolts uniformly in several steps. Seal Width: Torque: 3 to 4 mm 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) for 10 mm head A78726 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) for 12 mm head 64. INSTALL OIL STRAINER SUB-ASSY (a) Install a new gasket and the oil strainer with the bolt and 2 nuts. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 65. (a) (b) INSTALL OIL PAN SUB-ASSY NO.2 Remove any old seal packing from the contact surface. Apply a continuous bead of seal packing (seal width: 4 to 5 mm (0.16 to 0.20 in.)), as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTICE:
Remove any oil from the contact surface.
Apply seal packing to the inner side of the bolt holes.
Install the oil pan within 3 minutes after applying seal packing.
Do not expose the seal to engine oil for at least 2 hours after installing. (c) Install the oil pan No. 2 with the 10 bolts and 2 nuts. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) Seal Packing A A B Seal Width: 4 to 5 mm B A78727 66. (a) INSTALL OIL PAN DRAIN PLUG Install the drain plug with a new gasket. Torque: 45 N⋅m (459 kgf⋅cm, 33 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2683 14-191 ENGINE MECHANICAL Additional 3/4 Turn A78747 Seal Width: 3 to 5 mm Seal Packing A78728 INSTALL OIL FILTER SUB-ASSY Using a socket hexagon wrench 12, install the oil filter union. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) (b) Check and clean the oil filter installation surface. (c) Apply clean engine oil to the gasket of a new oil filter. (d) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. (e) Using SST, tighten it an additional 3/4 turn. SST 09228-07501 68. INSTALL WATER INLET HOUSING (a) Remove any old packing material from the contact surface. (b) Apply a continuous bead of seal packing (seal width: 3 to 5 mm (0.12 to 0.20 in.)) as shown in the illustration. Seal packing: Part No. 08826-00100 or equivalent NOTICE:
Remove any oil from the contact surface.
Install the water inlet housing within 3 minutes after applying seal packing.
Do not expose the seal to coolant for at least 2 hours after installing. (c) 9 1 6 8 5 PARTIAL ENGINE ASSY (3MZ-FE) 67. (a) SST 3 - Install the water inlet housing with the 8 bolts and 2 nuts. Uniformly tighten the bolts and nuts in the sequence shown in the illustration. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 7 2 4 10 A78314 69. (a) Front A78324 INSTALL CYLINDER HEAD GASKET Place a new cylinder head gasket on the cylinder block with the R mark upside down, as shown in the illustration. NOTICE:
Remove any oil from the contact surface.
Make sure the cylinder head gasket is facing in the correct direction.
Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2684 14-192 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 70. INSTALL CYLINDER HEAD SUB-ASSY NOTICE: The cylinder head bolts are tightened in 2 successive steps. (a) Front 7 2 4 6 5 3 1 8 (b) (c) Apply a light coat of engine oil on the threads of the cylinder head bolts. Install the plate washers to the cylinder head bolts. Uniformly install and tighten the 8 cylinder head bolts in the sequence shown in the illustration. Torque: 54 N⋅m (550 kgf⋅cm, 40 ft⋅lbf) A78717 (d) (e) 90 (f) Front Mark the front side of each cylinder head bolt head with paint, as shown in the illustration. Retighten the cylinder head bolts by 90 in the same sequence as step (c). Check that each painted mark is now at a 90 angle to the front. Painted mark A78730 (g) Front Using a socket hexagon wrench 8, install the hexagon bolt. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) A78716 71. (a) Front A78325 INSTALL CYLINDER HEAD GASKET NO.2 Place a new cylinder head gasket on the cylinder block with the L mark, as shown in the illustration. NOTICE:
Remove any oil from the contact surface.
Make sure the cylinder head gasket is facing in the correct direction.
Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2685 14-193 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 72. INSTALL CYLINDER HEAD LH NOTICE: The cylinder head bolts are tightened in 2 successive steps. (a) Front 5 3 1 8 7 2 4 6 (b) (c) Apply a light coat of engine oil to the threads of the cylinder head bolts. Install the plate washers to the cylinder head bolts. Uniformly install and tighten the 8 cylinder head bolts in the sequence shown in the illustration. Torque: 54 N⋅m (550 kgf⋅cm, 40 ft⋅lbf) A78719 (d) (e) 90 (f) Front Mark the front side of each cylinder head bolt head with paint, as shown in the illustration. Retighten the cylinder head bolts by 90 in the same sequence as step (c). Check that each painted mark is now at a 90 angle to the front. Painted mark A78730 (g) Using a socket hexagon wrench 8, install the hexagon bolt. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) 73. (a) INSTALL OIL CONTROL VALVE FILTER Check that no foreign matter is on the mesh part of the filter. Assemble the valve filter and the plug. Install a new gasket and the plug. Torque: 45 N⋅m (459 kgf⋅cm, 33 ft⋅lbf) Front A78718 (b) (c) A05418 74. (a) 75. INSTALL CYLINDER HEAD COVER REAR Install a new gasket and the rear cover with the 4 bolts. Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) INSTALL ENGINE HANGER NO.2 Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2686 14-194 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 76. INSTALL CAMSHAFT SUB GEAR (a) Clamp the camshaft in a vise on the hexagonal lobe. NOTICE: Be careful not to damage the camshaft. P12595 (b) Wave Washer Camshaft Sub Gear Install the camshaft gear bolt washer and the camshaft sub gear. HINT: Attach the pins on the gears to the gear bolt washer ends. (c) Install the wave washer. Camshaft Gear Bolt Washer A78732 (d) Using snap ring pliers, install the snap ring. Snap Ring Pliers A52353 (e) SST Main Gear Sub Gear A78733 Using SST, align the holes of the camshaft main gear and sub gear by turning the camshaft sub gear counterclockwise, and temporarily install a service bolt. SST 09960-10010 (09962-01000, 09963-00500) (f) Align the gear teeth of the main gear and sub gear, and tighten the service bolt. Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) NOTICE: Be careful not to damage the camshaft journals. HINT: When installing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2687 14-195 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 77. (a) Align A78734 INSTALL CAMSHAFT TIMING GEAR ASSY Align the alignment pin with the alignment pin groove and install the VVT-i on the camshaft. NOTICE: Install the VVT-i with the lock-pin engaged and locked at the extreme retarded angle position. (b) Apply engine oil to the nut, the mounting surface of the VVT-i and the screw threads. NOTICE:
Be sure to apply the oil, otherwise the specified torque cannot be obtained.
New nuts must be used when replacing the VVT-i unit. (c) Using a 46 mm socket wrench, install and tighten a lock nut by turning it counterclockwise. Torque: 150 N⋅m (1,530 kgf⋅cm, 111 ft⋅lbf) NOTICE:
The lock nut has LH threads.
Never use any tools other than the socket wrench. Other tools will deform the cam angle rotor. A05738 78. INSTALL NO.2 CAMSHAFT NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps must be carried out. (a) 90 (b) Apply new engine oil to the thrust portion and journal of the camshaft. Place the No. 2 camshaft at a 90 angle of the timing mark (2 dot marks) on the cylinder head. A78735 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2688 14-196 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) (c) Install the oil seal to the camshaft. NOTICE:
Do not turn over the oil seal lip.
Insert the oil seal until it stops. (d) Apply MP grease to a new oil seal lip. (e) Remove any old packing material from the contact surface. Front A78736 (f) Apply seal packing to the No. 1 bearing cap, as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTICE:
Install the No. 1 bearing cap within 5 minutes after applying seal packing.
Do not expose the seal to engine oil for at least 2 hours after installing. Seal Packing A78737 (g) (h) Install the 5 bearing caps in their proper locations. Apply a light coat of engine oil on the threads of the bearing cap bolts. (i) Uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf) A05283 6 10 2 4 9 8 5 1 3 7 A78738 79. INSTALL CAMSHAFT NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps must be carried out. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2689 14-197 ENGINE MECHANICAL (a) (b) (c) - PARTIAL ENGINE ASSY (3MZ-FE) Apply new engine oil to the thrust portion and journal of the camshaft. Align the camshaft drive and driven gear’s timing marks (2 dot mark each). Place the camshaft on the cylinder head. Align A78739 (d) (e) Install the 5 bearing caps in their proper locations. Apply a light coat of engine oil on the threads of the bearing cap bolts. (f) Uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf) Remove the service bolt. A05204 5 9 1 3 10 6 7 (g) 2 4 8 A78740 80. INSTALL NO.4 CAMSHAFT SUB-ASSY NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps must be carried out. (a) (b) 90 (c) Apply new engine oil to the thrust portion and journal of the camshaft. Place the No. 4 camshaft at a 90 angle of the timing mark (1 dot mark) on the cylinder head. Apply MP grease to a new oil seal lip. A78741 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2690 14-198 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) (d) Install the oil seal to the camshaft. NOTICE:
Do not turn over the oil seal lip.
Insert the oil seal until it stops. Front (e) Remove any old packing material from the contact surface. A78742 (f) Apply seal packing to the No. 1 bearing cap, as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTICE:
Install the No. 1 bearing cap within 5 minutes after applying seal packing.
Do not expose the seal to engine oil for at least 2 hours after installing. Seal Packing A78737 (g) (h) Install the 5 bearing caps in their proper locations. Apply a light coat of engine oil on the threads of the bearing cap bolts. (i) Uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf) A05209 9 5 1 10 3 6 7 2 4 8 A78743 81. INSTALL NO.3 CAMSHAFT SUB-ASSY NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps must be carried out. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2691 14-199 ENGINE MECHANICAL (a) (b) (c) - PARTIAL ENGINE ASSY (3MZ-FE) Apply new engine oil to the thrust portion and journal of the camshaft. Align the camshaft drive and driven gear’s timing marks (1 dot mark each). Place the camshaft on the cylinder head. Align A78744 (d) (e) Install the 5 bearing caps in their proper locations. Apply a light coat of engine oil on the threads of the bearing cap bolts. (f) Uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf) Remove the service bolt. A05214 10 6 9 2 4 5 (g) 1 8 3 7 A78745 82. (a) INSTALL WATER PUMP ASSY Install a new gasket and the water pump with the 3 bolts and 3 nuts. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) A78535 83. (a) Inward Sensor INSTALL CRANKSHAFT TIMING PULLEY Align the keyway of the timing pulley with the key located on the crankshaft and slide the timing pulley into place. NOTICE: Do not scratch the sensor area of the crankshaft timing pulley. (b) Install the timing belt plate with the bolt. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) A78746 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2692 14-200 ENGINE MECHANICAL 84. - PARTIAL ENGINE ASSY (3MZ-FE) INSTALL TIMING BELT IDLER BRACKET Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) 85. INSTALL TIMING BELT NO.3 COVER (a) Visually check for cracks and breaks on the gasket of the timing belt cover. HINT: If water is entering through cracks or breaks in the gasket, repair according to these guidelines: 1) if the crack length is within 2 to 3 cm (0.79 to 1.18 in.), repair with seal packing; or 2) if the crack length is over 3 cm (1.18 in.), replace the gasket. (b) If the timing belt cover gasket needs to be repaired, follow Seal Packing the procedure below. Gasket (1) Repair the cracks and breaks by applying the seal packing to the damaged area. Seal packing: Part No. 08826-00080 or equivalent NOTICE: When applying the seal packing, apply it as wide and high as the gasket. (c) If the timing belt cover gasket needs to be replaced, follow A78748 the procedure below. (1) Using a screwdriver and gasket scraper, remove the remaining gasket. NOTICE: Be careful not to damage the timing belt cover. (2) E F D Joining Line Joining Portion Gasket E Joining G Line Remove the backing paper from a new gasket, and affix the gasket along the groove of the timing belt cover, as shown in the illustration. NOTICE:
Affix the gasket in the center of the groove.
At the corners, try to keep the gasket thickness uniform. Length: Gasket D E F G Specified Condition 335 mm (13.19 in.) 180 mm (7.09 in.) 133 mm (5.24 in.) 72 mm (2.83 in.) (3) Seal Packing A78749 If there is a gap on the joint of the gasket, apply seal packing to close the gap. Seal packing: Part No. 08826-00080 or equivalent NOTICE: When applying the seal packing, apply it as wide and high as the gasket. (d) Install the timing belt cover with the 6 bolts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2693 14-201 ENGINE MECHANICAL Front 86. (a) Front - PARTIAL ENGINE ASSY (3MZ-FE) INSTALL CAMSHAFT TIMING PULLEY Install the camshaft timing pulley with the belt guide properly oriented and tighten the bolt temporarily. HINT:

Face the belt guide of the RH timing pulley towards the front of the engine. Face the belt guide of the LH timing pulley towards the rear of the engine. A78750 (b) RH SST 150 mm A78763 Using SST, tighten the RH pulley bolt. Torque: 125 N⋅m (1,275 kgf⋅cm, 92 ft⋅lbf) SST 09960- 10010 (09962- 01000, 09963- 01000), 09249-63010 NOTICE: The torque specification above is the SST without extension tool specification. Use the special formula to calculate the SST with extension tool torque specification (see page 01-5 ). Extended length of SST (09249-63010): 150 mm (5.91 in.) (c) LH Using SST, tighten the LH pulley bolt. Torque: 125 N⋅m (1,275 kgf⋅cm, 92 ft⋅lbf) SST 09960-10010 (09962-01000, 09963-01000) SST A90212 87. 88. 89. (a) INSTALL CRANKSHAFT POSITION SENSOR INSTALL TIMING BELT IDLER SUB-ASSY NO.2 Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) INSTALL TIMING BELT IDLER SUB-ASSY NO.1 Using a socket hexagon wrench 10, install the plate washer and timing belt idler No. 1 with the pivot bolt. Torque: 34 N⋅m (348 kgf⋅cm, 25 ft⋅lbf) 90. INSTALL TIMING BELT (a) Remove any oil or water on the pulleys, and keep them clean. NOTICE:
If there is a trace of water and/or oil on the timing belt, repair the leakage and install a new timing belt.
Do not use cleaning agents on the pulleys when cleaning them. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2694 14-202 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) (b) Inspect the idler pulleys. (1) Check that the idler pulley turns smoothly. (2) Visually check the sealed portion of the idler pulley for oil leakage. If there is any doubt about the idller pulleys condition, replace the idller pulleys. (c) Inspect the water pump. (1) Turn the pulley, and check that the water pump bearing moves smoothly without any noise. (2) Visually check the drain hole for coolant leakage. If there is any doubt about the water pump condition, replace the water pump. (d) Temporarily install the crankshaft pulley bolt and washer to the crankshaft. (e) Turn the crankshaft counterclockwise by approximately 60. NOTICE: To prevent contacting the piston head and the valve head from colliding, set the crankshaft pulley at approximately 60 BTDC/compression position. Approx. 60 Turn A82349 (f) Using SST, turn the crankshaft pulley, and align the timing marks of the timing pulley with the No. 3 timing belt cover. SST 09960-10010 (09962-01000, 09963-01000) (g) Turn the crankshaft, and align the timing mark of the crankshaft timing pulley with the oil pump body. SST A78751 A05062 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2695 14-203 ENGINE MECHANICAL (h) (i) (j) - PARTIAL ENGINE ASSY (3MZ-FE) Face the front mark on the timing belt forward. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys. A52840 (k) (4) (2) (5) (3) (6) Install the timing belt in this order. 1st Crankshaft timing pulley 2nd Water pump pulley 3rd LH camshaft timing pulley 4th No. 2 idler pulley 5th RH camshaft timing pulley 6th No. 1 idler pulley (1) A78702 A36238 91. INSTALL TIMING BELT TENSIONER (a) Set the timing belt tensioner uprightly on the press. (b) Slowly press in the push rod. NOTICE: Do not apply pressure of more than 9.8 kN (1,000 kgf, 2,205 lbf) to the rod. (c) Align the holes of the push rod and housing, pass a 1.5 mm hexagon wrench through the holes to keep the setting position of the push rod. (d) Release the press. (e) Temporarily install the tensioner with the 2 bolts. Torque: 27 N⋅m (280 kgf⋅cm, 20 ft⋅lbf) NOTICE: Install the tensioner’s bolts uniformly and evenly. Installing the tensioner at an angle may cause it to malfunction. (f) Remove the 1.5 mm hexagon wrench from the tensioner. (g) Turn the crankshaft 2 revolutions slowly, and align the timing mark of the crankshaft timing pulley with the oil pump body. NOTICE: Always turn the crankshaft clockwise. Turn A78326 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2696 14-204 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) (h) Check that the timing marks of the RH and LH timing pulleys are aligned with the timing marks of the No. 3 timing belt cover, as shown in the illustration. If the marks do not align, remove the timing belt and reinstall it. (i) Remove the crankshaft pulley bolt. A05052 92. (a) INSTALL TIMING BELT GUIDE NO.2 Install the timing belt guide, facing the cup side toward the engine front. A36239 93. INSTALL ENGINE MOUNTING BRACKET RH Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) 94. INSTALL TIMING BELT NO.2 COVER (a) Visually check for cracks and breaks on the gasket of the timing belt cover. If there is a trace that water is entering at the visual check, replace the timing belt cover. (b) Install the timing belt cover. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) 95. INSTALL TIMING BELT NO.1 COVER (a) Visually check for cracks and breaks on the gasket of the timing belt cover. If there is a trace that water is entering at the visual check, replace the timing belt cover. (b) Install the timing belt cover. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) 96. (a) (b) INSTALL CRANKSHAFT PULLEY Align the keyway of the pulley with the key located on the crankshaft and slide the pulley into place. Using SST, install the pulley bolt. SST 09213-54015 (91651-60855), 09330-00021 Torque: 220 N⋅m (2,243 kgf⋅cm, 162 ft⋅lbf) SST A78753 97. (a) (b) 98. INSTALL OIL LEVEL GAGE GUIDE Apply a light coat of engine oil to a new O-ring and install it to the level gage guide. Install the level gage guide. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) INSTALL OIL LEVEL GAGE SUB-ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2697 14-205 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 99. INSTALL VVT SENSOR Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 100. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 101. INSPECT VALVE CLEARANCE (See page 14-127 ) 102. ADJUST VALVE CLEARANCE (See page 14-127 ) : Seal Packing Front A78673 103. INSTALL CYLINDER HEAD COVER SUB-ASSY (a) Install the gasket to the cylinder head cover. (b) Apply seal packing to the cylinder head, as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 3 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing. (c) Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 104. INSTALL CYLINDER HEAD COVER SUB-ASSY LH (a) Install the gasket to the cylinder head cover. (b) Apply seal packing to the cylinder head, as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTICE:
Remove any oil from the contact surface. Front
Install the cylinder head cover within 3 minutes after applying seal packing. A78674
Do not start the engine for at least 2 hours after installing. (c) Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) INSTALL OIL FILLER CAP SUB-ASSY INSTALL VENTILATION VALVE SUB-ASSY Apply adhesive to 2 or 3 threads. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent Install the ventilation valve. Torque: 19 N⋅m (193 kgf⋅cm, 14 ft⋅lbf) INSTALL SPARK PLUG Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf) ADD ENGINE OIL : Seal Packing 105. 106. (a) (b) 107. 108. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2698 14-149 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 141PJ-02 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See page 11-35 ) REMOVE FRONT WHEELS REMOVE ENGINE UNDER COVER NO.1 REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSY LH REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSY RH REMOVE FRONT FENDER APRON SEAL LH REMOVE FRONT FENDER APRON SEAL RH DRAIN ENGINE OIL DRAIN ENGINE COOLANT (See page 16-26 ) DRAIN AUTOMATIC TRANSAXLE FLUID DRAIN TRANSFER OIL (4WD TYPE) REMOVE FR WIPER ARM LH (See page 66-7 ) REMOVE FR WIPER ARM RH (See page 66-7 ) REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See page 66-7 ) REMOVE WINDSHIELD WIPER LINK ASSY (See page 66-7 ) REMOVE COWL PANEL SUB-ASSY REMOVE FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER 18. (a) (b) REMOVE V-BANK COVER SUB-ASSY Using a 5 mm hexagon wrench, remove the 3 nuts. Disconnect the 2 clips, and remove the cover. A81195 19. 20. 21. 22. 23. 24. 25. 26. REMOVE BATTERY REMOVE AIR CLEANER CAP SUB-ASSY REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSY REMOVE AIR CLEANER CASE REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14-125 ) REMOVE VANE PUMP V BELT (See page 14-125 ) REMOVE GENERATOR ASSY (See page 19-40 ) REMOVE GENERATOR BRACKET NO.2 27. (a) REMOVE GENERATOR BELT ADJUSTING BAR Remove the 2 bolts, 2 nuts and adjusting bar. A52889 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2642 14-150 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 28. (a) REMOVE ENGINE MOVING CONTROL ROD Remove the 4 bolts and control rod. 29. (a) REMOVE ENGINE MOUNTING STAY NO.2 RH Remove the bolt, mounting stay No. 2 RH and mounting bracket No. 2 RH. A90268 A52344 30. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (a) Remove the bolt, nut and adjusting bar bracket. (b) Remove the 3 bolts and disconnect the compressor. HINT: Hang up the hoses instead of detaching them. Adjusting Bar Bracket 31. 32. (a) A52901 SEPARATE TRANSMISSION CONTROL CABLE ASSY (See page 40-73 ) DISCONNECT UNION TO CHECK VALVE HOSE Remove the vacuum hose for the brake booster. 33. (a) Fuel Pipe Clamp No. 1 DISCONNECT FUEL PIPE SUB-ASSY NO.1 Remove the fuel pipe clamp. A60083 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2643 14-151 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) (b) A 34. 35. 36. 37. 38. 39. DISCONNECT DISCONNECT DISCONNECT DISCONNECT DISCONNECT DISCONNECT Disconnect the connector from the tube while pinching part A with fingers as shown in the illustration. NOTICE:
Check for contamination in the pipe and around the connector. Clean if necessary and then disconnect the connector.
Disconnect the connector with your hands. A
Do not bend, fold or rotate the nylon tube.
If the pipe and connector are stuck together, push and B12941 pull the connector until it comes free.
Put the pipe and connector ends in vinyl bags to prevent damage and contamination. HEATER INLET WATER HOSE HEATER OUTLET WATER HOSE RADIATOR HOSE INLET RADIATOR HOSE OUTLET OIL COOLER INLET TUBE NO.1 OIL COOLER OUTLET TUBE NO.1 40. DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.1 41. DISCONNECT STEERING GEAR OUTLET RETURN TUBE A80810 A52327 42. REMOVE GLOVE COMPARTMENT DOOR ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2644 14-152 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 43. (a) SEPARATE ENGINE WIRE Disconnect the engine wire from the ECM and junction block. (b) Disconnect the engine wire from the engine room junction block. (1) Remove the nut and separate the wire harness. (2) Using a screwdriver, release the engine room junction block. Disconnect the engine wire by pulling it upward. A80811 (c) Remove the 2 nuts and pull out the engine wire. (d) Remove the body ground. REMOVE PROPELLER SHAFT ASSY (4WD TYPE) (See page 30-12 ) DISCONNECT EXHAUST PIPE SUB-ASSY FRONT NO.3 (See page 15-5 ) DISCONNECT EXHAUST PIPE ASSY FRONT (See page 15-5 ) REMOVE EXHAUST PIPE SUPPORT BRACKET NO.1 (See page 15-5 ) DISCONNECT FRONT STABILIZER LINK ASSY LH Using a 6 mm socket hexagon wrench, hold the ball stud. Remove the nut and disconnect the stabilizer link. DISCONNECT FRONT STABILIZER LINK ASSY RH 44. 45. 46. 47. 48. (a) (b) 49. HINT: Use the same procedures described for the LH side. 50. (a) REMOVE FRONT AXLE HUB LH NUT Using SST and a hammer, strike the lock nut covering to remove it. SST SST 09930-00010 NOTICE:
Set the drive shaft’s groove so that it faces up. Then use the SST and hammer.
Remove the covering from the lock nut completely or the screw of the drive shaft may be damaged. C65981
Do not sharpen the tip of the SST. (b) Using a 30 mm socket wrench, remove the lock nut. REMOVE FRONT AXLE HUB RH NUT 51. HINT: Use the same procedures described for the LH side. 52. DISCONNECT SPEED SENSOR FRONT LH (a) Remove the bolt and disconnect the speed sensor from the steering knuckle. NOTICE: Keep the speed sensor tip and connection free from foreign matter. 53. DISCONNECT SPEED SENSOR FRONT RH HINT: Use the same procedures described for the LH side. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2645 14-153 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 54. (a) (b) SEPARATE TIE ROD END SUB-ASSY LH Remove the cotter pin and nut. Using SST, disconnect the tie rod end from the steering knuckle. SST 09628-6201 1 NOTICE: Do not damage the dust cover of the ball joint. SST C65311 55. SEPARATE TIE ROD END SUB-ASSY RH HINT: Use the same procedures described for the LH side. 56. (a) (b) SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH Remove the bolt and 2 nuts, and separate the front suspension arm from the lower ball joint. Using a plastic hammer, disconnect the drive shaft from the axle hub. C65935 57. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH HINT: Use the same procedures described for the LH side. 58. (b) REMOVE DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT Using SST, hold the crankshaft. SST 09213-54015 (91651-60855), 09330-00021 Remove the 2 bolts and flywheel housing under cover. (c) Remove the 6 torque converter setting bolts. (a) SST A36243 A52328 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2646 14-154 ENGINE MECHANICAL 59. (a) - PARTIAL ENGINE ASSY (3MZ-FE) SEPARATE STEERING INTERMEDIATE SHAFT SUB-ASSY Loosen the sliding yoke bolt. A60062 (b) A60063 Place matchmarks on the steering intermediate shaft and control valve shaft. (c) Remove the bolt and disconnect the steering intermediate shaft. (d) To prevent the steering wheel from rotating, fix the wheel with the seat belt. NOTICE: If the steering wheel is not fixed, the spiral cable will be damaged. 60. (a) (b) REMOVE ENGINE ASSEMBLY WITH TRANSAXLE Set the engine lifter. Remove the 6 bolts, 2 nuts, and frame side rail plate subassembly LH and RH. (c) Remove the 6 bolts, 2 nuts, and front suspension member brace rear LH and RH. Carefully, remove the engine assembly from the vehicle. A80812 (d) A80813 (e) (f) Install the engine hanger as shown in the illustration. Part No.: No. 2 engine hanger 12282-20020 Bolt 91621-60822 Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) Using a chain block and an engine sling device, hang the engine assembly. A36439 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2647 14-155 ENGINE MECHANICAL 61. (a) (b) - PARTIAL ENGINE ASSY (3MZ-FE) REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY Disconnect the A/F sensor connector. Remove the 3 bolts and insulator. A91368 (c) 3 6 1 (d) 2 5 Uniformly loosen and remove the 6 nuts in the sequence shown in the illustration. Remove the manifold and gasket. 4 A91369 62. INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSY (a) Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.50 mm (0.0196 in.) If the warpage is greater than the maximum, replace the manifold. A91370 63. (a) (b) (c) REMOVE VANE PUMP ASSY Remove the power steering oil pressure sensor harness. Remove the pressure feed tube clamp. Remove the 2 bolts and vane pump. A52890 64. 65. REMOVE STABILIZER BAR FRONT (See page 26-22 ) REMOVE POWER STEERING LINK ASSY (See page 51-28 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2648 14-156 ENGINE MECHANICAL RH LH - PARTIAL ENGINE ASSY (3MZ-FE) 66. (a) REMOVE FRONT FRAME ASSY Remove the 2 nuts and disconnect the engine mounting insulator RH and LH. (b) Remove the nut and disconnect the engine mounting insulator FR. (c) Remove the 2 bolts and disconnect the engine mounting insulator RR. A78403 A80816 A80817 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. REMOVE FRONT DRIVE SHAFT ASSY LH (See page 30-21 ) REMOVE FRONT DRIVE SHAFT ASSY RH (2WD TYPE) (See page 30-21 ) REMOVE FRONT DRIVE SHAFT ASSY RH (4WD TYPE) (See page 30-21 ) REMOVE STARTER ASSY (See page 19-28 ) REMOVE ENGINE MOUNTING BRACKET FR REMOVE AUTOMATIC TRANSAXLE ASSY (2WD TYPE) (See page 40-20 ) REMOVE TRANSFER STIFFENER PLATE RH (4WD TYPE) REMOVE AUTOMATIC TRANSAXLE W/TRANSFER (4WD TYPE) (See page 40-20 ) REMOVE ENGINE MOUNTING BRACKET RR REMOVE DRIVE PLATE & RING GEAR SUB-ASSY (See page 14-246 ) INSTALL ENGINE STAND REMOVE ENGINE HANGER NO.2 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2649 14-157 ENGINE MECHANICAL (a) - PARTIAL ENGINE ASSY (3MZ-FE) 79. (a) (b) REMOVE EMISSION CONTROL VALVE SET Disconnect the 2 VSV connectors. Remove the wire harness clamp. (c) (d) (e) (f) (g) Disconnect the fuel vapor feed hose No. 1. Disconnect the fuel vapor feed hose No. 2. Disconnect the 2 vacuum hoses. Remove the clamp. Remove the 2 nuts and the emission control valve set. 80. (a) (b) (c) (d) REMOVE INTAKE AIR SURGE TANK Disconnect the throttle motor connector. Disconnect the water bypass hose No. 3. Disconnect the water bypass hose No. 2. Disconnect the union to check valve hose. (e) Disconnect the ventilation hose. (f) Remove the 3 nuts and disconnect the pressure feed tube. (b) (a) A79751 (d) (e) (e) (f) (c) A82428 (d) (a) (c) (b) A81623 (e) A79706 (f) A81678 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2650 14-158 ENGINE MECHANICAL (h) (g) - PARTIAL ENGINE ASSY (3MZ-FE) (g) (h) (i) Remove the 2 bolts and engine hanger No. 1. Remove the 2 bolts and surge tank stay No. 1. Remove the 2 bolts and surge tank stay No. 2. (j) (k) Using a socket hexagon wrench 8, remove the 4 bolts. Remove the 2 nuts, emission control valve bracket and intake air surge tank. Remove the gasket from the intake air surge tank. (i) A81674 (l) A82427 81. (a) INSPECT INTAKE AIR SURGE TANK Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.10 mm (0.0039 in.) If the warpage is greater than the maximum, replace the manifold. A85565 (b) (a) (b) 82. (a) (b) (b) (b) REMOVE INTAKE MANIFOLD Remove the nut and disconnect the ground cable. Disconnect the 6 fuel injector connectors. (b) (b) A81200 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2651 14-159 ENGINE MECHANICAL 10 4 3 11 7 PARTIAL ENGINE ASSY (3MZ-FE) (c) Uniformly loosen and remove the 9 bolts and 2 nuts in the sequence shown in the illustration. Remove the intake manifold. 83. (a) INSPECT INTAKE MANIFOLD Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head and intake air surge tank for warpage. Maximum warpage: 2 6 8 - 5 9 1 A81201 Cylinder Head Side Item Specified Condition Intake air surge tank side 0.15 mm (0.0059 in.) Cylinder head side 0.08 mm (0.0031 in.) If warpage is greater than the maximum, replace the manifold. Air Intake Chamber Side A85566 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2652 14-160 ENGINE MECHANICAL 84. (a) (b) (e) (b) (c) (d) (e) (c) (f) - PARTIAL ENGINE ASSY (3MZ-FE) REMOVE WATER OUTLET Disconnect the radiator hose inlet. Disconnect the engine coolant temperature sensor connector. Remove the clamp. Remove the 2 bolts, 2 nuts and 2 washers. Lock the hose clamp as shown in the illustration and remove the water outlet together with the water bypass hose No. 1. Remove the 2 gaskets from the 2 cylinder heads. A81203 85. REMOVE IGNITION COIL ASSY 86. (a) (b) REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY NO.2 Disconnect the A/F sensor connector. Remove the bolt, nut and insulator No. 3. (c) Remove the 2 bolts and insulator No. 2. A86565 A86566 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2653 14-161 ENGINE MECHANICAL 4 7 6 3 (d) 2 - PARTIAL ENGINE ASSY (3MZ-FE) (e) Uniformly loosen and remove the 7 nuts in the sequence shown in the illustration. Remove the converter and gasket. (f) Remove the 2 bolts and manifold stay. 5 1 A86567 A86568 87. INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSY NO.2 (a) Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.50 mm (0.0196 in.) If the warpage is greater than the maximum, replace the manifold. A90216 88. REMOVE ENGINE MOUNTING BRACKET RH 89. (a) REMOVE PUMP BRACKET Remove the 3 bolts and pump bracket. A05189 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2654 14-162 ENGINE MECHANICAL 90. 91. 92. 93. 94. - PARTIAL ENGINE ASSY (3MZ-FE) REMOVE REMOVE REMOVE REMOVE REMOVE GENERATOR BRACKET NO.1 COMPRESSOR MOUNTING BRACKET NO.1 WATER INLET PIPE (See page 16-31 ) WATER INLET (See page 16-31 ) THERMOSTAT (See page 16-31 ) 95. REMOVE ENGINE OIL PRESSURE SWITCH ASSY (a) Remove the oil pressure switch. Oil Pressure Switch A52637 96. (a) 97. REMOVE KNOCK SENSOR Remove the 2 nuts and 2 sensors. REPLACE PARTIAL ENGINE ASSY 98. (a) Upper 0 to 5 INSTALL KNOCK SENSOR Install the 2 knock sensors with the 2 nuts, as shown in the illustration. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) Engine Front A79750 99. (a) (b) 100. 101. 102. 103. 104. 105. 106. INSTALL ENGINE OIL PRESSURE SWITCH ASSY Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833-00080 THREE BOND 1344, LOCTITE 242 or equivalent Install the oil pressure switch. Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf) INSTALL THERMOSTAT (See page 16-31 ) INSTALL WATER INLET (See page 16-31 ) INSTALL WATER INLET PIPE (See page 16-31 ) INSTALL COMPRESSOR MOUNTING BRACKET NO.1 Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf) INSTALL GENERATOR BRACKET NO.1 Torque: 58 N⋅m (591 kgf⋅cm, 43 ft⋅lbf) INSTALL PUMP BRACKET Torque: 32 N⋅m (326 kgf⋅cm, 24 ft⋅lbf) INSTALL ENGINE MOUNTING BRACKET RH Torque: 54 N⋅m (551 kgf⋅cm, 40 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2655 14-163 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 107. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY NO.2 (a) Install the manifold stay with the 2 bolts, as shown in the illustration. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) A86568 1 4 (b) 6 (c) 2 5 Install a new gasket and the converter sub-assy No. 2 with the 7 nuts. Uniformly, tighten the 7 nuts in the sequence shown in the illustration. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) Retighten nuts 1 and 2 as shown in the illustration. 3 7 A86567 (d) Install the insulator No. 2 with the bolt and nut, as shown in the illustration. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) (e) Install the insulator No. 3 with the bolt and nut, as shown in the illustration. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) Connect the A/F sensor connector. A86566 (f) A86565 108. INSTALL IGNITION COIL ASSY Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2656 14-164 ENGINE MECHANICAL 109. (a) (b) (c) - PARTIAL ENGINE ASSY (3MZ-FE) INSTALL WATER OUTLET Install 2 new gaskets to the 2 cylinder heads. Install the water outlet together with the water bypass hose No. 1 and unlock the hose clamp. Tighten the 2 bolts, 2 nuts and 2 washers. Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf) Install the clamp. Connect the engine coolant temperature sensor connector. Connect the radiator hose inlet. (d) (e) (f) 110. INSTALL INTAKE MANIFOLD (a) Install the intake manifold with the 9 bolts, 2 nuts and 2 washers. Uniformly tighten the bolts and nuts in the sequence shown in the illustration. Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf) (b) Retighten the water outlet mounting bolts and nuts. Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf) (c) Install the ground cable with the nut. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) (d) Connect the heater inlet water hose. 2 8 10 6 4 9 1 7 11 3 5 A81201 111. INSTALL INTAKE AIR SURGE TANK (a) Install a new gasket to the intake air surge tank. (b) Install the intake air surge tank and emission control valve bracket with the 2 nuts. Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) (c) Using a socket hexagon wrench 8, tighten the 4 bolts. Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) A82427 (d) (e) (f) (e) (f) (d) Install the surge tank stay No. 2 with the 2 bolts. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) Install the surge tank stay No. 1 with the 2 bolts. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) Install the engine hanger No. 1 with the 2 bolts. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) A81674 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2657 14-165 ENGINE MECHANICAL (g) - PARTIAL ENGINE ASSY (3MZ-FE) (g) Install the pressure feed tube with the 3 nuts. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) (h) Connect the ventilation hose. (i) (j) (k) (l) Connect Connect Connect Connect A81678 (h) A79706 (i) the the the the union to the check valve hose. water bypass hose No. 2. water bypass hose No. 3. throttle motor connector. (l) (K) (j) A81623 (d) (c) (c) (a) (a) (a) (b) 112. INSTALL EMISSION CONTROL VALVE SET (a) Install the emission control valve set with the 2 nuts. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) (b) Install the clamp. (c) Connect the 2 vacuum hoses. (d) Connect the fuel vapor feed hose No. 2. (e) Connect the fuel vapor feed hose No. 1. (e) A82428 (f) (g) Install the wire harness clamp. Connect the 2 VSV connectors. (g) (g) (f) A79751 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2658 14-166 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 113. INSTALL ENGINE HANGER NO.2 Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) 114. REMOVE ENGINE STAND 115. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY (See page 14-246 ) 116. INSTALL ENGINE MOUNTING BRACKET RR 117. INSTALL AUTOMATIC TRANSAXLE W/TRANSFER (4WD TYPE) (See page 40-20 ) 118. INSTALL TRANSFER STIFFENER PLATE RH (4WD TYPE) 119. INSTALL AUTOMATIC TRANSAXLE ASSY (2WD TYPE) (See page 40-18 ) 120. INSTALL ENGINE MOUNTING BRACKET FR 121. INSTALL STARTER ASSY (See page 19-28 ) 122. INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30-21 ) 123. INSTALL FRONT DRIVE SHAFT ASSY RH (2WD TYPE) (See page 30-21 ) 124. INSTALL FRONT DRIVE SHAFT ASSY RH (4WD TYPE) (See page 30-21 ) 125. INSTALL FRONT FRAME ASSY (a) Install the engine mounting insulator RH and LH with the 2 nuts. Torque: 95 N⋅m (969 kgf⋅cm, 70 ft⋅lbf) A78403 (b) Install the engine mounting insulator FR with the nut. Torque: 87 N⋅m (887 kgf⋅cm, 64 ft⋅lbf) (c) Install the engine mounting insulator RR with the 2 bolts. Torque: 75 N⋅m (765 kgf⋅cm, 55 ft⋅lbf) A80816 A80817 126. INSTALL POWER STEERING LINK ASSY (See page 51-28 ) 127. INSTALL STABILIZER BAR FRONT (See page 26-22 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2659 14-167 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 128. INSTALL VANE PUMP ASSY (a) Install the vane pump with the 2 bolts. Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) HINT: After adjusting the V-ribbed belt, tighten bolt A. A A52337 1 4 129. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY (a) Install a new gasket and the exhaust manifold RH. Uniformly tighten the 6 nuts in the sequence shown in the illustration. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) (b) Retighten nuts 1 and 2 shown in the illustration. 6 5 3 2 A91369 (c) (d) Install the insulator with the 3 bolts, as shown in the illustration. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) Connect the A/F sensor connector. A91368 B B B C B C A A A80812 130. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (a) Set the engine assembly with transaxle on the engine lifter. (b) Install the engine assembly to the vehicle. (c) Install the frame side rail plate RH and LH with the 6 bolts and 2 nuts. Torque: 85 N⋅m (867 kgf⋅cm, 63 ft⋅lbf) for bolt A 32 N⋅m (326 kgf⋅cm, 24 ft⋅lbf) for bolt B and nut C (d) A A C B B C Install the front suspension member brace rear RH and LH with the 6 bolts and 2 nuts. Torque: 85 N⋅m (867 kgf⋅cm, 63 ft⋅lbf) for bolt A 32 N⋅m (326 kgf⋅cm, 24 ft⋅lbf) for bolt B and nut C B B A80813 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2660 14-168 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 131. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSY (a) Align the matchmarks on the intermediate shaft and the control valve shaft, and install the bolt. Torque: 35 N⋅m (357 kgf⋅cm, 26 ft⋅lbf) A60063 (b) Tighten the sliding yoke bolt. Torque: 35 N⋅m (357 kgf⋅cm, 26 ft⋅lbf) A60062 SST A36243 132. INSTALL DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT (a) Using SST, hold the crankshaft. SST 09213-54015 (91651-60855), 09330-00021 (b) Using kerosene or gasoline, clean the bolts thoroughly. (c) Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent (d) Install the 6 torque converter set bolts. Torque: 41 N⋅m (418 kgf⋅cm, 30 ft⋅lbf) NOTICE: First tighten the green colored bolt and then tighten the 5 bolts. (e) Install the flywheel housing under cover with the 2 bolts. Torque: 8.0 N⋅m (82 kgf⋅cm, 70 in.⋅lbf) A52328 133. INSTALL FRONT SUSPENSION ARM SUB- ASSY LOWER NO.1 LH (a) Install the drive shaft to the steering knuckle. (b) Install the suspension lower arm with the bolt and 2 nuts. Torque: 127 N⋅m (1,295 kgf⋅cm, 94 ft⋅lbf) C65935 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2661 14-169 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 134. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH HINT: Use the same procedures described for the LH side. 135. INSTALL TIE ROD END SUB-ASSY LH (a) Connect the tie rod end to the steering knuckle and install a new castle nut. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) NOTICE:
Prevent any lubricant from contacting the thread and the taper portions.
After tightening the castle nut, tighten it to the additional direction within 60 to put into a cotter pin. (b) Insert a new cotter pin. 136. INSTALL TIE ROD END SUB-ASSY RH HINT: Use the same procedures described for the LH side. 137. INSTALL SPEED SENSOR FRONT LH (See page 32-40 ) 138. INSTALL SPEED SENSOR FRONT RH (See page 32-40 ) 139. INSTALL FRONT AXLE HUB LH NUT (a) Using a 30 mm socket wrench, install a new hub nut. Torque: 294 N⋅m (2,998 kgf⋅cm, 217 ft⋅lbf) (b) Using a chisel and hammer, tap the front axle hub LH nut. C65982 140. INSTALL FRONT AXLE HUB RH NUT HINT: Use the same procedures described for the LH side. 141. INSTALL FRONT STABILIZER LINK ASSY LH (a) Using a 6 mm socket hexagon wrench, hold the ball stud and install the nut. Torque: 74 N⋅m (755 kgf⋅cm, 55 ft⋅lbf) 142. INSTALL FRONT STABILIZER LINK ASSY RH HINT: Use the same procedures described for the LH side. 143. INSTALL EXHAUST PIPE SUPPORT BRACKET NO.1 (See page 15-5 ) 144. CONNECT EXHAUST PIPE ASSY FRONT (See page 15-5 ) 145. CONNECT EXHAUST PIPE SUB-ASSY FRONT NO.3 (See page 15-5 ) 146. INSTALL PROPELLER SHAFT (4WD TYPE) (See page 30-12 ) 147. CONNECT ENGINE WIRE 148. INSTALL GLOVE COMPARTMENT DOOR ASSY 149. CONNECT STEERING GEAR OUTLET RETURN TUBE 150. CONNECT OIL RESERVOIR TO PUMP HOSE NO.1 151. CONNECT OIL COOLER OUTLET TUBE NO.1 152. CONNECT OIL COOLER INLET TUBE NO.1 153. CONNECT RADIATOR HOSE OUTLET 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2662 14-170 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 154. CONNECT RADIATOR HOSE INLET 155. CONNECT HEATER OUTLET WATER HOSE 156. CONNECT HEATER INLET WATER HOSE 157. CONNECT FUEL PIPE SUB-ASSY NO.1 (a) Push in the fuel tube connector to the fuel pipe until connector makes a ”click” sound. NOTICE:
Check for damage or contamination on the connected part of the pipe.
After having finished the connection, check if the pipe and the connector are securely connected by trying to pull them apart. B12944 (b) Install the fuel pipe clamp. 158. CONNECT UNION TO CHECK VALVE HOSE 159. INSTALL TRANSMISSION CONTROL CABLE ASSY (See page 40-20 ) 160. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (a) Install the compressor with the 3 bolts. Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf) (b) Install the adjusting bar bracket with the bolt and nut. Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf) for bolt 26 N⋅m (265 kgf⋅cm, 19 ft⋅lbf) for nut Adjusting Bar Bracket A52901 161. INSTALL ENGINE MOUNTING STAY NO.2 RH (a) Install the mounting stay and mounting bracket with the bolt. Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) A52344 B A A 162. INSTALL ENGINE MOVING CONTROL ROD (a) Install the control rod and bracket with the 4 bolts. Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) for bolt A 23 N⋅m (235 kgf⋅cm, 17 ft⋅lbf) for bolt B A A90268 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2663 14-171 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 163. INSTALL GENERATOR BELT ADJUSTING BAR (a) Install the adjusting bar with the 2 bolts and 2 nuts. Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) for nut A 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) for bolt B 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) for bolt C A C B A52342 164. INSTALL GENERATOR BRACKET NO.2 Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) 165. INSTALL GENERATOR ASSY (See page 19-40 ) 166. INSTALL VANE PUMP V BELT (See page 14-125 ) 167. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14-125 ) 168. INSPECT DRIVE BELT TENSION (See page 14-121 ) 169. INSTALL AIR CLEANER CASE 170. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSY 171. INSTALL AIR CLEANER CAP SUB-ASSY 172. CONNECT VACUUM HOSES Vacuum Hose Routing Diagram From Canister Actuator Vacuum Surge Tank VSV for EVAP Vacuum Tank VSV for IAC Valve No. 2 Engine Mounting Insulator FR Cap VSV for Control Engine Mount (ACM) A91373 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2664 14-172 ENGINE MECHANICAL - PARTIAL ENGINE ASSY (3MZ-FE) 173. INSTALL BATTERY 174. INSTALL V-BANK COVER SUB-ASSY (a) Fit the 2 retainers and install the V-bank cover. (b) Using a socket hexagon wrench 5, tighten the 3 nuts. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) A81195 175. INSTALL FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER Torque: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf) 176. INSTALL COWL PANEL SUB-ASSY 177. INSTALL WINDSHIELD WIPER LINK ASSY (See page 66-7 ) 178. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSY (See page 66-7 ) 179. INSTALL FR WIPER ARM LH (See page 66-7 ) 180. INSTALL FR WIPER ARM RH (See page 66-7 ) 181. INSTALL FRONT WHEELS 182. ADD TRANSFER OIL (4WD TYPE) 183. INSPECT TRANSFER OIL (4WD TYPE) 184. ADD AUTOMATIC TRANSAXLE FLUID 185. ADD ENGINE OIL 186. ADD ENGINE COOLANT (See page 16-26 ) 187. ADD POWER STEERING FLUID 188. BLEED POWER STEERING FLUID (See page 51-3 ) 189. INSPECT AUTOMATIC TRANSAXLE FLUID 190. CHECK FOR ENGINE OIL LEAKS 191. CHECK FOR ENGINE COOLANT LEAKS (See page 16-20 ) 192. CHECK POWER STEERING FLUID LEAKAGE 193. INSPECT FOR FUEL LEAKS 194. CHECK FOR EXHAUST GAS LEAKS 195. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26-7 ) 196. INSPECT IGNITION TIMING (See page 14-121 ) 197. INSPECT ENGINE IDLE SPEED (See page 14-121 ) 198. INSPECT CO/HC (See page 14-121 ) 199. CHECK ABS SPEED SENSOR SIGNAL (See page 05-765 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2665 14-206 ENGINE MECHANICAL - TIMING BELT (3MZ-FE) TIMING BELT (3MZ-FE) 141PL-01 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. REMOVE FRONT WHEEL RH REMOVE FR WIPER ARM LH (See page 66-7 ) REMOVE FR WIPER ARM RH (See page 66-7 ) REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See page 66-7 ) REMOVE WINDSHIELD WIPER LINK ASSY (See page 66-7 ) REMOVE COWL PANEL SUB-ASSY REMOVE ENGINE UNDER COVER NO.1 REMOVE FRONT FENDER APRON SEAL RH REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14-125 ) REMOVE VANE PUMP V BELT (See page 14-125 ) REMOVE ENGINE MOVING CONTROL ROD (See page 14-149 ) REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-149 ) REMOVE GENERATOR BRACKET NO.2 14. (a) REMOVE CRANKSHAFT PULLEY Using SST, loosen the pulley bolt. SST 09213-54015 (91651-60855), 09330-00021 SST A52823 SST (b) Using SST and the pulley bolt, remove the pulley. SST 09950- 50013 (09951- 05010, 09952- 05010, 09953-05020, 09954-05031) NOTICE: Before using SST, apply lubricating oil to the threads and tip of the center bolt 100. A52839 15. REMOVE TIMING BELT NO.1 COVER 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2699 14-207 ENGINE MECHANICAL 16. (a) Clamp Clamp (b) - TIMING BELT (3MZ-FE) REMOVE TIMING BELT NO.2 COVER Disconnect the engine wire protector clamps from the timing belt No. 3 cover. Remove the 5 bolts and timing belt cover. A05050 17. 18. REMOVE ENGINE MOUNTING BRACKET RH REMOVE TIMING BELT GUIDE NO.2 19. (a) REMOVE TIMING BELT Set the No. 1 cylinder to TDC/compression. (1) Temporarily install the crankshaft pulley bolt with the washer to the crankshaft. (2) Turn the crankshaft clockwise, and align the timing marks of the crankshaft timing pulley and oil pump body. A05051 (3) (4) Check that the timing marks of the camshaft timing pulleys and No. 3 timing belt cover are aligned. If not, turn the crankshaft 1 revolution (360). Remove the crankshaft pulley bolt. A05052 (b) If planning to reuse the timing belt, check that there are 4 installation marks on the timing belt, as shown in the illustration. (1) If the installation marks have disappeared, put new installation marks on the timing belt before removing. A52840 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2700 14-208 ENGINE MECHANICAL - TIMING BELT (3MZ-FE) (c) Approx. 60 Turn A78327 Set the No. 1 cylinder to approximately 60 BTDC/compression. (1) Turn the crankshaft counterclockwise by approximately 60. NOTICE: With the timing belt removed: The crankshaft pulley must be at the correct angle to avoid damage in later steps. If the crankshaft pulley is at the wrong angle and then the camshaft timing pulley and the camshaft are removed, the piston head and valve head may come in contact and be damaged. (d) Remove the timing belt tensioner. NOTICE: Do not reinstall the tensioner with its plunger extended. (e) (3) (5) (2) (4) (1) Remove the timing belt in this order. 1st No. 1 idler pulley 2nd RH camshaft timing pulley 3rd No. 2 idler pulley 4th LH camshaft timing pulley 5th Water pump pulley 6th Crankshaft timing pulley (6) A78702 EM3336 20. INSPECT TIMING BELT NOTICE:
Do not bend, twist or turn the timing belt inside out.
Do not allow the timing belt to come into contact with oil, water or steam.
Do not utilize timing belt tension when instaling the mounting bolt of the camshaft timing pulley. Check the belt for any defects, as shown in the installation. Also, check these points below. (a) If there is premature parting:
Check for proper installation.
Check the timing cover gasket for no damage and proper installation. (b) If the belt teeth are cracked or damaged, check to see if either camshaft is locked. (c) If there is noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler pulley lock and water pump. (d) If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2701 14-209 ENGINE MECHANICAL - TIMING BELT (3MZ-FE) (e) If there is noticeable wear on the belt teeth:
Check the timing cover for damage.
Check that the gasket has been installed correctly.
Check for foreign object on the pulley teeth. If there is any doubt about the belt condition, replace the timing belt. 21. INSTALL TIMING BELT (a) Remove any oil or water on the pulleys, and keep them clean. NOTICE:
If there is a trace of water and/or oil on the timing belt, repair the leakage and install a new timing belt.
Do not use cleaning agents on the pulleys when cleaning them. (b) Inspect the idler pulleys. (1) Check that the idler pulleys turn smoothly. (2) Visually check the sealed portion of the idler pulleys for oil leakage. If there is any doubt about the idler pulleys condition, replace the idler pulleys. (c) Inspect the water pump. (1) Turn the pulley, and check that the water pump bearing moves smoothly without any noise. (2) Visually check the drain hole for coolant leakage. If there is any doubt about the water pump condition, replace the water pump. (d) Temporarily install the crankshaft pulley bolt and washer to the crankshaft. (e) Turn the crankshaft counterclockwise by approximately 60. NOTICE: To prevent the piston head and the valve head from colliding, set the crankshaft pulley at approximately 60 BTDC/ compression position. Approx. 60 Turn A82349 (f) Using SST, turn the timing pulleys, and align the timing marks of the timing pulleys with the No. 3 timing belt cover. SST 09960-10010 (09962-01000, 09963-01000) SST A78751 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2702 14-210 ENGINE MECHANICAL - TIMING BELT (3MZ-FE) (g) Turn the crankshaft, and align the timing mark of the crankshaft timing pulley with the oil pump body. (h) (i) Face the front mark on the timing belt forward. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys. A05062 (j) A52840 (k) (4) (2) (5) (3) (6) Install the timing belt in this order. 1st Crankshaft timing pulley 2nd Water pump pulley 3rd LH camshaft timing pulley 4th No. 2 idler pulley 5th RH camshaft timing pulley 6th No. 1 idler pulley (1) A78702 A36238 22. INSTALL TIMING BELT TENSIONER ASSY (a) Set the timing belt tensioner uprightly on the press. (b) Slowly press in the push rod. NOTICE: Do not apply pressure of more than 9.8 kN (1,000 kgf, 2,205 lbf) to the rod. (c) Align the holes of the push rod and housing, pass a 1.5 mm hexagon wrench through the holes to keep the setting position of the push rod. (d) Release the push rod. (e) Temporarily install the tensioner with the 2 bolts. Torque: 27 N⋅m (275 kgf⋅cm, 20 ft⋅lbf) NOTICE: Install the tensioner’s bolts uniformly and evenly. Installing the tensioner at an angle may cause it to malfunction. (f) Remove the 1.5 mm hexagon wrench from the tensioner. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2703 14-21 1 ENGINE MECHANICAL - TIMING BELT (3MZ-FE) (g) Turn the crankshaft 2 revolutions slowly and align the timing mark of the crankshaft timing pulley with the oil pump body. NOTICE: Always turn the crankshaft clockwise. Turn A78326 (h) Check that the timing marks of the RH and LH timing pulleys are aligned with the timing marks of the No. 3 timing belt cover, as shown in the illustration. If the marks do not align, remove the timing belt and reinstall it. (i) Remove the crankshaft pulley bolt. A05052 23. (a) INSTALL TIMING BELT GUIDE NO.2 Install the timing belt guide, facing the cup side toward the engine front. A36239 24. INSTALL ENGINE MOUNTING BRACKET RH Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) INSTALL TIMING BELT NO.2 COVER Visually check for cracks and breaks on the gasket of the timing belt cover. 25. (a) HINT: If it is judged that water is entering at the visual check, replace the timing belt cover. (b) Install the timing belt cover. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) 26. INSTALL TIMING BELT NO.1 COVER (a) Visually check for cracks and breaks on the gasket of the timing belt cover. HINT: If there is a trace that water is entering at the visual check, replace the timing belt cover. (b) Install the timing belt cover. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) (c) Install the engine wire protector cover to the timing belt No. 3 cover. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2704 14-212 ENGINE MECHANICAL 27. (a) (b) - TIMING BELT (3MZ-FE) INSTALL CRANKSHAFT PULLEY Align the pulley set key with the key groove of the pulley, and slide on the pulley. Using SST, install the pulley bolt. SST 09213-54015 (91651-60855), 09330-00021 Torque: 220 N⋅m (2,243 kgf⋅cm, 162 ft⋅lbf) SST A52823 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. INSTALL GENERATOR BRACKET NO.2 Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-149 ) INSTALL ENGINE MOVING CONTROL ROD (See page 14-149 ) INSTALL VANE PUMP V BELT (See page 14-125 ) INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14-125 ) INSPECT DRIVE BELT TENSION (See page 14-121 ) INSTALL FRONT FENDER APRON SEAL RH INSTALL ENGINE UNDER COVER NO.1 INSTALL COWL PANEL SUB-ASSY INSTALL WINDSHIELD WIPER LINK ASSY(See page 66-7 ) INSTALL FR WIPER ARM LH (See page 66-7 ) INSTALL FR WIPER ARM RH (See page 66-7 ) INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSY (See page 66-7 ) INSTALL FRONT WHEEL RH 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2705 14-213 ENGINE MECHANICAL - CAMSHAFT (RH BANK) (3MZ-FE) CAMSHAFT (RH BANK) (3MZ-FE) 141PM-01 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. DRAIN ENGINE COOLANT (See page 16-26 ) REMOVE FR WIPER ARM LH (See page 66-7 ) REMOVE FR WIPER ARM RH (See page 66-7 ) REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See page 66-7 ) REMOVE WINDSHIELD WIPER LINK ASSY (See page 66-7 ) REMOVE COWL PANEL SUB-ASSY REMOVE FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER REMOVE V-BANK COVER SUB-ASSY (See page 14-149 ) REMOVE AIR CLEANER CAP SUB-ASSY REMOVE EMISSION CONTROL VALVE SET (See page 14-149 ) REMOVE INTAKE AIR SURGE TANK (See page 14-149 ) REMOVE IGNITION COIL ASSY REMOVE CYLINDER HEAD COVER SUB-ASSY (See page 14-173 ) REMOVE FRONT WHEEL RH REMOVE ENGINE UNDER COVER NO.1 REMOVE FRONT FENDER APRON SEAL RH REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14-125 ) REMOVE VANE PUMP V BELT (See page 14-125 ) REMOVE ENGINE MOVING CONTROL ROD (See page 14-149 ) REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-149 ) REMOVE GENERATOR BRACKET NO.2 REMOVE CRANKSHAFT PULLEY (See page 14-173 ) REMOVE TIMING BELT NO.1 COVER REMOVE TIMING BELT NO.2 COVER (See page 14-206 ) REMOVE ENGINE MOUNTING BRACKET RH REMOVE TIMING BELT GUIDE NO.2 REMOVE TIMING BELT (See page 14-206 ) REMOVE TIMING BELT IDLER SUB-ASSY NO.2 29. (a) RH REMOVE CAMSHAFT TIMING PULLEY Using SST, remove the bolt and RH timing pulley. SST 09960- 10010 (09962- 01000, 09963- 01000), 09249-63010 SST A90211 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2706 14-214 ENGINE MECHANICAL (b) LH - CAMSHAFT (RH BANK) (3MZ-FE) Using SST, remove the bolt and LH timing pulley. SST 09960-10010 (09962-01000, 09963-01000) HINT: Arrange the camshaft timing pulleys (RH and LH sides) so that they can be returned to their original locations when reassembled. SST A90212 30. (a) Clamp Clamp (b) REMOVE TIMING BELT NO.3 COVER Disconnect the 3 engine wire harness clamps from the timing belt No. 3 cover. Remove the 6 bolts and the timing belt cover. Clamp A05077 31. REMOVE CAMSHAFT NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps must be carried out. (a) Align the camshaft drive and driven gear’s timing marks (2 dot marks each) by turning the camshaft with a wrench. Align A78706 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2707 14-215 ENGINE MECHANICAL (b) Main Gear Sub Gear 10 6 CAMSHAFT (RH BANK) (3MZ-FE) Secure the exhaust camshaft sub gear to the main gear with a service bolt. Recommended service bolt: Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16 to 20 mm Service Bolt A78707 - Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) HINT: When removing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt. (c) 2 8 1 5 4 9 7 3 Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps and the camshaft. NOTICE:
Do not pry out the camshaft.
Be careful not to damage the portion of the cylinder head receiving the shaft thrust. A78708 5 32. (a) 1 9 7 2 6 3 10 8 4 A78709 REMOVE NO.2 CAMSHAFT Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps and the No. 2 camshaft. NOTICE:
Do not pry out the camshaft.
Be careful not to damage the portion of the cylinder head receiving the shaft thrust. (b) Remove the oil seal from the No. 2 camshaft. 33. REMOVE CAMSHAFT TIMING GEAR ASSY NOTICE: Do not remove or install the camshaft timing gear (VVT-i) unless you are replacing the VVT-i or the camshaft. (a) Clamp the camshaft in a vise on the hexagonal lobe. NOTICE: Do not damage the camshaft. A05739 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2708 14-216 ENGINE MECHANICAL - CAMSHAFT (RH BANK) (3MZ-FE) (b) A05740 Using a 46 mm socket wrench, remove the lock nut by turning it clockwise. NOTICE:
Remove the lock nut with the lock-pin engaged and locked at the extreme retarded angle position.
The lock nut has LH threads.
Only use the socket wrench. Other tools will deform the cam angle rotor. (c) Remove the timing gear (VVT-i). NOTICE: Never remove the 3 bolts on the gear. If it is difficult to remove the VVT-i, tap it lightly using a plasticfaced hammer and then remove it. 34. REMOVE CAMSHAFT SUB GEAR (a) Clamp the camshaft in a vise on the hexagonal lobe. NOTICE: Do not damage the camshaft. P12596 (b) Using SST, turn the sub gear counterclockwise, and remove the service bolt. SST 09960-10010 (09962-01000, 09963-00500) (c) (d) Using snap ring pliers, remove the snap ring. Remove the wave washer, camshaft sub gear and camshaft gear spring. SST P12797 Snap Ring Pliers A52353 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2709 14-217 ENGINE MECHANICAL - CAMSHAFT (RH BANK) (3MZ-FE) 35. INSTALL CAMSHAFT SUB GEAR (a) Clamp the camshaft in a vise on the hexagonal lobe. NOTICE: Do not damage the camshaft. P12595 (b) Wave Washer Camshaft Sub Gear Install the camshaft gear bolt washer and the camshaft sub gear. HINT: Attach the pins on the gears to the gear spring ends. (c) Install the wave washer. Camshaft Gear Bolt Washer A78732 (d) Using snap ring pliers, install the snap ring. Snap Ring Pliers A52353 (e) SST Main Gear Sub Gear P12974 Using SST, align the holes of the camshaft main gear and sub gear by turning the camshaft sub gear counterclockwise, and temporarily install a service bolt. SST 09960-10010 (09962-01000, 09963-00500) (f) Align the gear teeth of the main gear and sub gear, and tighten the service bolt. Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) NOTICE: Do not damage the camshaft journals. HINT: When installing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2710 14-218 ENGINE MECHANICAL - CAMSHAFT (RH BANK) (3MZ-FE) 36. (a) Align A78734 INSTALL CAMSHAFT TIMING GEAR ASSY Align the alignment pin with the alignment pin groove and install the VVT-i on the camshaft. NOTICE: Install the VVT-i with the lock-pin engaged and locked at the most retarded angle position. (b) Apply engine oil to the nut, the mounting surface of the VVT-i and the screw threads. NOTICE:
Be sure to apply the oil, otherwise the specified torque cannot be obtained.
A new nut must be used when replacing the VVT-i unit. (c) Using a 46 mm socket wrench, install and tighten the lock nut by turning it counterclockwise. Torque: 150 N⋅m (1,530 kgf⋅cm, 111 ft⋅lbf) NOTICE:
The lock nut has LH threads.
Only use the socket wrench. Other tools will deform the cam angle rotor. A05738 37. INSTALL NO.2 CAMSHAFT NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being installed. If the camshaft is not level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps must be carried out. (a) Apply new engine oil to the thrust portion and journal of the camshaft. (b) Place the No. 2 camshaft at a 90 angle of the timing mark (2 dot marks) on the cylinder head. (c) Apply MP grease to a new oil seal lip. 90 A05201 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2711 14-219 ENGINE MECHANICAL - CAMSHAFT (RH BANK) (3MZ-FE) (d) Install the oil seal to the camshaft. NOTICE:
Do not turn over the oil seal lip.
Insert the oil seal until it stops. Front A52366 (e) Seal Packing A52367 Remove any old packing material from the contact surface. (f) Apply seal packing to the No. 1 bearing cap, as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTICE:
Install the No. 1 bearing cap within 5 minutes after applying seal packing.
Do not expose the seal to engine oil for at least 2 hours after installing. (g) Install the 5 bearing caps in their proper locations. (h) Apply a light coat of engine oil on the threads of the bearing cap bolts. A05283 6 (i) 10 2 4 Uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf) 9 8 5 1 3 7 A78738 38. INSTALL CAMSHAFT NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being installed. If the camshaft is not level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps must be carried out. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2712 14-220 ENGINE MECHANICAL (a) (b) (c) - CAMSHAFT (RH BANK) (3MZ-FE) Apply new engine oil to the thrust portion and journal of the camshaft. Align the camshaft drive and driven gear’s timing marks (2 dot marks each). Place the camshaft on the cylinder head. Align A59546 (d) (e) Install the 5 bearing caps in their proper locations. Apply a light coat of engine oil to the threads of the bearing cap bolts. (f) Uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf) Remove the service bolt. A59547 5 9 1 3 10 6 7 (g) 2 4 8 A78740 39. (a) INSTALL TIMING BELT NO.3 COVER Visually check for cracks and breaks in the gasket of the timing belt cover. HINT: If water is entering through cracks or breaks in the gasket, repair according to these guidelines: 1) if the crack length is within 2 to 3 cm (0.79 to 1.18 in.), repair with seal packing; or 2) if the crack length is over 3 cm (1.18 in.), replace the gasket. Seal Packing (b) When repairing the timing belt cover gasket, follow the procedure below. (1) Repair the cracks and breaks by applying the seal packing to the damaged area. Seal packing: Part No. 08826-00080 or equivalent NOTICE: When applying the seal packing, apply it as wide and high as the gasket. Gasket A52838 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2713 14-221 ENGINE MECHANICAL - CAMSHAFT (RH BANK) (3MZ-FE) (c) If the timing belt cover gasket needs to be replaced, follow the procedure below. (1) Using a screwdriver and gasket scraper, remove the remaining gasket. NOTICE: Be careful not to damage the timing belt cover. (2) E F D Joining Line Joining Portion Gasket E Joining G Line Remove the backing paper from a new gasket, and affix the gasket along the groove of the timing belt cover, as shown in the illustration. NOTICE:
Affix the gasket in the center of the groove.
At the corners, try to keep the gasket thickness uniform. Length: Gasket D E F G Specified Condition 335 mm (13.19 in.) 180 mm (7.09 in.) 133 mm (5.24 in.) 72 mm (2.83 in.) (3) Seal Packing A78749 Front If there is a gap on the joint of the gasket, apply seal packing to close the gap. Seal packing: Part No. 08826-00080 or equivalent NOTICE: When applying the seal packing, apply it as wide and high as the gasket. (d) Install the timing belt cover with the 6 bolts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) 40. (a) Front INSTALL CAMSHAFT TIMING PULLEY Install the camshaft timing pulley with the belt guide properly oriented and tighten the bolt temporarily. HINT:

Face the belt guide of the RH timing pulley towards the front of the engine. Face the belt guide of the LH timing pulley towards the rear of the engine. A52833 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2714 14-222 ENGINE MECHANICAL - CAMSHAFT (RH BANK) (3MZ-FE) (b) RH SST 150 mm A78763 Using SST, tighten the RH pulley bolt. SST 09960- 10010 (09962- 01000, 09963- 01000), 09249-63010 Torque: 125 N⋅m (1,275 kgf⋅cm, 92 ft⋅lbf) NOTICE: The torque specification above is for the SST without extension tool specification. Use the special formula to calculate the SST with extension tool torque specification (see page 01-5 ). Extended length of SST (09249-63010): 150 mm (5.91 in.) (c) LH Using SST, tighten the LH pulley bolt. SST 09960-10010 (09962-01000, 09963-01000) Torque: 125 N⋅m (1,275 kgf⋅cm, 92 ft⋅lbf) SST A78762 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. INSTALL TIMING BELT IDLER SUB-ASSY NO.2 Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) INSPECT TIMING BELT (See page 14-206 ) INSTALL TIMING BELT (See page 14-206 ) INSTALL TIMING BELT TENSIONER ASSY (See page 14-206 ) INSTALL TIMING BELT GUIDE NO.2 (See page 14-206 ) INSTALL ENGINE MOUNTING BRACKET RH Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) INSTALL TIMING BELT NO.2 COVER (See page 14-206 ) INSTALL TIMING BELT NO.1 COVER (See page 14-206 ) INSTALL CRANKSHAFT PULLEY (See page 14-173 ) INSTALL GENERATOR BRACKET NO.2 Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-149 ) INSTALL ENGINE MOVING CONTROL ROD (See page 14-149 ) INSPECT VALVE CLEARANCE (See page 14-127 ) ADJUST VALVE CLEARANCE (See page 14-127 ) INSTALL VANE PUMP V BELT (See page 14-125 ) INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14-125 ) INSPECT DRIVE BELT TENSION (See page 14-121 ) INSTALL CYLINDER HEAD COVER SUB-ASSY (See page 14-173 ) INSTALL IGNITION COIL ASSY Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) INSTALL INTAKE AIR SURGE TANK (See page 14-149 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2715 14-223 ENGINE MECHANICAL 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. - CAMSHAFT (RH BANK) (3MZ-FE) INSTALL EMISSION CONTROL VALVE SET (See page 14-149 ) INSTALL AIR CLEANER CAP SUB-ASSY CONNECT VACUUM HOSES (See page 14-149 ) INSTALL V-BANK COVER SUB-ASSY (See page 14-149 ) INSTALL FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER Torque: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf) INSTALL COWL PANEL SUB-ASSY INSTALL WINDSHIELD WIPER LINK ASSY (See page 66-7 ) INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSY (See page 66-7 ) INSTALL FR WIPER ARM LH (See page 66-7 ) INSTALL FR WIPER ARM RH (See page 66-7 ) INSTALL FRONT WHEEL RH ADD ENGINE COOLANT (See page 16-26 ) CHECK FOR ENGINE COOLANT LEAKS (See page 16-20 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2716 14-224 ENGINE MECHANICAL - CAMSHAFT (LH BANK) (3MZ-FE) CAMSHAFT (LH BANK) (3MZ-FE) 141PN-01 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. DRAIN ENGINE COOLANT (See page 16-26 ) REMOVE FR WIPER ARM LH (See page 66-7 ) REMOVE FR WIPER ARM RH (See page 66-7 ) REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See page 66-7 ) REMOVE WINDSHIELD WIPER LINK ASSY (See page 66-7 ) REMOVE COWL PANEL SUB-ASSY REMOVE FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER REMOVE V-BANK COVER SUB-ASSY (See page 14-149 ) REMOVE RADIATOR HOSE INLET REMOVE IGNITION COIL ASSY REMOVE CYLINDER HEAD COVER SUB-ASSY LH (See page 14-173 ) REMOVE FRONT WHEEL RH REMOVE ENGINE UNDER COVER NO.1 REMOVE FRONT FENDER APRON SEAL RH REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14-125 ) REMOVE VANE PUMP V BELT (See page 14-125 ) REMOVE ENGINE MOVING CONTROL ROD (See page 14-149 ) REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-149 ) REMOVE GENERATOR BRACKET NO.2 REMOVE CRANKSHAFT PULLEY (See page 14-173 ) REMOVE TIMING BELT NO.1 COVER REMOVE TIMING BELT NO.2 COVER (See page 14-206 ) REMOVE ENGINE MOUNTING BRACKET RH REMOVE TIMING BELT GUIDE NO.2 REMOVE TIMING BELT (See page 14-206 ) REMOVE TIMING BELT IDLER SUB-ASSY NO.2 27. (a) RH REMOVE CAMSHAFT TIMING PULLEY Using SST, remove the bolt and RH timing pulley. SST 09960- 10010 (09962- 01000, 09963- 01000), 09249-63010 SST A90211 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2717 14-225 ENGINE MECHANICAL (b) LH - CAMSHAFT (LH BANK) (3MZ-FE) Using SST, remove the bolt and LH timing pulley. SST 09960-10010 (09962-01000, 09963-01000) HINT: Arrange the camshaft timing pulleys (RH and LH sides) so that they can be returned to their original locations when reassembled. SST A90212 28. (a) Clamp Clamp (b) REMOVE TIMING BELT NO.3 COVER Disconnect the 3 engine wire harness clamps from the timing belt No. 3 cover. Remove the 6 bolts and the timing belt cover. Clamp A05077 29. REMOVE NO.3 CAMSHAFT SUB-ASSY NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps must be carried out. (a) Align Align the camshaft drive and driven gear’s timing marks (1 dot mark each) by turning the camshaft with a wrench. A78710 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2718 14-226 ENGINE MECHANICAL (b) Service Bolt - CAMSHAFT (LH BANK) (3MZ-FE) Secure the exhaust camshaft sub gear to the main gear with a service bolt. Recommended service bolt: Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16 to 20 mm Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) Main Gear Sub Gear A78711 (c) 1 5 2 9 6 7 10 8 3 HINT: When removing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt. 4 Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps and the No. 3 camshaft. NOTICE:
Do not pry out the camshaft.
Be careful not to damage the portion of the cylinder head receiving the shaft thrust. A78712 6 30. (a) 2 10 1 8 5 9 4 7 3 A78713 REMOVE NO.4 CAMSHAFT SUB-ASSY Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Remove the 5 bearing caps and the No. 4 camshaft. NOTICE:
Do not pry out the camshaft.
Be careful not to damage the portion of the cylinder head receiving the shaft thrust. (b) Remove the oil seal from the No. 4 camshaft. 31. REMOVE CAMSHAFT TIMING GEAR ASSY NOTICE: Do not remove or install the timing gear (VVT-i) unless you are replacing the VVT-i or the camshaft. (a) Clamp the camshaft in a vise on the hexagonal lobe. NOTICE: Do not damage the camshaft. A05739 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2719 14-227 ENGINE MECHANICAL - CAMSHAFT (LH BANK) (3MZ-FE) (b) A05740 Using a 46 mm socket wrench, remove the lock nut by turning it clockwise. NOTICE:
Remove it with the lock-pin engaged and locked at the extreme retarded angle position.
The lock nut has LH threads.
Only use the socket wrench. Other tools will deform the cam angle rotor. (c) Remove the timing gear (VVT-i). NOTICE: Never remove the 3 bolts on the gear. If it is difficult to remove the VVT-i, tap it lightly using a plasticfaced hammer and then remove it. 32. REMOVE CAMSHAFT SUB GEAR NO.3 (a) Clamp the camshaft in a vise on the hexagonal lobe. NOTICE: Be careful not to damage the camshaft. P12596 (b) Using SST, turn the sub gear counterclockwise, and remove the service bolt. SST 09960-10010 (09962-01000, 09963-00500) (c) (d) Using snap ring pliers, remove the snap ring. Remove the wave washer, camshaft sub gear and camshaft gear bolt washer. SST A78715 Snap Ring Pliers HINT: Arrange the camshaft sub gears and gear bolt washers (RH and LH sides) so that they can be returned to their original location when reassembled. A52353 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2720 14-228 ENGINE MECHANICAL - CAMSHAFT (LH BANK) (3MZ-FE) 33. INSTALL CAMSHAFT SUB GEAR NO.3 (a) Clamp the camshaft in a vise on the hexagonal lobe. NOTICE: Be careful not to damage the camshaft. P12595 (b) Wave Washer Camshaft Sub Gear Install the camshaft gear bolt washer and the camshaft sub gear. HINT: Attach the pins on the gears to the gear bolt washer ends. (c) Install the wave washer. Camshaft Gear Bolt Washer A78732 (d) Using snap ring pliers, install the snap ring. Snap Ring Pliers A52353 (e) SST Main Gear Sub Gear A78733 Using SST, align the holes of the camshaft main gear and sub gear by turning the camshaft sub gear counterclockwise, and temporarily install a service bolt. SST 09960-10010 (09962-01000, 09963-00500) (f) Align the gear teeth of the main gear and sub gear, and tighten the service bolt. Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) NOTICE: Be careful not to damage the camshaft journals. HINT: When installing the camshaft, make certain that the torsional spring force of the sub gear has been eliminated by installation of the service bolt. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2721 14-229 ENGINE MECHANICAL - CAMSHAFT (LH BANK) (3MZ-FE) 34. (a) Align A78734 INSTALL CAMSHAFT TIMING GEAR ASSY Align the alignment pin with the alignment pin groove and install the VVT-i on the camshaft. NOTICE: Install the VVT-i with the lock-pin engaged and locked at the extreme retarded angle position. (b) Apply engine oil on the nut, the mounting surface of the VVT-i and the screw threads. NOTICE:
Be sure to apply the oil, otherwise the specified torque cannot be obtained.
New nuts must be used when replacing the VVT-i unit. (c) Using a 46 mm socket wrench, install and tighten a lock nut by turning it counterclockwise. Torque: 150 N⋅m (1,530 kgf⋅cm, 111 ft⋅lbf) NOTICE:
The lock nut has LH threads.
Never use any tools other than the socket wrench. Other tools will deform the cam angle rotor. A05738 35. INSTALL NO.4 CAMSHAFT SUB-ASSY NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps must be carried out. (a) (b) 90 (c) Apply new engine oil to the thrust portion and journal of the camshaft. Place the No. 4 camshaft at a 90 angle of the timing mark (1 dot mark) on the cylinder head. Apply MP grease to a new oil seal lip. A78741 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2722 14-230 ENGINE MECHANICAL - CAMSHAFT (LH BANK) (3MZ-FE) (d) Install the oil seal to the camshaft. NOTICE:
Do not turn over the oil seal lip.
Insert the oil seal until it stops. Front A78742 (e) Seal Packing A78737 Remove any old packing material from the contact surface. (f) Apply seal packing to the No. 1 bearing cap, as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent NOTICE:
Install the No. 1 bearing cap within 5 minutes after applying seal packing.
Do not expose the seal to engine oil for at least 2 hours after installing. (g) Install the 5 bearing caps in their proper locations. (h) Apply a light coat of engine oil to the threads of the bearing cap bolts. A05209 (i) 9 5 1 Uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf) 10 3 6 7 2 4 8 A78743 36. INSTALL NO.3 CAMSHAFT SUB-ASSY NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps must be carried out. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2723 14-231 ENGINE MECHANICAL (a) (b) (c) - CAMSHAFT (LH BANK) (3MZ-FE) Apply new engine oil to the thrust portion and journal of the camshaft. Align the camshaft drive and driven gear’s timing marks (1 dot mark each). Place the camshaft on the cylinder head. Align A78744 (d) (e) Install the 5 bearing caps in their proper locations. Apply a light coat of engine oil to the threads of the bearing cap bolts. (f) Uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration. Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf) Remove the service bolt. A05214 10 6 9 2 4 5 (g) 1 8 3 7 A78745 37. (a) INSTALL TIMING BELT NO.3 COVER Visually check for cracks and breaks on the gasket of the timing belt cover. HINT: If water is entering through cracks or breaks in the gasket, repair according to these guidelines: 1) if the crack length is within 2 to 3 cm (0.79 to 1.18 in.), repair with seal packing; or 2) if the crack length is over 3 cm (1.18 in.), replace the gasket. Seal Packing (b) If the timing belt cover gasket needs to be repaired, follow the procedure below. (1) Repair the cracks and breaks by applying the seal packing to the damaged area. Seal packing: Part No. 08826-00080 or equivalent NOTICE: When applying the seal packing, apply it as wide and high as the gasket. Gasket A78748 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2724 14-232 ENGINE MECHANICAL - CAMSHAFT (LH BANK) (3MZ-FE) (c) If the timing belt cover gasket needs to be replaced, follow the procedure below. (1) Using a screwdriver and gasket scraper, remove the remaining gasket. NOTICE: Be careful not to damage the timing belt cover. (2) E F D Joining Line Joining Portion Gasket E Joining G Line Remove the backing paper from a new gasket, and affix the gasket along the groove of the timing belt cover, as shown in the illustration. NOTICE:
Affix the gasket in the center of the groove.
At the corners, try to keep the gasket thickness uniform. Length: Gasket D E F G Specified Condition 335 mm (13.19 in.) 180 mm (7.09 in.) 133 mm (5.24 in.) 72 mm (2.83 in.) (3) Seal Packing A78749 Front If there is a gap on the joint of the gasket, apply seal packing to close the gap. Seal packing: Part No. 08826-00080 or equivalent NOTICE: When applying the seal packing, apply it as wide and high as the gasket. (d) Install the timing belt cover with the 6 bolts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) 38. (a) Front INSTALL CAMSHAFT TIMING PULLEY Install the camshaft timing pulley with the belt guide properly oriented and tighten the bolt temporarily. HINT:

Face the belt guide of the RH timing pulley towards the front of the engine. Face the belt guide of the LH timing pulley towards the rear of the engine. A78750 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2725 14-233 ENGINE MECHANICAL - CAMSHAFT (LH BANK) (3MZ-FE) (b) RH SST 150 mm A78763 Using SST, tighten the RH pulley bolt. SST 09960- 10010 (09962- 01000, 09963- 01000), 09249-63010 Torque: 125 N⋅m (1,275 kgf⋅cm, 92 ft⋅lbf) NOTICE: The torque specification above is for the SST without extension tool specification. Use the special formula to calculate the SST with extension tool torque specification (see page 01-5 ). Extended length of SST (09249-63010): 150 mm (5.91 in.) (c) LH Using SST, tighten the LH pulley bolt. SST 09960-10010 (09962-01000, 09963-01000) Torque: 125 N⋅m (1,275 kgf⋅cm, 92 ft⋅lbf) SST A78762 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. INSTALL TIMING BELT IDLER SUB-ASSY NO.2 Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) INSPECT TIMING BELT (See page 14-206 ) INSTALL TIMING BELT (See page 14-206 ) INSTALL TIMING BELT TENSIONER ASSY (See page 14-206 ) INSTALL TIMING BELT GUIDE NO.2 (See page 14-206 ) INSTALL ENGINE MOUNTING BRACKET RH Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) INSTALL TIMING BELT NO.2 COVER (See page 14-206 ) INSTALL TIMING BELT NO.1 COVER (See page 14-206 ) INSTALL CRANKSHAFT PULLEY (See page 14-173 ) INSTALL GENERATOR BRACKET NO.2 Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-149 ) INSTALL ENGINE MOVING CONTROL ROD (See page 14-149 ) INSPECT VALVE CLEARANCE (See page 14-127 ) ADJUST VALVE CLEARANCE (See page 14-127 ) INSTALL VANE PUMP V BELT (See page 14-125 ) INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14-125 ) INSPECT DRIVE BELT TENSION (See page 14-121 ) INSTALL CYLINDER HEAD COVER SUB-ASSY LH (See page 14-173 ) INSTALL IGNITION COIL ASSY Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) INSTALL RADIATOR HOSE INLET 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2726 14-234 ENGINE MECHANICAL 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. - CAMSHAFT (LH BANK) (3MZ-FE) INSTALL V-BANK COVER SUB-ASSY (See page 14-149 ) INSTALL FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER Torque: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf) INSTALL COWL PANEL SUB-ASSY INSTALL WINDSHIELD WIPER LINK ASSY (See page 66-7 ) INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSY (See page 66-7 ) INSTALL FR WIPER ARM LH (See page 66-7 ) INSTALL FR WIPER ARM RH (See page 66-7 ) INSTALL FRONT WHEEL RH ADD ENGINE COOLANT (See page 16-26 ) CHECK FOR ENGINE COOLANT LEAKS (See page 16-20 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2727 14-235 ENGINE MECHANICAL - CYLINDER HEAD GASKET (3MZ-FE) CYLINDER HEAD GASKET (3MZ-FE) 141PO-02 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See page 11-35 ) DRAIN ENGINE COOLANT (See page 16-26 ) DRAIN ENGINE OIL REMOVE FR WIPER ARM LH (See page 66-7 ) REMOVE FR WIPER ARM RH (See page 66-7 ) REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See page 66-7 ) REMOVE WINDSHIELD WIPER LINK ASSY (See page 66-7 ) REMOVE COWL PANEL SUB-ASSY REMOVE FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER REMOVE V-BANK COVER SUB-ASSY (See page 14-149 ) REMOVE AIR CLEANER CAP SUB-ASSY REMOVE EMISSION CONTROL VALVE SET (See page 14-149 ) REMOVE INTAKE AIR SURGE TANK (See page 14-149 ) DISCONNECT FUEL PIPE SUB-ASSY NO.1 (See page 14-149 ) 15. (a) (b) DISCONNECT HEATER INLET WATER HOSE Lock the hose clamp, as shown in the illustration. Disconnect the heater inlet water hose. (b) (a) A79759 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. REMOVE INTAKE MANIFOLD (See page 14-149 ) DISCONNECT RADIATOR HOSE INLET REMOVE WATER OUTLET (See page 14-149 ) REMOVE FRONT WHEEL RH REMOVE ENGINE UNDER COVER NO.1 REMOVE FRONT FENDER APRON SEAL RH REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14-125 ) REMOVE VANE PUMP V BELT (See page 14-125 ) REMOVE ENGINE MOVING CONTROL ROD (See page 14-149 ) REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-149 ) REMOVE GENERATOR BRACKET NO.2 REMOVE CRANKSHAFT PULLEY (See page 14-173 ) REMOVE TIMING BELT NO.1 COVER REMOVE TIMING BELT NO.2 COVER (See page 14-206 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2728 14-236 ENGINE MECHANICAL 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. - CYLINDER HEAD GASKET (3MZ-FE) REMOVE ENGINE MOUNTING BRACKET RH REMOVE TIMING BELT GUIDE NO.2 REMOVE TIMING BELT (See page 14-206 ) REMOVE TIMING BELT IDLER SUB-ASSY NO.2 REMOVE CAMSHAFT TIMING PULLEY (See page 14-213 ) REMOVE TIMING BELT NO.3 COVER (See page 14-213 ) SEPARATE VANE PUMP ASSY (See page 14-149 ) REMOVE PROPELLER SHAFT (4WD TYPE) (See page 30-12 ) DISCONNECT EXHAUST PIPE SUB-ASSY FRONT NO.3 (See page 15-5 ) REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY (See page 14-149 ) REMOVE IGNITION COIL ASSY REMOVE CYLINDER HEAD COVER SUB-ASSY (See page 14-173 ) REMOVE CAMSHAFT (See page 14-213 ) REMOVE NO.2 CAMSHAFT (See page 14-213 ) 44. (a) (b) REMOVE CYLINDER HEAD SUB-ASSY Disconnect the camshaft timing oil control valve connector. Remove the nut and disconnect the engine wire harness clamp. A78401 (c) Front Using a socket hexagon wrench 8, remove the hexagon bolt. A78716 (d) Uniformly loosen the 8 cylinder head bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers. NOTICE:
Be careful not to drop the washers into the cylinder head.
Head warpage or cracking could result from removing bolts in an incorrect order. Front 2 7 5 3 4 6 8 1 A78717 45. REMOVE CYLINDER HEAD GASKET 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2729 14-237 ENGINE MECHANICAL - CYLINDER HEAD GASKET (3MZ-FE) 46. (a) INSPECT CYLINDER HEAD SET BOLT Using a vernier caliper, measure the tension portion diameter of the bolt. Standard outside diameter: 8.95 to 9.05 mm (0.3524 to 0.3563 in.) Minimum outside diameter: 8.75 mm (0.3445 in.) If the diameter is less than the minimum, replace the bolt. Tension Portion A52828 47. (a) INSTALL CYLINDER HEAD GASKET Place a new cylinder head gasket on the cylinder block with the R mark upside down, as shown in the illustration. NOTICE:
Remove any oil from the contact surface.
Be careful of the installation direction.
To avoid damage to the gasket, place the cylinder head on the gasket carefully. Front A78324 48. INSTALL CYLINDER HEAD SUB-ASSY NOTICE: The cylinder head bolts are tightened in 2 successive steps. (a) Front 7 2 4 6 5 3 1 8 (b) (c) Apply a light coat of engine oil on the threads of the cylinder head bolts. Install the plate washers to the cylinder head bolts. Uniformly install and tighten the 8 cylinder head bolts in the sequence shown in the illustration. Torque: 54 N⋅m (550 kgf⋅cm, 40 ft⋅lbf) A78717 (d) (e) 90 (f) Front Mark the front side of each cylinder head bolt head with paint, as shown in the illustration. Retighten the cylinder head bolts by 90 in the same sequence as step (c). Check that each painted mark is now at a 90 angle to the front. Painted mark A78730 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2730 14-238 ENGINE MECHANICAL (g) Front (h) - CYLINDER HEAD GASKET (3MZ-FE) Using a socket hexagon wrench 8, install the hexagon bolt. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) Connect the engine wire harness clamp with the nut. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) A78716 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81. 82. 83. INSTALL NO.2 CAMSHAFT (See page 14-213 ) INSTALL CAMSHAFT (See page 14-213 ) INSTALL CYLINDER HEAD COVER SUB-ASSY (See page 14-213 ) INSTALL IGNITION COIL ASSY Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY (See page 14-149 ) CONNECT EXHAUST PIPE SUB-ASSY FRONT NO.3 (See page 15-5 ) INSTALL PROPELLER SHAFT (4WD TYPE) (See page 30-12 ) INSTALL VANE PUMP ASSY (See page 14-149 ) INSTALL TIMING BELT NO.3 COVER (See page 14-213 ) INSTALL CAMSHAFT TIMING PULLEY (See page 14-213 ) INSTALL TIMING BELT IDLER SUB-ASSY NO.2 Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) INSPECT TIMING BELT (See page 14-206 ) INSTALL TIMING BELT (See page 14-206 ) INSTALL TIMING BELT TENSIONER ASSY (See page 14-206 ) INSTALL TIMING BELT GUIDE NO.2 (See page 14-206 ) INSTALL ENGINE MOUNTING BRACKET RH Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) INSTALL TIMING BELT NO.2 COVER (See page 14-206 ) INSTALL TIMING BELT NO.1 COVER (See page 14-206 ) INSTALL CRANKSHAFT PULLEY (See page 14-173 ) INSTALL GENERATOR BRACKET NO.2 Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-149 ) INSTALL ENGINE MOVING CONTROL ROD (See page 14-149 ) INSTALL VANE PUMP V BELT (See page 14-125 ) INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14-125 ) INSPECT DRIVE BELT TENSION (See page 14-121 ) INSTALL WATER OUTLET (See page 14-149 ) CONNECT RADIATOR HOSE INLET INSTALL INTAKE MANIFOLD (See page 14-149 ) CONNECT HEATER INLET WATER HOSE CONNECT FUEL PIPE SUB-ASSY NO.1 (See page 14-149 ) INSTALL INTAKE AIR SURGE TANK (See page 14-149 ) INSTALL EMISSION CONTROL VALVE SET (See page 14-149 ) INSTALL AIR CLEANER CAP SUB-ASSY CONNECT VACUUM HOSES (See page 14-149 ) INSTALL V-BANK COVER SUB-ASSY (See page 14-149 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2731 14-239 ENGINE MECHANICAL - CYLINDER HEAD GASKET (3MZ-FE) 84. INSTALL FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER Torque: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf) 85. INSTALL COWL PANEL SUB-ASSY 86. INSTALL WINDSHIELD WIPER LINK ASSY (See page 66-7 ) 87. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSY (See page 66-7 ) 88. INSTALL FR WIPER ARM LH (See page 66-7 ) 89. INSTALL FR WIPER ARM RH (See page 66-7 ) 90. INSTALL FRONT WHEEL RH 91. ADD ENGINE OIL 92. ADD ENGINE COOLANT (See page 16-26 ) 93. CHECK FOR ENGINE OIL LEAKS 94. CHECK FOR ENGINE COOLANT LEAKS (See page 16-20 ) 95. INSPECT FOR FUEL LEAKS 96. CHECK FOR EXHAUST GAS LEAKS 97. INSPECT IGNITION TIMING (See page 14-121 ) 98. INSPECT ENGINE IDLE SPEED (See page 14-121 ) 99. INSPECT COMPRESSION (See page 14-121 ) 100. INSPECT CO/HC (See page 14-121 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2732 14-240 ENGINE MECHANICAL - CYLINDER HEAD GASKET NO.2 (3MZ-FE) CYLINDER HEAD GASKET NO.2 (3MZ-FE) 141PP-01 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See page 11-35 ) DRAIN ENGINE COOLANT (See page 16-26 ) DRAIN ENGINE OIL REMOVE FR WIPER ARM LH (See page 66-7 ) REMOVE FR WIPER ARM RH (See page 66-7 ) REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See page 66-7 ) REMOVE WINDSHIELD WIPER LINK ASSY (See page 66-7 ) REMOVE COWL PANEL SUB-ASSY REMOVE FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER REMOVE V-BANK COVER SUB-ASSY (See page 14-149 ) REMOVE AIR CLEANER CAP SUB-ASSY REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSY REMOVE AIR CLEANER CASE REMOVE EMISSION CONTROL VALVE SET (See page 14-149 ) REMOVE INTAKE AIR SURGE TANK (See page 14-149 ) DISCONNECT FUEL PIPE SUB-ASSY NO.1 (See page 14-149 ) DISCONNECT HEATER INLET WATER HOSE (See page 14-235 ) REMOVE INTAKE MANIFOLD (See page 14-149 ) REMOVE RADIATOR HOSE INLET REMOVE WATER OUTLET (See page 14-149 ) REMOVE RADIATOR HOSE OUTLET REMOVE WATER INLET PIPE REMOVE OIL LEVEL GAGE SUB-ASSY REMOVE OIL LEVEL GAGE GUIDE REMOVE FRONT WHEEL RH REMOVE ENGINE UNDER COVER NO.1 REMOVE FRONT FENDER APRON SEAL RH REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14-125 ) REMOVE VANE PUMP V BELT (See page 14-125 ) REMOVE ENGINE MOVING CONTROL ROD (See page 14-149 ) REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-149 ) REMOVE GENERATOR BRACKET NO.2 REMOVE CRANKSHAFT PULLEY (See page 14-173 ) REMOVE TIMING BELT NO.1 COVER REMOVE TIMING BELT NO.2 COVER (See page 14-206 ) REMOVE ENGINE MOUNTING BRACKET RH REMOVE TIMING BELT GUIDE NO.2 REMOVE TIMING BELT (See page 14-206 ) REMOVE TIMING BELT IDLER SUB-ASSY NO.2 REMOVE CAMSHAFT TIMING PULLEY (See page 14-224 ) REMOVE TIMING BELT NO.3 COVER (See page 14-224 ) DISCONNECT EXHAUST PIPE ASSY FRONT (See page 15-5 ) REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY NO.2 (See page 14-149 ) REMOVE IGNITION COIL ASSY REMOVE CYLINDER HEAD COVER SUB-ASSY LH (See page 14-173 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2733 14-241 ENGINE MECHANICAL 46. 47. - CYLINDER HEAD GASKET NO.2 (3MZ-FE) REMOVE NO.3 CAMSHAFT SUB-ASSY (See page 14-224 ) REMOVE NO.4 CAMSHAFT SUB-ASSY (See page 14-224 ) 48. (a) (b) (c) (d) REMOVE CYLINDER HEAD LH Disconnect the VVT sensor connector. Disconnect the camshaft timing oil control valve connector. Remove the bolt and disconnect the ground cable. Remove the bolt and the wire harness clamp bracket. A80822 (e) Using a socket hexagon wrench 8, remove the hexagon bolt. Front A78718 (f) Uniformly loosen the 8 cylinder head bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers. NOTICE:
Be careful not to drop the washers into the cylinder head.
Head warpage or cracking could result from removing bolts in an incorrect order. Front 4 6 8 1 2 7 5 3 A78719 49. 50. REMOVE CYLINDER HEAD GASKET NO.2 INSPECT CYLINDER HEAD SET BOLT (See page 14-235 ) 51. (a) INSTALL CYLINDER HEAD GASKET NO.2 Place a new cylinder head gasket on the cylinder block with the L mark, as shown in the illustration. NOTICE:
Remove any oil from the contact surface.
Be careful of the installation direction.
To avoid damage to the gasket, place the cylinder head on the gasket carefully. Front A78325 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2734 14-242 ENGINE MECHANICAL - CYLINDER HEAD GASKET NO.2 (3MZ-FE) 52. INSTALL CYLINDER HEAD LH NOTICE: The cylinder head bolts are tightened in 2 successive steps. (a) Front 5 3 1 8 7 2 4 6 (b) (c) Apply a light coat of engine oil on the threads of the cylinder head bolts. Install the plate washer to the cylinder head bolt. Uniformly install and tighten the 8 cylinder head bolts in the sequence shown in the illustration. Torque: 54 N⋅m (550 kgf⋅cm, 40 ft⋅lbf) A78719 (d) (e) 90 (f) Front Mark the front side of each cylinder head bolt head with paint, as shown in the illustration. Retighten the cylinder head bolts by 90in the same sequence as step (c). Check that each painted mark is now at a 90 angle to the front. Painted mark A78730 (g) Front 5 3 1 8 (h) (i) 7 2 4 Using a socket hexagon wrench 8, install the hexagon bolt. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) Install the wire harness clamp bracket with the bolt. Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) Connect the ground cable with the bolt. Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) 6 A78719 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. INSTALL NO.4 CAMSHAFT SUB-ASSY (See page 14-224 ) INSTALL NO.3 CAMSHAFT SUB-ASSY (See page 14-224 ) INSTALL CYLINDER HEAD COVER SUB-ASSY LH (See page 14-173 ) INSTALL IGNITION COIL ASSY Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY NO.2 (See page 14-149 ) CONNECT EXHAUST PIPE ASSY FRONT (See page 15-5 ) INSTALL TIMING BELT NO.3 COVER (See page 14-224 ) INSTALL CAMSHAFT TIMING PULLEY (See page 14-224 ) INSTALL TIMING BELT IDLER SUB-ASSY NO.2 INSPECT TIMING BELT (See page 14-206 ) INSTALL TIMING BELT (See page 14-206 ) INSTALL TIMING BELT TENSIONER ASSY (See page 14-206 ) INSTALL TIMING BELT GUIDE NO.2 (See page 14-206 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2735 14-243 ENGINE MECHANICAL 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81. 82. 83. 84. 85. 86. 87. 88. 89. 90. 91. 92. 93. 94. 95. 96. 97. 98. 99. 100. 101. 102. 103. 104. 105. 106. 107. - CYLINDER HEAD GASKET NO.2 (3MZ-FE) INSTALL ENGINE MOUNTING BRACKET RH Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) INSTALL TIMING BELT NO.2 COVER (See page 14-206 ) INSTALL TIMING BELT NO.1 COVER (See page 14-206 ) INSTALL CRANKSHAFT PULLEY (See page 14-173 ) INSTALL GENERATOR BRACKET NO.2 Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-149 ) INSTALL ENGINE MOVING CONTROL ROD (See page 14-149 ) INSTALL VANE PUMP V BELT (See page 14-125 ) INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14-125 ) INSPECT DRIVE BELT TENSION (See page 14-121 ) INSTALL OIL LEVEL GAGE GUIDE (See page 14-173 ) INSTALL OIL LEVEL GAGE SUB-ASSY INSTALL WATER INLET PIPE CONNECT RADIATOR HOSE OUTLET INSTALL WATER OUTLET (See page 14-149 ) CONNECT RADIATOR HOSE INLET INSTALL INTAKE MANIFOLD (See page 14-149 ) CONNECT HEATER INLET WATER HOSE CONNECT FUEL PIPE SUB-ASSY NO.1 (See page 14-149 ) INSTALL INTAKE AIR SURGE TANK (See page 14-149 ) INSTALL EMISSION CONTROL VALVE SET (See page 14-149 ) INSTALL AIR CLEANER CASE INSTALL AIR CLEANER CAP SUB-ASSY CONNECT VACUUM HOSES (See page 14-149 ) INSTALL V-BANK COVER SUB-ASSY (See page 14-149 ) INSTALL FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER Torque: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf) INSTALL COWL PANEL SUB-ASSY INSTALL WINDSHIELD WIPER LINK ASSY (See page 66-7 ) INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSY (See page 66-7 ) INSTALL FR WIPER ARM LH (See page 66-7 ) INSTALL FR WIPER ARM RH (See page 66-7 ) INSTALL FRONT WHEEL RH ADD ENGINE OIL ADD ENGINE COOLANT (See page 16-26 ) CHECK FOR ENGINE OIL LEAKS CHECK FOR ENGINE COOLANT LEAKS (See page 16-20 ) INSPECT FOR FUEL LEAKS CHECK FOR EXHAUST GAS LEAKS INSPECT IGNITION TIMING (See page 14-121 ) INSPECT ENGINE IDLE SPEED (See page 14-121 ) INSPECT COMPRESSION (See page 14-121 ) INSPECT CO/HC (See page 14-121 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2736 14-244 ENGINE MECHANICAL - OIL PUMP SEAL (3MZ-FE) OIL PUMP SEAL (3MZ-FE) 141PQ-01 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. REMOVE FR WIPER ARM LH (See page 66-7 ) REMOVE FR WIPER ARM RH (See page 66-7 ) REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See page 66-7 ) REMOVE WINDSHIELD WIPER LINK ASSY (See page 66-7 ) REMOVE COWL PANEL SUB-ASSY REMOVE FRONT WHEEL RH REMOVE ENGINE UNDER COVER NO.1 REMOVE FRONT FENDER APRON SEAL RH REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14-125 ) REMOVE VANE PUMP V BELT (See page 14-125 ) REMOVE ENGINE MOVING CONTROL ROD (See page 14-149 ) REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-149 ) REMOVE GENERATOR BRACKET NO.2 REMOVE CRANKSHAFT PULLEY (See page 14-173 ) REMOVE TIMING BELT NO.1 COVER REMOVE TIMING BELT NO.2 COVER (See page 14-206 ) REMOVE ENGINE MOUNTING BRACKET RH REMOVE TIMING BELT GUIDE NO.2 REMOVE TIMING BELT (See page 14-206 ) REMOVE CRANKSHAFT TIMING PULLEY (See page 14-173 ) 21. (a) (b) Cut Position REMOVE OIL PUMP SEAL Using a knife, cut through the oil seal lip. Using a screwdriver with its tip wrapped in tape, pry out the oil seal. NOTICE: After the removal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper. A52844 22. INSTALL OIL PUMP SEAL (a) Apply MP grease to a new oil seal lip. NOTICE: Keep the lip free of foreign matter. (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the oil pump edge. SST 09223-00010 NOTICE:
Be careful not to tap the oil seal slantingly.
Wipe off extra grease on the crankshaft. SST A13770 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2737 14-245 ENGINE MECHANICAL 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. - OIL PUMP SEAL (3MZ-FE) INSTALL CRANKSHAFT TIMING PULLEY (See page 14-173 ) INSPECT TIMING BELT (See page 14-206 ) INSTALL TIMING BELT (See page 14-206 ) INSTALL TIMING BELT TENSIONER ASSY (See page 14-206 ) INSTALL TIMING BELT GUIDE NO.2 (See page 14-206 ) INSTALL ENGINE MOUNTING BRACKET RH Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) INSTALL TIMING BELT NO.2 COVER (See page 14-206 ) INSTALL TIMING BELT NO.1 COVER (See page 14-206 ) INSTALL CRANKSHAFT PULLEY (See page 14-173 ) INSTALL GENERATOR BRACKET NO.2 Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-149 ) INSTALL ENGINE MOVING CONTROL ROD (See page 14-149 ) INSTALL VANE PUMP V BELT (See page 14-125 ) INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14-125 ) INSPECT DRIVE BELT TENSION (See page 14-121 ) INSTALL COWL PANEL SUB-ASSY INSTALL WINDSHIELD WIPER LINK ASSY (See page 66-7 ) INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSY (See page 66-7 ) INSTALL FR WIPER ARM LH (See page 66-7 ) INSTALL FR WIPER ARM RH (See page 66-7 ) INSTALL FRONT WHEEL RH CHECK FOR ENGINE OIL LEAKS 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2738 14-246 ENGINE MECHANICAL - ENGINE REAR OIL SEAL (3MZ-FE) ENGINE REAR OIL SEAL (3MZ-FE) 141PR-02 REPLACEMENT 1. 2. REMOVE AUTOMATIC TRANSAXLE ASSY (2WD TYPE) (See page 40-20 ) REMOVE AUTOMATIC TRANSAXLE W/TRANSFER (4WD TYPE) (See page 40-20 ) 3. (a) REMOVE DRIVE PLATE & RING GEAR SUB-ASSY Using SST, hold the crankshaft. SST 09213-54015 (91651-60855), 09330-00021 (b) Remove the 8 bolts, the rear spacer, the drive plate and the front spacer. SST A36243 A91073 4. (a) (b) REMOVE ENGINE REAR OIL SEAL Using a knife, cut off the oil seal lip. Using a screwdriver with its tip wrapped in tape, pry out the oil seal. NOTICE: After the removal, check if the crankshaft is not damaged. If it is damaged, smooth the surface with 400-grit sandpaper. Cut Position Cut Position A52843 SST A36743 5. INSTALL ENGINE REAR OIL SEAL (a) Apply MP grease to a new oil seal lip. NOTICE: Keep the lip off foreign materials. (b) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-15030, 09950-70010 (09951-07100) NOTICE:
Be careful not to tap the oil seal at an angle.
Wipe off extra grease from the crankshaft. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2739 14-247 ENGINE MECHANICAL - ENGINE REAR OIL SEAL (3MZ-FE) 6. (a) SST A36243 1 5 7 3 4 8 6 2 7. 8. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY Using SST, hold the crankshaft. SST 09213-54015 (91651-60855), 09330-00021 (b) Clean the bolts and bolt holes. (c) Apply adhesive to 2 or 3 threads of the bolts. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent (d) Install the front spacer, the drive plate and the rear spacer on the crankshaft. (e) Uniformly install and tighten the 8 bolts in the sequence shown in the illustration. Torque: 83 N⋅m (846 kgf⋅cm, 61 ft⋅lbf) NOTICE: Do not start the engine for at least an hour after installing. A05416 INSTALL AUTOMATIC TRANSAXLE W/TRANSFER (4WD TYPE) (See page 40-20 ) INSTALL AUTOMATIC TRANSAXLE ASSY (2WD TYPE) (See page 40-20 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2740 14-248 ENGINE MECHANICAL - CYLINDER HEAD ASSY (3MZ-FE) CYLINDER HEAD ASSY (3MZ-FE) 141PS-01 COMPONENTS Valve Adjusting Shim Valve Lifter Valve Spring Retainer Rock Valve Spring Retainer RH Cylinder: w/ Head Straight Screw Plug No. 1 Inner Compression Spring LH Cylinder: w/ Head Straight Screw Plug No. 2
Valve Stem Oil Seal Valve Spring Seat
Exhaust Valve Guide Bush
Gasket Semicircular Plug 44 (449, 32)
Gasket Cylinder Head Sub-assy Intake Valve Exhaust Valve N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part A78310 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2741 14-249 ENGINE MECHANICAL - CYLINDER HEAD ASSY (3MZ-FE) 141PT-01 OVERHAUL 1. REMOVE W/HEAD STRAIGHT SCREW PLUG NO.1 (RH CYLINDER) (a) Using a straight hexagon wrench 14, remove the 2 screw plugs. 2. REMOVE W/HEAD STRAIGHT SCREW PLUG NO.2 (LH CYLINDER) (a) Using a straight hexagon wrench 14, remove the 2 screw plugs. 3. REMOVE VALVE LIFTER HINT: Store the lifters in the correct order so that they can be returned to their original locations when reassembled. 4. (a) REMOVE INTAKE VALVE Using SST, compress the valve spring and remove the 2 retainer rocks, retainer, spring, spring seat and valve. SST 09202-70020 (09202-00010) HINT: Store the valves, valve springs, spring seat, retainer rock and spring retainers in the correct order so that they can be returned to their original locations when reassembled. SST A05224 5. (a) REMOVE EXHAUST VALVE Using SST, compress the valve spring and remove the 2 retainer rocks, retainer, spring, spring seat and valve. SST 09202-70020 (09202-00010) HINT: Store the valves, valve springs, spring seat, retainer rock and spring retainers in the correct order so that they can be returned to their original locations when reassembled. SST A51796 6. (a) 7. 8. REMOVE VALVE STEM OIL O SEAL OR RING Using needle-nose pliers, remove the oil seal. REMOVE VALVE SPRING SEAT REMOVE SEMICIRCULAR PLUG 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2742 14-250 ENGINE MECHANICAL 9. (a) Cylinder Block Surface - CYLINDER HEAD ASSY (3MZ-FE) INSPECT CYLINDER HEAD FOR FLATNESS Using a precision straight edge and a feeler gauge, measure the surface contacting the cylinder block and the manifolds for warpage. Maximum warpage: Item Specified Condition Cylinder block surface 0.05 mm (0.0020 in.) Intake manifold surface 0.10 mm (0.0039 in.) Exhaust manifold surface 0.10 mm (0.0039 in.) If the warpage is greater than the maximum, replace the cylinder head. Intake Manifold Surface Exhaust Manifold Surface A78773 10. (a) INSPECT CYLINDER HEAD FOR CRACKS Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. A05227 11. (a) Overall Length INSPECT INTAKE VALVE Check the valve overall length. Standard overall length: 95.45 mm (3.7579 in.) Minimum overall length: 94.95 mm (3.7382 in.) If the overall length is less than the minimum, replace the valve. EM2534 (b) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 5.470 to 5.485 mm (0.2154 to 0.2159 in.) If the diameter is less than the minimum, replace the intake valve. Z00052 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2743 14-251 ENGINE MECHANICAL - CYLINDER HEAD ASSY (3MZ-FE) (c) Check the valve head margin thickness. Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness: 0.5 mm (0.020 in.) If the margin thickness is less than the minimum, replace the valve. Margin Thickness EM0181 12. (a) Overall Length INSPECT EXHAUST VALVE Check the valve overall length. Standard overall length: 95.40 mm (3.7559 in.) Minimum overall length: 94.90 mm (3.7362 in.) If the overall length is less than the minimum, replace the valve. EM2534 (b) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: 5.465 to 5.480 mm (0.2152 to 0.2157 in.) If the diameter is less than the minimum, replace the exhaust valve. Z00052 (c) Check the valve head margin thickness. Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness: 0.5 mm (0.020 in.) If the margin thickness is less than the minimum, replace the valve. Margin Thickness EM0181 13. (a) INSPECT INNER COMPRESSION SPRING Using a vernier caliper, measure the free length of the valve spring. Free length: 45.50 mm (1.7913 in.) If the free length is not as specified, replace the valve spring. EM0801 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2744 14-252 ENGINE MECHANICAL - CYLINDER HEAD ASSY (3MZ-FE) (b) Using steel squares, measure the deviation of the valve spring. Maximum deviation: 2.0 mm (0.079 in.) If the deviation is greater than the maximum, replace the valve spring. Deviation EM0988 (c) Using a spring tester, measure the tension of the valve spring at the specified installed length. Installed tension: 186 to 206 N (19.0 to 21.0 kgf, 41.9 to 46.3 lbf) at 33.8 mm (1.331 in.) If the installed tension is not as specified, replace the valve spring. EM0281 14. (a) (b) P12754 INSPECT VALVE GUIDE BUSH OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the guide bush. Bush inside diameter: 5.510 to 5.530 mm (0.2169 to 0.2177 in.) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement. Standard oil clearance: Item Specified Condition Intake 0.025 to 0.060 mm (0.0010 to 0.0024 in.) Exhaust 0.030 to 0.065 mm (0.0012 to 0.0026 in.) Maximum oil clearance: Item Specified Condition Intake 0.080 mm (0.0031 in.) Exhaust 0.100 mm (0.0039 in.) If the clearance is greater than the maximum, replace the valve and guide bush. 15. (a) REMOVE VALVE GUIDE BUSH Heat the cylinder head to approximately 80 to 100C (176 to 212F). A05234 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2745 14-253 ENGINE MECHANICAL (b) SST - CYLINDER HEAD ASSY (3MZ-FE) Using SST and a hammer, tap out the guide bush. SST 09201- 10000, 09201- 01055, 09950- 70010 (09951-07100) P12803 16. (a) INSTALL VALVE GUIDE BUSH Using a caliper gauge, measure the bush bore diameter of the cylinder head. Diameter: 10.295 to 10.313 mm (0.4053 to 0.4060 in.) If the bush bore diameter of the cylinder head is greater than 10.313 mm (0.4060 in.), machine the bush bore to the dimension of 10.345 to 10.363 mm (0.4073 to 0.4080 in.). Bush diameter: P12956 34.5 mm (1.358 in.) 10.333 to 10.344 mm (0.4068 to 0.4072 in.) O/S 10.383 to 10.394 mm (0.4088 to 0.4092 in.) HINT: Use different bushes on the intake and exhaust. Bush length: Exhaust Intake STD 40.5 mm (1.594 in.) Intake 34.5 mm (1.358 in.) Exhaust 40.5 mm (1.594 in.) A52198 (b) SST (c) A78778 Heat the cylinder head to approximately 80 to 100C (176 to 212F) Using SST and a hammer, tap in a new guide bush to the specified protrusion height. SST 09201- 10000, 09201- 01055, 09950- 70010 (09951-07100) Protrusion height: Item Specified Condition Intake 11.1 to 11.5 mm (0.437 to 0.453 in.) Exhaust 8.9 to 9.3 mm (0.350 to 0.336 in.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2746 14-254 ENGINE MECHANICAL (d) - CYLINDER HEAD ASSY (3MZ-FE) Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard specified clearance between the guide bush and the valve stem. Standard oil clearance: Item Specified Condition Intake 0.025 to 0.060 mm (0.0010 to 0.0024 in.) Exhaust 0.030 to 0.065 mm (0.0012 to 0.0026 in.) Z09124 17. (a) INSPECT VALVE SEATS Apply a light coat of prussian blue (or white lead) to the valve face. (b) Lightly press the valve against the seat. NOTICE: Do not rotate the valve. (c) Width A78779 45 30 Check the valve face and valve seat according to the following procedure. (1) If blue appears 360 around the valve face, the valve face is concentric. If not, replace the valve. (2) If blue appears 360 around the valve seat, the guide and valve face are concentric. If not, resurface the valve seat. (3) Check that the valve seat contact is in the middle of the valve face with the width between 1.0 to 1.4 mm (0.039 to 0.055 in.). 18. REPAIR VALVE SEATS NOTICE: Releasing the seat-cutter pressure gradually helps to make smoother valve seat faces. (a) If the seating is too high on the valve face, use 30 and 45 cutters to correct the seat. 1.0-1.4mm 1.0 to 1.4mm A51797 (b) (c) 60 45 1.0 to 1.4 mm (d) If the seating is too low on the valve face, use 60 and 45 cutters to correct the seat. Handrub the valve and valve seat with an abrasive compound. Recheck the valve seating position. A78781 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2747 14-255 ENGINE MECHANICAL 19. (a) - CYLINDER HEAD ASSY (3MZ-FE) INSPECT VALVE LIFTER Using a micrometer, measure the lifter diameter. Lifter diameter: 30.966 to 30.976 mm (1.2191 to 1.2195 in.) EM6368 20. (a) P12685 INSPECT VALVE LIFTER OIL CLEARANCE Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31.009 to 31.025 mm (1.2208 to 1.2215 in.) (b) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.033 to 0.059 mm (0.0013 to 0.0023 in.) Maximum oil clearance: 0.070 mm (0.0028 in.) If the oil clearance is greater than the maximum, replace the lifter. If necessary, replace the cylinder head. 21. INSPECT CAMSHAFT GEAR BACKLASH (a) Install the camshaft timing gear assembly. (b) Install the camshafts to the cylinder head. NOTICE:
Install without valves and sub gear.
Install with its timing mark matched. (c) A33264 Set the dial indicator to the teeth of the intake camshaft at a right angle (90). (d) Measure the backlash of the camshaft timing gear at least 4 positions. Standard backlash: 0.020 to 0.200 mm (0.0008 to 0.0079 in.) Maximum backlash: 0.300 mm (0.0118 in.) If the backlash is greater than the maximum, replace the camshafts. 22. (a) (b) A05238 INSPECT CAMSHAFT THRUST CLEARANCE Install the camshafts. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.040 to 0.090 mm (0.0016 to 0.035 in.) Maximum thrust clearance: 0.120 mm (0.0047 in.) If the thrust clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head together. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2748 14-256 ENGINE MECHANICAL 23. (a) (b) - CYLINDER HEAD ASSY (3MZ-FE) INSPECT CAMSHAFT OIL CLEARANCE Clean the bearing caps and camshaft journals. Place the camshafts on the cylinder head. (c) Lay a strip of plastigage across each of the camshaft journal. (d) Install the bearing caps. Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf) NOTICE: Do not turn the camshaft. (e) Remove the bearing caps. A05239 (f) A05240 RH Cylinder 10 mm (0.39 in.) Measure the plastigage at its widest point. Standard oil clearance: Intake #4, #5 journals 0.025 to 0.057 mm (0.0010 to 0.0022 in.) Other journals 0.025 to 0.062 mm (0.0010 to 0.0024 in.) Maximum oil clearance: 0.100 mm (0.0039 in.) If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head together. NOTICE: Completely remove the plastigage. 24. (a) INSTALL RING W/HEAD PIN (RH CYLINDER) Using a plastic-faced hammer, tap in a new ring pin to the specified protrusion height. Protrusion height: 3 mm (0.12 in.) 25. (a) INSTALL RING PIN (LH CYLINDER) Using a plastic-faced hammer, tap in a new ring pin to the specified protrusion height. Protrusion height: 3 mm (0.12 in.) 8 mm (0.31 in.) A78782 LH Cylinder 10 mm (0.39 in.) 8 mm (0.31 in.) A78783 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2749 14-257 ENGINE MECHANICAL 26. (a) Protrusion Height Mark P05423 A51817 CYLINDER HEAD ASSY (3MZ-FE) INSTALL SPARK PLUG TUBE Using paint, mark the standard position from the edge. Standard protrusion height: 42.4 to 43.4 mm (1.669 to 1.709 in.) HINT: Use either end of the spark plug tube. (b) Apply adhesive to the spark plug tube where it will be pressed into the cylinder head. Adhesive: Part No. 08833-00070 THREE BOND 1324 or equivalent NOTICE:
Install the spark plug tube within 3 minutes after applying adhesive.
Do not deform the spark plug tube.
Do not expose the seal to coolant for at least 1 hour after installing. (c) Press Wooden Block - Protrusion Height Using a press and wooden block, install the spark plug tube to the required protrusion height. NOTICE: Be careful not to drip the adhesive. A78785 27. (a) INSTALL PCV PIPE (RH CYLINDER) Using a wooden block and hammer, tap in 2 new PCV pipes until its top edge is flush with the cylinder head edge. NOTICE: Be careful not to damage the cylinder head edge. Wooden Block Flush P12869 A51801 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2750 14-258 ENGINE MECHANICAL 28. (a) RH Cylinder - CYLINDER HEAD ASSY (3MZ-FE) INSTALL STUD BOLT Install the stud bolts on the intake side. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 49 mm (1.93 in.) M8 LH Cylinder 49 mm (1.93 in.) M8 A78787 A78788 29. (a) A87849 INSTALL STUD BOLT Install the stud bolts on the exhaust side. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) Intake Exhaust Light Brown Gray A78789 SST 30. INSTALL VALVE STEM OIL O SEAL OR RING (a) Apply a light coat of engine oil on the valve stem. NOTICE: Pay close attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust or installing the exhaust oil seal to the intake can cause installation problems later. HINT: The intake valve oil seal is light brown and the exhaust valve oil seal is gray. (b) Using SST, push in a new oil seal. SST 09201-41020 NOTICE: Failure to use SST will cause the seal to be damaged or improperly seated. A78790 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2751 14-259 ENGINE MECHANICAL - CYLINDER HEAD ASSY (3MZ-FE) 31. (a) SST A78770 INSTALL INTAKE VALVE Install the valve, spring seat, valve spring and spring retainer. NOTICE: Install the same part in the same combination to the original locations. (b) Using SST, compress the valve spring and place the 2 keepers around the valve stem. SST 09202-70020 (09202-00010) (c) Using a plastic-faced hammer and a discarded valve with its tip wrapped in tape, lightly tap the installed valve to ensure that it is securely fit. NOTICE: Be careful not to damage the installed valve stem tip. A05246 32. (a) SST A78772 INSTALL EXHAUST VALVE Install the valve, spring seat, valve spring and spring retainer. NOTICE: Install the same parts in the same combination to the original locations. (b) Using SST, compress the valve spring and place the 2 keepers around the valve stem. SST 09202-70020 (09202-00010) (c) Using a plastic-faced hammer and a discarded valve with its tip wrapped in tape, lightly tap the installed valve to ensure that it is securely fit. NOTICE: Be careful not to damage the installed valve stem tip. A05246 33. INSTALL VALVE LIFTER (a) Apply a light coat of engine oil to the valve lifter. NOTICE: Install the same part in the same combination to the original locations. (b) Install the valve lifter. (c) Check that the valve lifter rotates smoothly by hand. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2752 14-260 ENGINE MECHANICAL 34. (a) (b) Seal Packing - CYLINDER HEAD ASSY (3MZ-FE) INSTALL SEMICIRCULAR PLUG Remove any old seal packing (FIPG) material. Apply seal packing to the semicircular plug grooves. Seal packing: Part No. 08826-00080 or equivalent A51804 (c) Install the 2 semicircular plugs to the cylinder heads. NOTICE:
Install the plugs so that they are flush with the top of the cylinder head.
Install the semicircular plugs within 3 minutes after applying seal packing.
Do not expose the seal to engine oil for at least 2 hours after installing. : Semicircular Plug RH Cylinder Front LH Cylinder A78792 35. (a) 36. (a) INSTALL W/HEAD STRAIGHT SCREW PLUG NO.1 (RH CYLINDER) Using a straight hexagon wrench 14, install 2 new gaskets and the 2 screw plugs. Torque: 44 N⋅m (449 kgf⋅cm, 32 ft⋅lbf) INSTALL W/HEAD STRAIGHT SCREW PLUG NO.2 (LH CYLINDER) Using a straight hexagon wrench 14, install 2 new gaskets and the 2 screw plugs. Torque: 44 N⋅m (449 kgf⋅cm, 32 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2753 14-261 ENGINE MECHANICAL - CYLINDER BLOCK ASSY (3MZ-FE) CYLINDER BLOCK ASSY (3MZ-FE) 141PU-01 COMPONENTS 3 Piston Ring (No. 1 Compression Ring) Piston Ring (No. 2 Compression Ring) Piston Ring (Expander) Piston Ring (Side Rail)  Piston Pin Hole Snap Ring Piston Pin Piston  Piston Pin Hole Snap Ring  Connecting Rod Small End Bush Connecting Rod Sub-assy Connecting Rod Bearing Connecting Rod Cap See page (14-263 ) 1st: 25 (255, 18) 2nd: Turn 90  Gasket 50 (510, 37) Cylinder Block w/ Head Straight Screw No. 3 Plug 39 (398, 29) Cylinder Block Water Drain Cock Sub-assy 30 (306, 22) Cylinder Block w/ Head Straight Screw No. 1 Plug  Gasket Cylinder Block Sub-assy  Gasket 30 (306, 22) 39 (398, 29)
Cylinder Block Water Drain Cock Sub-assy Cylinder Block w/ Head Straight Screw No. 2 Plug N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part
Precoated part Water Seal Plate 18 (184, 13) A78311 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2754 14-262 ENGINE MECHANICAL - CYLINDER BLOCK ASSY (3MZ-FE) Cylinder Block Sub-assy  Seal Washer ×4 27 (275, 20) Crankshaft Bearing Upper Crankshaft Thrust Washer Crankshaft Crankshaft Bearing Lower Crankshaft Thrust Washer Crankshaft Bearing Cap ×4 See page (14-263 ) 1st: 22 (224, 16) 2nd: Turn 90 × 16 27 (275, 20) ×4  Seal Washer N·m (kgf·cm, ft·lbf) : Specified torque  Non-reusable part A78312 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2755 14-263 ENGINE MECHANICAL - CYLINDER BLOCK ASSY (3MZ-FE) 141PV-02 OVERHAUL 1. 2. 3. (a) 4. (a) 5. (a) REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY REMOVE WATER SEAL PLATE REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.1 PLUG Using a socket hexagon wrench 10, remove the screw plug. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.2 PLUG Using a socket hexagon wrench 10, remove the screw plug. REMOVE CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.3 PLUG Using a socket hexagon wrench 10, remove the screw plug. 6. (a) P12695 Plastigage INSPECT CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.150 to 0.300 mm (0.0059 to 0.0118 in.) Maximum thrust clearance: 0.350 mm (0.0138 in.) If the thrust clearance is greater than the maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft. Connecting rod thickness: 20.80 to 20.85 mm (0.8189 to 0.8209 in.) 7. INSPECT CONNECTING ROD OIL CLEARANCE (a) Check that the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly. (b) Remove the 2 connecting rod cap bolts. (c) Clean the crank pin, the bearing and the connecting rod. (d) Check the crank pin and bearing for pitting and scratches. (e) Lay a strip of plastigage across the crank pin. (f) Check that the protrusion of the connecting rod cap is facing the correct direction. Apply a light coat of engine oil to the threads of the connecting rod cap bolts. A78793 Front (g) Protrusion A78794 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2756 14-264 ENGINE MECHANICAL (h) - CYLINDER BLOCK ASSY (3MZ-FE) Tighten the bolts in several steps by the specified torque. Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf) P12697 (i) Mark the front side of each connecting cap bolt with paint. (j) Retighten the cap bolts by 90 as shown in the illustration. NOTICE: Do not turn the crankshaft. (k) Remove the 2 bolts, the connecting rod cap and the lower bearing. Painted Mark 90 90 Front A78795 (l) Measure the plastigage at its widest point. Standard oil clearance: 0.038 to 0.066 mm (0.0015 to 0.0026 in.) Maximum oil clearance: 0.080 mm (0.0031 in.) If the oil clearance is greater than the maximum, replace the bearings. If necessary, grind or replace the crankshaft. (m) Completely remove the plastigage. P12698 HINT: If replacing the bearing, replace it with one that has the same number as the connecting rod. There are 4 sizes of standard bearings: 1, 2, 3 and 4. Standard bearing center wall thickness: Number Mark A79803 Mark Center Wall Thickness mm (in.) 1 1.484 to 1.486 (0.05843 to 0.05850) 2 1.487 to 1.489 (0.05854 to 0.05862) 3 1.490 to 1.492 (0.05866 to 0.05874) 4 1.493 to 1.495 (0.05878 to 0.05886) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2757 14-265 ENGINE MECHANICAL 8. (a) (b) - CYLINDER BLOCK ASSY (3MZ-FE) REMOVE PISTON SUB-ASSY W/CONNECTING ROD Using a ridge reamer, remove all the carbon from the top of the cylinder. Push out the piston and the connecting rod assembly from the top of the cylinder block. HINT:
A05258 9.
Keep the bearings, the connecting rod and the cap together. Arrange the piston and the connecting rod assemblies in the correct order so they can be returned to their original locations when reassembled. REMOVE CONNECTING ROD BEARING 10. (a) (b) REMOVE PISTON RING SET Using a piston ring expander, remove the 2 compression rings. Remove the 2 side rails and oil ring by hand. 11. (a) REMOVE PISTON PIN HOLE SNAP RING Using a small screwdriver, pry out the 2 snap rings. 12. (a) REMOVE W/PIN PISTON SUB-ASSY Gradually heat the piston to approximately 80C (176F). A78315 P12403 80C A78797 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2758 14-266 ENGINE MECHANICAL (b) - CYLINDER BLOCK ASSY (3MZ-FE) Using a plastic-faced hammer and a brass bar, lightly tap out the piston pin and remove the connecting rod. HINT:

The piston and pin are a matched set. Store the pistons, the pins, the rings, the connecting rods and the bearings in the correct order so that they can be returned to their original locations when reassembled. P12415 13. (a) P12799 5 8 INSPECT CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.04 to 0.24 mm (0.0016 to 0.0094 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than the maximum, replace the thrust washers as a set. Check the crankshaft for wear, repair or replace if necessary. Thrust washer thickness: 1.93 to 1.98 mm (0.0760 to 0.0780 in.) 14. (a) INSPECT CRANKSHAFT OIL CLEARANCE Uniformly loosen and remove the 8 main bearing cap bolts and seal washers in the sequence shown in the illustration. (b) Uniformly loosen and remove the 16 main bearing cap bolts in the sequence shown in the illustration. 7 6 2 3 4 1 6 14 2 10 8 16 A87850 4 12 11 3 15 13 7 9 5 1 A87851 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2759 14-267 ENGINE MECHANICAL (c) - CYLINDER BLOCK ASSY (3MZ-FE) Remove the 4 main bearing caps and 4 lower bearings. Also remove the 2 lower thrust washers, located under the No. 2 main bearing cap. A87852 Cylinder Block M a i n Bearing Cap Joint Surface A87853 NOTICE: Using a screwdriver, push up on the cap little by little, alternating from the right and left side until the cap is free. Take care not to damage the contact surfaces of the cap and cylinder block. HINT:
Keep the lower bearing and main bearing cap together.
Arrange the main bearing caps and lower thrust washers in the correct order. (d) Lift out the crankshaft. HINT: Keep the upper bearings together with the cylinder block. (e) Clean each main journal and bearing. (f) Check each main journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. A87854 Plastigage (g) (h) Place the crankshaft on the cylinder block. Lay a strip of plastigage across each journal. (i) Install the 4 main bearing caps. A87856 A87855 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2760 14-268 ENGINE MECHANICAL - CYLINDER BLOCK ASSY (3MZ-FE) NOTICE: Do not turn the crankshaft. (j) Remove the main bearing caps (see steps (a) to (c)). (k) Measure the plastigage at its widest point. Standard oil clearance: No. 1 and No. 4 journals 0.014 to 0.034 mm (0.0006 to 0.0013 in.) No. 2 and No. 3 journals 0.026 to 0.046 mm (0.0010 to 0.0018 in.) Maximum oil clearance: A87857 No.1 No.2 No.3 No.4 Number Mark No.2 No.3 No.4 No.1 Number Mark No. 1 and No. 4 journals 0.050 mm (0.0020 in.) No. 2 and No. 3 journals 0.060 mm (0.0024 in.) If the oil clearance is greater than the maximum, replace the bearings. If necessary, replace the crankshaft. HINT: If using a bearing, replace it with one that has the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table on the next page for the appropriate bearing number. The No. 1 and No. 4 journal bearings have 5 standard bearing sizes, marked 3, 4, 5, 6 and 7 accordingly. The No. 2 and No. 3 journal bearings have 5 standard bearing sizes, marked 1, 2, 3, 4 and 5 accordingly. Number Mark A87858 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2761 14-269 ENGINE MECHANICAL - CYLINDER BLOCK ASSY (3MZ-FE) No. 1 and No. 4 journal bearings Cylinder block + Crankshaft = 0 to 5 6 to 11 12 to 17 18 to 23 24 to 28 Replacement Bearing 3 4 5 6 7 HINT: EXAMPLE Cylinder block imprinted number mark is 06 Crankshaft imprinted number mark is 08 6 + 8 = 14 Select the bearing marked ”5” No. 1 and No. 4 journal standard bearings selection chart Cylinder block number mark Crankshaft number mark 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 00 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 01 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 02 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 6 03 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 6 6 04 3 3 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 05 3 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 06 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 07 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 08 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 7 09 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 7 7 10 4 4 5 5 5 5 5 5 6 6 6 6 6 6 7 7 7 11 4 5 5 5 5 5 5 6 6 6 6 6 6 7 7 7 7 12 5 5 5 5 5 5 6 6 6 6 6 6 7 7 7 7 7 EXAMPLE: Cylinder block ”06”, Crankshaft ”08” = Use bearing ”5” 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2762 14-270 ENGINE MECHANICAL - CYLINDER BLOCK ASSY (3MZ-FE) No. 2 and No. 3 journal bearings Cylinder block + Crankshaft = 0 to 5 6 to 11 12 to 17 18 to 23 24 to 28 Replacement Bearing 3 4 5 6 7 HINT: EXAMPLE Cylinder block imprinted number mark is 06 Crankshaft imprinted number mark is 08 6 + 8 = 14 Select the bearing marked ”3” No.2 and No.3 journal standard bearings selection chart Cylinder block number mark Crankshaft number mark 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 00 1 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 01 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 02 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 4 03 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 4 4 04 1 1 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 05 1 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 06 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 4 07 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 4 4 08 2 2 2 2 3 3 3 3 3 3 4 4 4 4 4 4 5 09 2 2 2 3 3 3 3 3 3 4 4 4 4 4 4 5 5 10 2 2 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 11 2 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 12 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 EXAMPLE: Cylinder block ”06”, Crankshaft ”08” = Use bearing ”3” 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2763 14-271 ENGINE MECHANICAL - CYLINDER BLOCK ASSY (3MZ-FE) Reference Item Mark Specified Condition Cylinder block main journal bore diameter (A) 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 66.000 mm (2.5984 in.) 66.001 mm (2.5985 in.) 66.002 mm (2.5985 in.) 66.003 mm (2.5985 in.) 66.004 mm (2.5986 in.) 66.005 mm(2.5986 in.) 66.006 mm (2.5987 in.) 66.007 mm (2.5987 in.) 66.008 mm (2.5987 in.) 66.009 mm (2.5988 in.) 66.010 mm (2.5988 in.) 66.011 mm (2.5989 in.) 66.012 mm (2.5989 in.) 66.013 mm (2.5989 in.) 66.014 mm (2.5990 in.) 66.015 mm (2.5990 in.) 66.016 mm (2.5990 in.) Crankshaft main journal diameter (B) 00 01 02 03 04 05 06 07 08 09 10 11 12 61.000 mm (2.4016 in.) 60.999 mm (2.4015 in.) 60.998 mm (2.4015 in.) 60.997 mm (2.4015 in.) 60.996 mm (2.4014 in.) 60.995 mm (2.4014 in.) 60.994 mm (2.4013 in.) 60.993 mm (2.4012 in.) 60.992 mm (2.4012 in.) 60.991 mm (2.4012 in.) 60.990 mm (2.4012 in.) 60.989 mm (2.4011 in.) 60.988 mm (2.4011 in.) Standard bearing center wall thickness 1 2 3 4 5 6 7 2.486 to 2.489 mm (0.0979 to 0.0980 in.) 2.489 to 2.492 mm (0.0980 to 0.0981 in.) 2.492 to 2.495 mm (0.0981 to 0.0982 in.) 2.495 to 2.498 mm (0.0982 to 0.0983 in.) 2.498 to 2.501 mm (0.0983 to 0.0985 in.) 2.501 to 2.504 mm (0.0985 to 0.0986 in.) 2.504 to 2.507 mm (0.0986 to 0.0987 in.) (l) Completely remove the plastigage. 15. REMOVE CRANKSHAFT (a) Lift the crankshaft. (b) Remove the 4 upper main bearings and 2 upper thrust washers from the cylinder block. HINT: Arrange the main bearing caps, bearings and thrust washers in the correct order. 16. REMOVE CRANKSHAFT THRUST WASHER SET 17. REMOVE CRANKSHAFT BEARING 18. CLEAN CYLINDER BLOCK NOTICE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block. Always wash the cylinder block at a temperature of 45C (113F) or less. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2764 14-272 ENGINE MECHANICAL - CYLINDER BLOCK ASSY (3MZ-FE) 19. (a) INSPECT CYLINDER BLOCK FOR FLATNESS Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Maximum warpage: 0.05 mm (0.0020 in.) If the warpage is greater than the maximum, replace the cylinder block. Z09222 20. (a) INSPECT CYLINDER BORE Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions. Specified diameter: 92.000 to 92.132 mm (3.6220 to 3.6272 in.) If the measured diameters is greater than the maximum, replace the cylinder block. Thrust Direction Front Axial Direction A 10 mm B A88898 21. (a) 13.0 mm INSPECT W/PIN PISTON SUB-ASSY Using a micrometer, measure the diameter of the piston. When you measure the diameter, attach the micrometer to a location where 13.0 mm (0.512 in.) above from the piston bottom and meets at the right angles to the piston pin hole. Piston diameter: 91.953 to 91.967 mm (3.6202 to 3.6207 in.) A78316 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2765 14-273 ENGINE MECHANICAL - CYLINDER BLOCK ASSY (3MZ-FE) 22. (a) INSPECT PISTON OIL CLEARANCE Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.033 to 0.059 mm (0.0013 to 0.0023 in.) Maximum oil clearance: 0.130 mm (0.0051 in.) If the oil clearance is greater than the maximum, replace all the 6 pistons. If necessary, replace the cylinder block. 23. (a) INSPECT CONNECTING ROD SUB-ASSY Using a rod aligner and feeler gauge, check the connecting rod alignment. (1) Check for misalignment. Maximum misalignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If misalignment is greater than the maximum, replace the connecting rod assembly. Z00064 (2) Check for twist. Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If the twist is greater than the maximum, replace the connecting rod assembly. Z00065 24. (a) INSPECT PISTON PIN OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the connecting rod bush. Bush inside diameter: 22.005 to 22.014 mm (0.8663 to 0.8667 in.) (b) Using a micrometer, measure the piston pin diameter. Piston pin diameter: 21.997 to 22.006 mm (0.8660 to 0.8664 in.) EM6525 EM0227 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2766 14-274 ENGINE MECHANICAL - CYLINDER BLOCK ASSY (3MZ-FE) (c) Subtract the piston pin diameter measurement from the bush inside diameter measurement. Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 in.) Maximum oil clearance: 0.050 mm (0.0020 in.) If the oil clearance is greater than the maximum, replace the bush. If necessary, replace the piston and the piston pin together. 25. (a) REMOVE CONNECTING ROD SMALL END BUSH Using SST and a press, press out the bush. SST 09222-30010 26. (a) INSTALL CONNECTING ROD SMALL END BUSH Align the oil holes of a new bush and the connecting rod. (b) Using SST and a press, press in the bush. SST 09222-30010 (c) Using a pin hole grinder, hone the bushing to obtain the standard clearance between the bush and piston pin. Standard oil clearance: 0.005 to 0.011 mm (0.0002 to 0.0004 in.) SST A78803 Oil Hole A78804 SST A78803 EM6535 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2767 14-275 ENGINE MECHANICAL - CYLINDER BLOCK ASSY (3MZ-FE) (d) Check that the piston pin fits at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb. 27. (a) INSPECT RING GROOVE CLEARANCE Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove. Ring groove clearance: P00326 A78317 Item Specified Condition No. 1 0.03 to 0.08 mm (0.0012 to 0.0031 in.) No. 2 0.02 to 0.06 mm (0.0008 to 0.0024 in.) Oil 0.03 to 0.11 mm (0.0012 to 0.0043 in.) If the clearance is not as specified, replace the piston. 28. (a) INSPECT PISTON RING END GAP Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block. (b) Using a feeler gauge, measure the end gap. Standard end gap: 110 mm A78805 Item Specified Condition No. 1 0.30 to 0.40 mm (0.0118 to 0.0157 in.) No. 2 0.50 to 0.60 mm (0.0197 to 0.0236 in.) Oil (Side rail) 0.15 to 0.40 mm (0.0059 to 0.0157 in.) Maximum end gap: A37355 Item Specified Condition No. 1 0.95 mm (0.0374 in.) No. 2 1.05 mm (0.0413 in.) Oil (Side rail) 1.00 mm (0.0394 in.) If the end gap is greater than the maximum, replace the piston ring. If the end gap is greater than the maximum even with a new piston ring, replace the cylinder block. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2768 14-276 ENGINE MECHANICAL - CYLINDER BLOCK ASSY (3MZ-FE) 29. (a) INSPECT CONNECTING ROD BOLT Using a vernier caliper, measure the tension portion diameter of the bolt. Standard diameter: 7.20 to 7.30 mm (0.2830 to 0.2870 in.) Minimum diameter: 7.0 mm (0.2760 in.) If the diameter is less than the minimum, replace the bolt. EM6347 A15065 30. (a) INSPECT CRANKSHAFT BEARING CAP SET BOLT Using a vernier caliper, measure the tension portion diameter of the bolt. Standard diameter: 7.50 to 7.60 mm (0.2950 to 0.2990 in.) Minimum diameter: 7.20 mm (0.2830 in.) If the diameter is less than the minimum, replace the bolt. EM6347 A15065 31. (a) INSPECT CRANKSHAFT Using a dial indicator and V-blocks, measure the runout as shown in the illustration. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is greater than the maximum, replace the crankshaft. P12406 (b) A37157 Using a micrometer, measure the diameter of each main journal. Diameter: 60.988 to 61.000 mm (2.4011 to 2.4016 in.) If the diameter is not as specified, check the oil clearance (see step 7). If necessary, replace the crankshaft. (c) Check each main journal for taper and out-of-round, as shown in the illustration. Maximum taper and out-of-round: 0.02 mm (0.0008 in.) If the taper and out-of-round is greater than the maximum, replace the crankshaft. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2769 14-277 ENGINE MECHANICAL - CYLINDER BLOCK ASSY (3MZ-FE) (d) ZF6928 Using a micrometer, measure the diameter of each crank pin. Diameter: 52.992 to 53.000 mm (2.0863 to 2.0866 in.) If the diameter is not as specified, check the oil clearance (see step 7). (e) Check each crank pin for taper and out-of-round, as shown in the illustration. Maximum taper and out-of-round: 0.02 mm (0.0008 in.) If the taper and out-of-round is greater than the maximum, replace the crankshaft. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2770 14-278 ENGINE MECHANICAL 32. - CYLINDER BLOCK ASSY (3MZ-FE) INSTALL STUD BOLT Front Side Front Side 99 mm (3.90 in.) 29 mm (1.14 in.) M8 M6 Torque: 6.0 N⋅m (60 kgf⋅cm, 53 in.⋅lbf) Torque: 15 N⋅m (145 kgf⋅cm, 11 ft⋅lbf) Front Side Left Side 80 mm (3.15 in.) 28.5 mm (1.12 in.) M8 M10 Torque: 21 N⋅m (220 kgf⋅cm, 15 ft⋅lbf) Torque: 7.0 N⋅m (70 kgf⋅cm, 62 in.⋅lbf) Top Side Top Side 52.5 mm (2.07 in.) 27.5 mm (1.08 in.) M6 M8 Torque: 4.0 N⋅m (40 kgf⋅cm, 35 in.⋅lbf) Torque: 12 N⋅m (122 kgf⋅cm, 9 ft⋅lbf) A78318 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2771 14-279 ENGINE MECHANICAL 33. - CYLINDER BLOCK ASSY (3MZ-FE) INSTALL STRAIGHT PIN Front Side Right Side (FF) 4 mm (0.16 in.) 4 mm (0.16 in.) 12 mm (0.47 in.) 12 mm (0.47 in.) Protrusion Height: 6 mm (0.24 in.) Protrusion Height: 6 mm (0.24 in.) Top Side Bottom Side 4 mm (0.16 in.) 4 mm (0.16 in.) 12 mm (0.47 in.) 12 mm (0.47 in.) Protrusion Height: 6 mm (0.24 in.) Protrusion Height: 6 mm (0.24 in.) Backside Backside 4 mm (0.16 in.) 10 mm 12 mm (0.47 in.) Protrusion Height: 6 mm (0.24 in.) 22 mm (0.87 in.) Protrusion Height: 11 mm (0.43 in.) A78319 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2772 14-280 ENGINE MECHANICAL 34. - CYLINDER BLOCK ASSY (3MZ-FE) INSTALL RING PIN Top Side Bottom Side 11 mm (0.43 in.) 16 mm (0.63 in.) 8 mm (0.31 in.) 20 mm (0.79 in.) Protrusion Height: 10 mm (0.39 in.) Protrusion Height: 4 mm (0.16 in.) A78816 35. (a) INSTALL PISTON PIN HOLE SNAP RING Using a small screwdriver, install a new snap ring at one end of the piston pin hole. HINT: Be sure that the end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. A32958 P12418 80C 36. (a) INSTALL W/PIN PISTON SUB-ASSY Gradually heat the piston to about 80C (176F). (b) (c) Coat the piston pin with engine oil. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb until the pin contacts the snap ring. A78817 Front Mark Front Mark (Mold Mark) A78376 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2773 14-281 ENGINE MECHANICAL 37. (a) - CYLINDER BLOCK ASSY (3MZ-FE) INSTALL PISTON PIN HOLE SNAP RING Using a small screwdriver, install a new snap ring on the other end of the piston pin hole. HINT: Be sure that the end of gap of the snap ring is not aligned with the pin hole cutout portion of the piston. A32958 P12418 38. (a) (b) No. 1 2A INSTALL PISTON RING SET Install the oil ring expander and the 2 side rails by hand. Using a piston ring expander, install the 2 compression rings. HINT: The compression ring No. 2 is installed with code mark ”2A” faced upward, as shown in the illustration. No. 2 A78320 (c) Lower Side Rail No. 2 Compression Front Mark Position the piston rings so that the ring ends are arranged, as shown in the illustration. NOTICE: Do not align the ring ends. Expander No. 1 Compression Upper Side Rail A78321 39. (a) INSTALL CONNECTING ROD BEARING Align the key of the bearing with the keyway of the connecting rod or connecting cap. NOTICE: Clean the backside of the bearing and the bearing surface of the connecting rod. The surface should be free of dust and oils. P12402 No. 1 and No. 4 No. 2 and No. 3 Upper Lower 22.4 mm 40. INSTALL CRANKSHAFT BEARING HINT: Main bearings come in width of 22.4 mm (0.882 in.) and 19.0 mm (0.748 in.). Install the 22.4mm (0.882 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No. 2 and No. 3 positions. 19.0 mm A78806 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2774 14-282 ENGINE MECHANICAL - CYLINDER BLOCK ASSY (3MZ-FE) (a) Align the key of the bearing with the keyway of the cylinder block, and push in the 4 upper bearings. NOTICE: Do not apply engine oil to the bearing and its contact surface. P12599 (b) Align the key of the bearing with the keyway of the main bearing cap, and push in the 4 lower bearings. NOTICE: Do not apply engine oil to the bearing and its contact surface. HINT: A number is marked on each main bearing cap to indicate the installation position. Mark 1, 2, 3 or 4 A78807 41. (a) INSTALL CRANKSHAFT THRUST WASHER SET Install the 2 thrust washers under the No. 2 journal position of the cylinder block with the oil grooves facing outward. (b) Install the 2 thrust washers on the No. 2 bearing cap with the grooves facing outward. P12600 A05264 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2775 14-283 ENGINE MECHANICAL - CYLINDER BLOCK ASSY (3MZ-FE) 42. (a) INSTALL CRANKSHAFT Apply engine oil to the upper bearing and install the crankshaft on the cylinder block. (b) Examine the front marks and numbers. Install the bearing caps on the cylinder block. Apply a light coat of engine oil on the threads of the bearing cap bolts. Temporarily install the 8 main bearing cap bolts to the inside positions. (c) (d) A10530 (e) Install the main bearing cap by hand using the inner bolt as a guide. Stop the main bearing cap about 6 mm (0.23 in.) away from contacting with the block. (f) Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit. Apply a light coat of engine oil on the threads of the main bearing cap bolts. Less than 6 mm A78809 (g) A10529 (h) 11 3 15 9 1 7 13 5 6 2 4 8 Uniformly install and tighten the 16 main bearing cap bolts in the sequence shown in the illustration. Torque: 22 N⋅m (224 kgf⋅cm, 16 ft⋅lbf) 14 10 12 16 A78810 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2776 14-284 ENGINE MECHANICAL (i) (j) Painted Mark 90 (k) 90 Front (l) - CYLINDER BLOCK ASSY (3MZ-FE) Mark the front side of the bearing cap bolts with paint. Retighten the bearing cap bolts by 90 in the same sequence as step (h). Check that each painted mark is now at a 90 angle to the front. Check that the crankshaft turns smoothly. A78811 2 1 (m) 4 7 3 HINT: Use the short bolt for the marked positions (arrow). 6 8 Uniformly install and tighten the 8 main bearing cap bolts in the sequence shown in the illustration. Torque: 27 N⋅m (275 kgf⋅cm, 20 ft⋅lbf) 5 A91571 43. (a) Front Mark (Cavity) Front A78322 Front INSTALL PISTON SUB-ASSY W/CONNECTING ROD Apply engine oil to the cylinder walls, the pistons, and the surfaces of connecting rod bearings. (b) Check the position of the piston ring ends. (c) Using a piston ring compressor, push the piston that numbered correctly and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. NOTICE: Match the numbered connecting rod cap with the connecting rod. (d) Check that the protrusion of the connecting rod cap is facing the correct direction. (e) Apply a light coat of engine oil on the threads of the connecting rod cap bolts. Protrusion A78794 (f) Tighten the bolts in several steps by the specified torque. Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf) P12697 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2777 14-285 ENGINE MECHANICAL Painted Mark 90 90 - CYLINDER BLOCK ASSY (3MZ-FE) (g) (h) (i) Mark the front side of each connecting cap bolt with paint. Retighten the cap bolts by 90 as shown in the illustration. Check that the crankshaft turns smoothly. 44. INSTALL CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.1 PLUG Using a socket hexagon wrench 10, install a new gasket and the screw plug. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) Front A78795 Front Side (a) A78822 45. Left Side (a) INSTALL CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.2 PLUG Using a socket hexagon wrench 10, install a new gasket and the screw plug. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) A78823 46. Back Side (a) INSTALL CYLINDER BLOCK W/HEAD STRAIGHT SCREW NO.3 PLUG Using a socket hexagon wrench 10, install a new gasket and the screw plug. Torque: 50 N⋅m (510 kgf⋅cm, 37 ft⋅lbf) A78824 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2778 14-286 ENGINE MECHANICAL CYLINDER BLOCK ASSY (3MZ-FE) 47. (a) (b) A A B B - Seal Width: 3 to 5 mm A62377 INSTALL WATER SEAL PLATE Remove any old seal packing from the contact surface. Apply a continuous bead of seal packing (seal width: 3 to 5 mm (0.12 to 0.20 in.)), as shown in the illustration. Seal packing: Part No. 08826-00100 or equivalent NOTICE:
Remove any oil from the contact surface.
Install the seal plate within 3 minutes after applying seal packing.
Do not expose the seal to engine oil for at least 2 hours after installing. (c) Install the seal plate with the 2 nuts. Torque: 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) 48. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY (a) Apply adhesive to 2 or 3 threads of the drain cock end. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent (b) After applying the specified torque, rotate the drain cock clockwise, as shown in the illustration. Torque: 39 N⋅m (398 kgf⋅cm, 29 ft⋅lbf) NOTICE:
Install the drain cock within 3 minutes after applying adhesive.
Do not expose the seal to coolant for at least 1 hour after installing.
Do not rotate the drain cock more than 1 revolution (360) after tightening the drain cock with the specified torque.
Do not loosen the drain cock after setting it correctly. 10 45 A78323 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2779 15-1 EXHAUST - EXHAUST PIPE ASSY (2AZ-FE) EXHAUST PIPE ASSY (2AZ-FE) 150AZ-02 COMPONENTS Front Floor Heat Insulator No. 3 Main Muffler Heat Insulator Front Floor Heat Insulator No. 2 Heated Oxygen Sensor (Bank 1 Sensor 2) 44 (449, 35)
Rivet
Gasket
Gasket 4.9 (50, 43 in.⋅lbf) 48 (489, 35)
Rivet Exhaust Pipe Support 56 (571, 41)
Gasket Exhaust Pipe Assy Front Exhaust Pipe Assy Tail Exhaust Pipe Assy Center 48 (489, 35) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part A85589 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2780 15-2 EXHAUST - EXHAUST PIPE ASSY (2AZ-FE) 150CD-01 REPLACEMENT NOTICE: Check if an old gasket remains on the pipe. If remains, remove it. Check if any bolts or nuts are rusted. If rusted, replace them. 1. (a) (a) (b) (a) 2. (a) 3. (a) (b) 4. (a) (b) REMOVE EXHAUST PIPE ASSY TAIL Remove the 2 bolts and pipe tail from the exhaust pipe center. Remove the pipe tail from the exhaust pipe support. A85593 REMOVE HEATED OXYGEN SENSOR Disconnect the heated oxygen sensor (bank 1 sensor 2) connector. REMOVE EXHAUST PIPE ASSY CENTER Remove the 2 bolts and pipe center from the exhaust pipe front. Remove the pipe center from the 4 exhaust pipe supports. REMOVE EXHAUST PIPE ASSY FRONT Remove the 2 bolts and pipe front from the exhaust manifold. 5. (a) Exhaust Manifold Side INSTALL EXHAUST PIPE ASSY FRONT Install a new gasket and the pipe front to the exhaust manifold with the 2 bolts. Torque: 48 N⋅m (489 kgf⋅cm, 35 ft⋅lbf) Gasket A92682 6. (a) (b) 7. (a) INSTALL EXHAUST PIPE ASSY CENTER Install the pipe center to the 4 exhaust pipe supports. Install a new gasket and the pipe center to the pipe front with the 2 bolts. Torque: 56 N⋅m (571 kgf⋅cm, 41 ft⋅lbf) INSTALL HEATED OXYGEN SENSOR Install the heated oxygen sensor (bank 1 sensor 2) to the pipe front. Torque: 44 N⋅m (449 kgf⋅cm, 32 ft⋅lbf) HINT:

Before installing the sensor, twist the sensor wire counterclockwise 3 and 1/2 turns. After installing the sensor, check that the sensor wire is not twisted. If it is twisted, remove the sensor and reinstall it. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2781 15-3 EXHAUST 8. (a) (b) Tail Pipe Side (c) Gasket - EXHAUST PIPE ASSY (2AZ-FE) INSTALL EXHAUST PIPE ASSY TAIL Install the pipe tail to the exhaust pipe support. Install a new gasket and the pipe tail to the pipe center with the 2 bolts. Torque: 48 N⋅m (489 kgf⋅cm, 35 ft⋅lbf) Install the pipe to the 3 exhaust pipe supports. A51123 9. CHECK FOR EXHAUST GAS LEAKS If gas is leaking, tighten the areas necessary to stop the leak. If damaged, replace it. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2782 15-4 EXHAUST - EXHAUST PIPE ASSY (3MZ-FE) EXHAUST PIPE ASSY (3MZ-FE) 150B1-03 COMPONENTS Front Floor Heat Insulator No. 1 Front Floor Heat Insulator No. 2 Front Floor Heat Insulator No. 3 Main Muffler Heat Insulator
Rivet 21 (214, 15)
Gasket
Rivet 56 (571, 41) Exhaust Pipe Support Bracket No. 1
Gasket 21 (214, 15) 56 (571, 41) Heated Oxygen Sensor (Bank 1 Sensor 2) Heated Oxygen Sensor (Bank 2 Sensor 2) 44 (449, 35) 44 (449, 35) 4.9 (50, 43 in.⋅lbf)
Gasket
Rivet Exhaust Pipe Support 56 (571, 41) Exhaust Pipe Assy Front 48 (489, 35) Exhaust Pipe Sub-assy Front No. 3
Gasket
Gasket Exhaust Pipe Assy Tail Exhaust Pipe Assy Center 48 (489, 35) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part A85587 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2783 15-5 EXHAUST - EXHAUST PIPE ASSY (3MZ-FE) 150CE-01 REPLACEMENT NOTICE: Check if an old gasket remains on the pipe. If remains, remove it. Check if any bolts or nuts are rusted. If rusted, replace them. Bank 2, Sensor 2 1. (a) REMOVE HEATED OXYGEN SENSOR Remove the 2 heated oxygen sensors (bank 1, 2 sensor 2). 2. (a) REMOVE EXHAUST PIPE ASSY TAIL Remove the 2 bolts and pipe tail from the exhaust pipe center. Remove the pipe tail from the exhaust pipe supports. Bank 1, Sensor 2 A85590 (a) (b) (a) 3. (a) (b) (b) A85593 REMOVE EXHAUST PIPE ASSY CENTER Remove the 2 bolts and pipe center from the exhaust pipe front No. 3. Remove the pipe center from the 4 exhaust pipe supports. 4. (a) (b) (a) (a) REMOVE EXHAUST PIPE SUB-ASSY FRONT NO.3 Remove the 2 nuts and pipe front No. 3 from the exhaust manifold. Remove the 2 bolts and pipe front No. 3 from the exhaust pipe assy front. (b) (b) A85591 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2784 15-6 EXHAUST 5. (a) (b) - EXHAUST PIPE ASSY (3MZ-FE) REMOVE EXHAUST PIPE ASSY FRONT Loosen the clamp. Remove the 2 nuts and pipe. (a) (b) (b) A85592 6. (a) (b) INSTALL EXHAUST PIPE ASSY FRONT Install 2 new gaskets and the pipe with the Torque: 56 N⋅m (571 kgf⋅cm, 41 ft⋅lbf) Tighten the clamp. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) 7. (a) (b) (c) (c) (c) 2 nuts. INSTALL EXHAUST PIPE SUB-ASSY FRONT NO.3 Install 2 new gaskets to the pipe front No. 3. Install the front pipe No. 3 to the pipe front with the 2 bolts. Torque: 56 N⋅m (571 kgf⋅cm, 41 ft⋅lbf) Install the front pipe No. 3 to the exhaust manifold RH with the 2 nuts. Torque: 56 N⋅m (571 kgf⋅cm, 41 ft⋅lbf) (b) (b) A85591 8. (a) (b) INSTALL EXHAUST PIPE ASSY CENTER Install the pipe center to the 4 exhaust pipe supports. Install a new gasket and the pipe center to the front pipe No. 3 with the 2 bolts. Torque: 48 N⋅m (489 kgf⋅cm, 35 ft⋅lbf) 9. (a) (b) (b) (b) (a) INSTALL EXHAUST PIPE ASSY TAIL Install the pipe tail to the exhaust pipe support. Install a new gasket and the pipe tail to the pipe center with the 2 bolts. Torque: 48 N⋅m (489 kgf⋅cm, 35 ft⋅lbf) A85593 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2785 15-7 EXHAUST 10. (a) Bank 2, Sensor 2 - EXHAUST PIPE ASSY (3MZ-FE) INSTALL HEATED OXYGEN SENSOR Install the 2 heated oxygen sensors (bank 1, 2 sensor 2). Torque: 44 N⋅m (449 kgf⋅cm, 32 ft⋅lbf) HINT:

Before installing the sensor, twist the sensor wire counterclockwise 3 and 1/2 turns. After installing the sensor, check that the sensor wire is not twisted. If it is twisted, remove the sensor and reinstall it. Bank 1, Sensor 2 A85590 11. CHECK FOR EXHAUST GAS LEAKS If gas is leaking, tighten the areas necessary to stop the leak. If damaged, replace it. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2786 16-2 COOLING - COOLING SYSTEM (2AZ-FE) 1602Z-09 INSPECTION 1. INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening temperature is stamped on the thermostat. P13560 (a) Immerse the thermostat in water and gradually heat the water. (b) Check the valve opening temperature. Valve opening temperature: 80 to 84C (176 to 183F) If the valve opening temperature is not as specified, replace the thermostat. P00436 (c) Check the valve lift. Valve lift: 10 mm (0.39 in.) or more at 95C (203F) If the valve lift is not as specified, replace the thermostat. (d) Check that the valve is fully closed when the thermostat is at low temperatures (below 77C (171F)). If not closed, replace the thermostat. 10 mm A91387 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2788 16-3 COOLING - COOLING SYSTEM (2AZ-FE) 2. INSPECT RADIATOR CAP SUB-ASSY NOTICE:
If the reservoir cap has contaminations, always rinse it with water.
Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water.
When performing steps (a) and (b) below, keep the tester at an angle of over 30 above the horizontal. (a) Radiator Cap Tester 30 or more Radiator Cap A51912 Using a radiator cap tester, slowly pump the tester and check that air is being released from the vacuum valve. Pump speed: 1 push every 3 seconds or more NOTICE: Push the pump at a constant speed. If air is not being released from the vacuum valve, replace the reservoir cap. (b) Pump the tester and measure the relief valve opening pressure. Pump speed: 1 push within 1 second NOTICE: The specified pump speed should be followed for the first pump only. It will close the vacuum valve. Once the vacuum valve is closed, the pump speed can be reduced. Standard opening pressure: 93 to 122 kPa (0.95 to 1.25 kgf/cm2, 13.4 to 17.6 psi) Minimum opening pressure: 78 kPa (0.8 kgf/cm2, 11.4 psi) HINT: Use the tester’s maximum reading as the opening pressure. If the maximum reading is less than the minimum opening pressure, replace the radiator cap. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2789 16-1 COOLING - COOLING SYSTEM (2AZ-FE) COOLING SYSTEM (2AZ-FE) 1602Y-07 ON-VEHICLE INSPECTION 1. INSPECT COOLING SYSTEM FOR LEAKS (a) Remove the radiator cap. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (b) Fill the radiator with coolant and attach a radiator cap tester. (c) Warm up the engine. A93960 (d) Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm2, 17.1 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head. 2. CHECK ENGINE COOLANT LEVEL AT RESERVOIR (a) The engine coolant level should be between the ”LOW” and ”FULL” lines when the engine is cold. If low, check for leaks and add ”Toyota Super Long Life Coolant” or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology up to the ”FULL” line. Do not use plain water alone. 3. CHECK ENGINE COOLANT QUALITY (a) Remove the radiator cap. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (b) Check if there is any excessive deposits of rust or scale around the radiator cap and radiator filler hole. Also, the coolant should be free from oil. If excessively dirty, replace the coolant. (c) Reinstall the radiator cap. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2787 16-5 COOLING - COOLING FAN SYSTEM (2AZ-FE) 160PS-02 INSPECTION 1 5 2 1. (a) 3 Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 5 1 2 3 INSPECT RELAY (Marking: FAN NO. 1, FAN NO. 3) Measure the resistance of the relay. Standard: If the result is not as specified, replace the relay. B60778 1 4 2 4 3 2. (a) 5 Tester Connection Specified Condition 3-4 Below 1 Ω 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 5 1 2 3 A87121 INSPECT RELAY (Making: FAN NO. 2) Measure the resistance of the relay. Standard: If the result is not as specified, replace the relay. 3. (a) INSPECT ENGINE COOLANT TEMPERATURE SENSOR Measure the resistance between terminals 1 and 2. Standard: Condition 2.29 to 2.6 kΩ Approximately 80
C (176
F) 0.300 to 0.327 kΩ If the result is not as specified, replace the sensor. NOTICE: When checking the ECT sensor in the water, the terminals should be kept dry. After the check, dry the sensor. 30 20 10 5 Resistance kΩ Specified Condition Approximately 20
C (68
F) 3 2 1 0.5 0.3 0.2 0.1 -20 (-4) 0 20 40 60 80 100 (32) (68) (104) (140) (176) (212) Temperature
C (
F) A91388 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2791 16-4 COOLING - COOLING FAN SYSTEM (2AZ-FE) COOLING FAN SYSTEM (2AZ-FE) 16030-07 ON-VEHICLE INSPECTION HINT: The cooling fan may rotate when the ignition switch is turned from ACC to ON. This is normal. 1. CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 83
C (181
F)) (a) Turn the ignition switch ON. (b) Check that the cooling fan stops. If not, check the cooling fan relay and ECT sensor, and check for disconnected connector or wire breaks between the cooling fan relay and ECT sensor. (c) Disconnect the ECT sensor connector. (d) Check that the cooling fan rotates. If not, check the fuses, cooling fan relay, ECM and cooling fan, and check for a short circuit between the cooling fan relay and ECT Sensor.. (e) Reconnect ECT sensor connector. 2. CHECK COOLING FAN OPERATION WITH HIGH TEMPERATURE (Above 90
C (194
F)) (a) Start the engine, and raise ECT to above 90
C (194
F). (b) Check that the cooling fan rotates. If not, replace the ECT sensor. 3. INSPECT COOLING FAN (a) Disconnect the cooling fan connector. (b) Connect battery and ammeter to the cooling fan connector. (c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage: 5.2 to 8.2 A at 20
C (68
F) If not, replace the cooling fan. (d) Reconnect the cooling fan connector. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2790 16-6 COOLING - COOLANT (2AZ-FE) COOLANT (2AZ-FE) 16032-08 REPLACEMENT 1. DRAIN ENGINE COOLANT (a) Remove the radiator cap. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (b) Drain engine coolant by loosening the radiator drain plug and the engine’s cylinder block drain cock plug. HINT: Engine coolant inside the radiator is drained from the drain hole located on the bottom of the engine under cover. (c) Tighten the cylinder block drain cock plug. Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf) Radiator Cap Cylinder Block Drain Plug Radiator Drain Plug A94378 2. (a) (b) ADD ENGINE COOLANT Tighten the radiator drain plug. Add engine coolant into the radiator until it overflows. Capacity: Item w/ Heater (front only) w/ Heater (front and rear) Specified Condition Standard 6.3 liters (6.7 US qts, 5.5 Imp. qts) Towing 7.1 liters (7.5 US qts, 6.2 Imp. qts) Standard 7.7 liters (8.1 US qts, 6.8 Imp. qts) Towing 8.5 liters (9.0 US qts, 7.5 Imp. qts) HINT:


Use of improper coolants may damage the engine cooling system. Only use ”Toyota Super Long Life Coolant” or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology. New Toyota vehicles are filled with Toyota Super Long Life Coolant (color is pink, premixed ethyleneglycol concentration is approximately 50% and freezing temperature is -35C (-95F)). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2792 16-7 COOLING - COOLANT (2AZ-FE)
Observe the coolant level inside the radiator by pressing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add the coolant. NOTICE: Do not use plain water alone. (c) Pour coolant into the radiator reservoir tank until the coolant reaches the full line. (d) Install the radiator cap. (e) Start the engine and run the engine for 10 seconds. (f) Remove the radiator cap after 10 seconds. Pour coolant if the coolant level is lower. (g) Repeat steps (d) to (f) until the coolant level remains the same from steps (d) to (f). HINT: Perform the procedures above before the engine warms up. A warmed up engine causes the thermostat valve to open, and the air inside the engine circulates between the radiator and the engine. (h) Install the radiator cap. (i) Warm up the engine until the thermostat valve begins to open. HINT: As the engine warms up, press the radiator inlet and outlet hoses several times by hand. (j) Stop the engine and wait until the coolant cools down to the ambient temperature. If the coolant is below the full line, add coolant. (k) Install the radiator cap and check the radiator reservoir tank coolant level. If it is below the full line, add coolant. 3. CHECK FOR ENGINE COOLANT LEAKS (a) Fill the radiator with coolant and attach a radiator cap tester. (b) Pump it to 118 kPa (1.2 kgf/cm2, 17.1 psi) and check leakage. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2793 16-10 COOLING - WATER PUMP ASSY (2AZ-FE) 160PT-03 INSPECTION 1. (a) (b) A36661 INSPECT WATER PUMP ASSY Visually check for drain hole coolant leakage. Turn the pulley, and check that the water pump bearing moves smoothly and noiselessly. If the bearing moves roughly or noisily, replace the water pump assy. (c) Visually check the air holes for coolant leakage. If leakage is found, replace the water pump assy. if engine coolant has leaked onto the timing belt, replace the timing belt. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2796 16-8 COOLING - WATER PUMP ASSY (2AZ-FE) WATER PUMP ASSY (2AZ-FE) 1602V-08 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. DRAIN ENGINE COOLANT (See page 16-6 ) REMOVE FRONT WHEEL RH REMOVE FRONT FENDER APRON SEAL RH REMOVE ENGINE MOVING CONTROL ROD W/BRACKET (See page 14-24 ) REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-24 ) REMOVE ENGINE MOUNTING BRACKET NO.2 RH (See page 14-24 ) REMOVE FAN AND GENERATOR V BELT (See page 14-5 ) REMOVE GENERATOR ASSY (See page 19-16 ) 9. (a) SST (b) REMOVE WATER PUMP PULLEY Using SST, remove the 4 bolts and pump pulley. SST 09960-10010 (09962-01000, 09963-00700) Disconnect the crankshaft position sensor wire harness clamp. B11275 10. (a) 11. (a) REMOVE WATER PUMP ASSY Remove the 4 bolts, 2 nuts, bracket and water pump. INSTALL WATER PUMP ASSY Remove any old packing (FIPG) material and be careful not to drop any oil on the contacting surfaces of the water pump and cylinder block. HINT:
B11276

(b) Using a razor blade and gasket scraper, remove all the old packing (FIPG) materials from the gasket surfaces and sealing grooves. Thoroughly clean all components to remove all loose material. Using a non-residue solvent, clean both sealing surfaces. Apply seal packing to the water pump as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent HINT: 0.5 to 1.0 mm (0.020 to 0.040 in.) Seal Width: 2.2 to 2.5 mm A89934


Install a nozzle that has been cut to a 2.2 to 2.5 mm (0.087 to 0.098 in.) opening. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove the nozzle from the tube. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2794 16-9 COOLING (c) (d) - WATER PUMP ASSY (2AZ-FE) Install the water pump and bracket with the 4 bolts and 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) Connect the crankshaft position sensor wire harness clamp. B11276 12. (a) SST INSTALL WATER PUMP PULLEY Using SST, install the pump pulley with the 4 bolts. SST 09960-10010 (09962-01000, 09963-00700) Torque: 26 N⋅m (265 kgf⋅cm, 19 ft⋅lbf) B11275 13. 14. 15. 16. 17. 18. 19. 20. 21. INSTALL GENERATOR ASSY (See page 19-16 ) INSTALL FAN AND GENERATOR V BELT (See page 14-5 ) INSTALL ENGINE MOUNTING BRACKET NO.2 RH (See page 14-24 ) INSTALL ENGINE MOVING CONTROL ROD W/BRACKET (See page 14-24 ) INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-24 ) INSTALL FRONT FENDER APRON SEAL RH INSTALL FRONT WHEEL RH ADD ENGINE COOLANT (See page 16-6 ) CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2795 16-1 1 COOLING - THERMOSTAT (2AZ-FE) THERMOSTAT (2AZ-FE) 160U9-01 REPLACEMENT 1. 2. 3. 4. DRAIN ENGINE COOLANT (See page 16-6 ) REMOVE FAN AND GENERATOR V BELT (See page 14-5 ) REMOVE GENERATOR ASSY (See page 19-16 ) DISCONNECT RADIATOR HOSE INLET 5. (a) REMOVE WATER INLET Remove the 2 nuts and disconnect the water inlet from the cylinder block. A59903 6. REMOVE THERMOSTAT Top 10
10
Jiggle Valve 7. INSTALL THERMOSTAT (a) Install a new gasket to the thermostat. (b) Install the thermostat with the jiggle valve facing up. HINT: The jiggle valve may be set within 10
on either side of the prescribed position. B11281 8. (a) Top INSTALL WATER INLET Install the water inlet with the 2 nuts, as shown in the illustration. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) A90977 9. 10. 11. 12. 13. INSTALL RADIATOR HOSE INLET INSTALL GENERATOR ASSY (See page 19-16 ) INSTALL FAN AND GENERATOR V BELT (See page 14-5 ) ADD ENGINE COOLANT (See page 16-6 ) CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2797 16-13 COOLING - RADIATOR ASSY (2AZ-FE) 160PV-03 COMPONENTS Front Fender Apron Seal RH Fan and Generator V Belt 52 (530, 38) 21 (214, 15) Generator Assy 12.8 (130, 9) Radiator Reserve Tank Hose or Pipe Radiator Support Upper Radiator Assy Fan Motor Connector Radiator Support Lower Radiator Hose Outlet Radiator Hose Inlet Oil Cooler Outlet Hose No. 3 Oil Cooler Outlet Hose No. 2 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque A90980 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2799 16-14 COOLING - RADIATOR ASSY (2AZ-FE) 7.8 (80, 69 in.⋅lbf) ×6 Radiator Hose Outlet Fan Assy w/ Motor Oil Cooler Outlet Hose No. 2 Oil Cooler Outlet Hose No. 3 Radiator Assy N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque A90978 Radiator Cap
O-Ring Radiator Tank Upper
O-Ring Plate Washer Core 8.34 (85, 74 in.⋅lbf) Cooler Pipe 14.71 (150, 11)
O-Ring Oil Cooler Assy
O-Ring 8.34 (85, 74 in.⋅lbf) Plate Washer ECT Switch
O-Ring
O-Ring Drain Plug Radiator Tank Lower N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part A90979 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2800 16-12 COOLING - RADIATOR ASSY (2AZ-FE) RADIATOR ASSY (2AZ-FE) 160PU-03 ON-VEHICLE CLEANING 1. INSPECT FINS BLOCKAGE If the fins are clogged, wash them with water or a steam cleaner. Dry with compressed air. NOTICE:
If the distance between the steam cleaner and the core is too close, the fins may become damaged. Keep the following injection distance. Standard: A73603

Distance Steam Cleaner Pressures 300 mm (11.81 in.) 2,942 to 4,903 kPa (30 to 50 kgf/cm2, 427 to 711 psi) 500 mm (19.69 in.) 4,903 to 7,845 kPa (50 to 80 kgf/cm2, 711 to 1,138 psi) If the fins are bent, straighten them with a screwdriver or pliers. Never apply water directly onto the electronic components. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2798 16-16 COOLING - RADIATOR ASSY (2AZ-FE) 160PX-03 OVERHAUL 1. (a) (b) REMOVE DRAIN PLUG Remove the drain plug. Remove the O-ring. 2. Part A Dimension B SST Claw Stopper Bolt Overhaul Handle A87082 Tank SST ASSEMBLE SST SST 09230-01010 (a) Install the claw to the overhaul handle, inserting it in the hole in part A as shown in the illustration. (b) While gripping the handle, adjust the stopper bolt so that dimension B is as shown in the illustration. Dimension B: 0.2 to 0.3 mm (0.008 to 0.012 in.) NOTICE: If the stopper bolt is not adjusted, the claw may be damaged. 3. UNCAULK LOCK PLATE Using SST, grip the handle until stopped by the stopper bolt to uncaulk the lock plate. SST 09230-01010 (09231-01010, 09231-01030) Lock Plate Stopper Bolt A93944 4. (b) REMOVE RADIATOR TANK UPPER AND TANK LOWER Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a plastic-faced hammer, and remove the tank. Remove the O-ring. 5. (a) (b) (c) (d) REMOVE OIL COOLER ASSY Remove the cooler pipe Loosen the 2 nuts and 2 plate washers. Remove the oil cooler. Remove the 2 O-rings from the oil cooler. (a) Tap A93945 A93946 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2802 16-17 COOLING O-Ring Cooler Pipe Oil Cooler Assy 6. (a) (b) (c) Plate Washer Nut Radiator Tank Lower O-Ring (d) 30 - RADIATOR ASSY (2AZ-FE) INSTALL OIL COOLER ASSY Clean the O-ring contact surfaces of the lower tank and oil cooler. Install 2 new O-rings to the oil cooler. Install the oil cooler to the lower tank with the 2 plate washers and nuts. Torque: 8.34 N·m (85 kgf·cm, 74 in.·lbf) Install the cooler pipe in the direction indicated by the arrows in the illustration. Torque: 14.71 N·m (150 kgf·cm, 11 ft·lbf) 26.9 mm (1.059 in.) A94636 Lock Plate Lock Plate Core A87087 7. INSPECT LOCK PLATE FOR DAMAGE HINT:
If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. Therefore, first correct any deformation with pliers or similar object.
Water leakage will result if the bottom of the lock plate groove is damaged or dented. Repair or replace if necessary. NOTICE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced. 8. (a)  Normal X Twisted O-Ring INSTALL RADIATOR TANK UPPER AND TANK LOWER After checking that there are no foreign objects in the lock plate groove, install a new O-ring without twisting it. HINT: When cleaning the lock plate groove, lightly rub it with sandpaper without scratching it. X Twisted A87088 Tank CORRECT (b) (c) Install the tank without damaging the O-ring. Tap the lock plate with a plastic-faced hammer so that there is no gap between the lock plate and the tank. INCORRECT Lock Plate A93947 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2803 16-18 COOLING 9. Part A (a) Dimension B Punch Assembly SST (b) Stopper Bolt Overhaul Handle 3 7 2 1 6 4 RADIATOR ASSY (2AZ-FE) ASSEMBLE SST SST 09230-01010, 09231-14010 Install the punch assembly to the overhaul handle, inserting it in the hole in part A as shown in the illustration. While gripping the handle, adjust the stopper bolt so that dimension B is as shown in the illustration. Dimension: 8.4 mm (0.331 in.) A87090 10. (a) 5 - 8 CAULK LOCK PLATE Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, fully caulk the lock plate by gripping the handle until stopped by the stopper plate. SST 09230-01010 SST Tank Stopper Bolt Lock Plate A93948 HINT:
Do not tap the areas protruding around the pipes, brackets or tank ribs.
The points shown in the illustration and oil cooler near here (A/T) cannot be tapped with the SST. Use pliers or similar objects and be careful not to damage the core plates. A93949 A93950 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2804 16-19 COOLING - RADIATOR ASSY (2AZ-FE) (b) H Check the lock plate height (H) after completing the caulking. Plate height (H): 7.40 to 7.80 mm (0.2913 to 0.3071 in.) If not within the specified height, adjust the stopper bolt of the handle and caulk it again. A93951 11. (a) (b) INSTALL DRAIN PLUG Install a new O-ring to the drain plug. Install the drain plug. 12. (a) SST (b) (c) INSPECT FOR WATER LEAKS Plug the inlet and outlet pipes of the radiator with SST. SST 09230-01010 Using a radiator cap tester, apply pressure to the radiator. Test pressure: 177 kPa (1.8 kgf/cm2, 26 psi) Submerge the radiator in water. A93952 Tank Lock Plate (d) Inspect for leaks. HINT: On radiators with resin tanks, there is a clearance between the tank and lock plate where a minute amount of air will remain, giving the appearance of an air leak when the radiator is submerged in water Before doing the water leak test, first swish the radiator in water until all air bubbles disappear. O-Ring A87096 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2805 16-15 COOLING - RADIATOR ASSY (2AZ-FE) 160UA-01 REPLACEMENT HINT: The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. 1. DRAIN ENGINE COOLANT (See page 16-6 ) 2. DISCONNECT RADIATOR RESERVE TANK HOSE OR PIPE 3. DISCONNECT RADIATOR HOSE INLET 4. DISCONNECT RADIATOR HOSE OUTLET 5. DISCONNECT OIL COOLER OUTLET HOSE NO.2 6. DISCONNECT OIL COOLER OUTLET HOSE NO.3 7. REMOVE RADIATOR SUPPORT UPPER (a) Remove the radiator support upper with the 2 bolts. 8. REMOVE RADIATOR ASSY (a) Disconnect the fan motor connector. (b) Remove the radiator from the body. 9. REMOVE RADIATOR SUPPORT LOWER 10. REMOVE FAN ASSY W/MOTOR (a) Remove the 6 bolts and fan from the radiator. 11. INSTALL FAN ASSY W/MOTOR (a) Install the fan to the radiator with the 6 bolts. Torque: 7.8 N·m (80 kgf·cm, 69 in.⋅lbf) 12. INSTALL RADIATOR ASSY (a) Install the radiator to the body. (b) Connect the fan motor connector. 13. INSTALL RADIATOR SUPPORT UPPER (a) Install the radiator support upper with the 2 bolts. Torque: 12.8 N·m (130 kgf·cm, 9.4 ft·lbf) 14. ADD ENGINE COOLANT (See page 16-6 ) 15. CHECK FOR ENGINE COOLANT LEAKS (See page 16-1 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2801 16-21 COOLING - COOLING SYSTEM (3MZ-FE) 16035-09 INSPECTION 1. INSPECT THERMOSTAT HINT: The valve opening temperature is stamped on the thermostat. P13560 (a) Immerse the thermostat in water and gradually heat the water. (b) Check the valve opening temperature. Valve opening temperature: 80 to 84C (176 to 183F) If the valve opening temperature is not as specified, replace the thermostat. P00436 (c) Check the valve lift. Valve lift: 10 mm (0.39 in.) or more at 95C (203F) If the valve lift is not as specified, replace the thermostat. (d) Check that the valve is fully closed when the thermostat is at low temperatures (below 77C (171F)). If not closed, replace the thermostat. 10 mm A91387 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2807 16-22 COOLING - COOLING SYSTEM (3MZ-FE) 2. INSPECT RADIATOR CAP SUB-ASSY NOTICE:
If the reservoir cap has contaminations, always rinse it with water.
Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water.
When performing steps (a) and (b) below, keep the tester at an angle of over 30 above the horizontal. (a) Radiator Cap Tester 30 or more Radiator Cap A51912 Using a radiator cap tester, slowly pump the tester and check that air is being released from the vacuum valve. Pump speed: 1 push every 3 seconds or more NOTICE: Push the pump at a constant speed. If air is not being released from the vacuum valve, replace the reservoir cap. (b) Pump the tester and measure the relief valve opening pressure. Pump speed: 1 push within 1 second NOTICE: The specified pump speed should be followed for the first pump only. It will close the vacuum valve. Once the vacuum is closed, the pump speed can be reduced. Standard opening pressure: 93 to 122 kPa (0.95 to 1.25 kgf/cm2, 13.4 to 17.6 psi) Minimum opening pressure: 78 kPa (0.8 kgf/cm2, 11.4 psi) HINT: Use the tester’s maximum reading as the opening pressure. If the maximum reading is less than the minimum opening pressure, replace the radiator cap. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2808 16-20 COOLING - COOLING SYSTEM (3MZ-FE) COOLING SYSTEM (3MZ-FE) 16034-08 ON-VEHICLE INSPECTION 1. INSPECT COOLING SYSTEM FOR LEAKS (a) Remove the radiator cap. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (b) Fill the radiator with coolant and attach a radiator cap tester. (c) Warm up the engine. A93961 (d) Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm2, 17.1 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head. 2. CHECK ENGINE COOLANT LEVEL AT RESERVOIR (a) The engine coolant level should be between the ”LOW” and ”FULL” lines when the engine is cold. If low, check for leaks and add ”Toyota Super Long Life Coolant” or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology up to the ”FULL” line. Do not use plain water alone. 3. CHECK ENGINE COOLANT QUALITY (a) Remove the radiator cap. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (b) Check if there is any excessive deposits of rust or scale around the radiator cap and radiator filler hole. Also, the coolant should be free from oil. If excessively dirty, replace the coolant. (c) Reinstall the radiator cap. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2806 16-24 COOLING - COOLING FAN SYSTEM (3MZ-FE) 160Q0-02 INSPECTION 1 5 2 3 1. (a) Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 5 1 2 3 INSPECT RELAY (Marking: FAN NO. 1, FAN NO. 3) Check the resistance of the relay. Standard: If the result is not as specified, replace the relay. B60778 1 4 2 4 3 5 2. (a) Tester Connection Specified Condition 3-4 Below 1 Ω 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 5 1 2 3 A87121 If the result is not as specified, replace the relay. 3. (a) P01924 INSPECT RELAY (Marking: FAN NO. 2) Check the resistance of the relay. Standard: INSPECT ECT SWITCH (NO. 1) Check the resistance. Standard: Temperature Specified Condition Above 98
C (208
F) Below 1 Ω Below 88
C (190
F) 10 kΩ or higher If the result is not as specified, replace the switch. NOTICE: When checking the ECT sensor in water, the terminals should be kept dry. After the check, dry the sensor. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2810 16-25 COOLING 4. (a) - COOLING FAN SYSTEM (3MZ-FE) INSPECT ECT SWITCH (NO. 2) Check the resistance. Standard: Temperature P06722 Specified Condition Above 93
C (199
F) Below 1 Ω Below 83
C (181
F) 10 kΩ or higher If the result is not as specified, replace the switch. NOTICE: When checking the ECT sensor in water, the terminals should be kept dry. After the check, dry the sensor. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2811 16-23 COOLING - COOLING FAN SYSTEM (3MZ-FE) COOLING FAN SYSTEM (3MZ-FE) 16036-08 ON-VEHICLE INSPECTION HINT: The cooling fan may rotate when the ignition switch is turned from ACC to ON. This is normal. 1. CHECK COOLING FAN OPERATION AT LOW TEMPERATURE (Below 83
C (181
F)) (a) Turn the ignition switch ON. (b) Check that the cooling fan stops. If not, check the cooling fan relay and ECT switches, and check for disconnected connectors and wire breaks between the cooling fan relay and ECT switches. (c) Disconnect the ECT switch No. 1 connector. (d) Connect the terminals on the ECT switch No. 1 connector. (e) Check that the No. 1 cooling fan rotates at a high speed. If not, check the No. 1 cooling fan relay and No. 1 cooling fan. (f) Reconnect the ECT switch No. 1 connector. (g) Disconnect the ECT switch No. 2 connector. (h) Ground the terminal on the ECT switch No. 2 wire harness side connector. (i) Check that the No. 1 and No. 2 cooling fans rotate at a low speed. If not, check the No. 2 cooling fan relay, No. 3 cooling fan relay and No. 2 cooling fan. (j) Reconnect the ECT switch No. 2 connector. 2. CHECK COOLING FAN (a) Disconnect the cooling fan connector. (b) Connect the battery and ammeter to the cooling fan connector. (c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage: 8.5 to 11.5 A at 20
C (68
F) If not, replace the cooling fan. (d) Reconnect the cooling fan connector. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2809 16-26 COOLING - COOLANT (3MZ-FE) COOLANT (3MZ-FE) 16038-10 REPLACEMENT 1. DRAIN ENGINE COOLANT (a) Remove the radiator cap. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (b) Drain engine coolant by loosening the radiator drain cock plug and the engine’s cylinder block drain cock plug. HINT: Engine coolant inside the radiator is drained from the drain hole located on the bottom of the engine under cover. (c) Tighten the cylinder block drain cock plugs. Torque: 13 N⋅m (133 kgf⋅cm, 10 ft⋅lbf) Radiator Cap Cylinder Block Drain Cock Plug (4WD) Cylinder Block Drain Cock Plug Cylinder Block Drain Cock Plug (2WD) Radiator Drain Cock Plug A93316 2. (a) (b) ADD ENGINE COOLANT Tighten the radiator drain plug. Add engine coolant into the radiator until it overflows. Capacity: Item w/ heater (front only) Specified Condition Standard Towing w/ Rear heater (front and rear) 9.4 liters (9.9 US qts, 8.3 Imp. qts) 10.1 liters (10.7 US qts, 8.9 Imp. qts) Standard 10.7 liters (11.3 US qts, 9.4 Imp. qts) Towing 11.4 liters (12.0 US qts, 10.0 Imp. qts) HINT:

Use of improper coolants may damage the engine cooling system. Only use ”Toyota Super Long Life Coolant” or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2812 16-27 COOLING - COOLANT (3MZ-FE)
New Toyota vehicles are filled with Toyota Super Long Life Coolant (color is pink, premixed ethyleneglycol concentration is approximately 50% and freezing temperature is -35C (-95F)).
Observe the coolant level inside the radiator by pressing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add the coolant. NOTICE: Do not use plain water alone. (c) Pour coolant into the radiator reservoir tank until the coolant reaches the full line. (d) Install the radiator cap. (e) Warm up the engine. HINT: As the engine warms up, press the inlet and outlet radiator hoses several times by hand. (f) Stop the engine and wait until the coolant cools down to the ambient temperature. (g) Remove the radiator cap and check the coolant level inside the radiator. (h) If the coolant level is below the full level, repeat steps (c) to (g) until the coolant level stays the same from step (c) to (g). (i) Install the radiator cap and check the radiator reservoir tank coolant level. If it is below the full line, add coolant. 3. CHECK FOR ENGINE COOLANT LEAKS (a) Fill the radiator with coolant and attach a radiator cap tester. (b) Pump it to 118 kPa (1.2 kgf/cm2, 17.1 psi) and check leakage. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2813 16-30 COOLING - WATER PUMP ASSY (3MZ-FE) 160Q1-03 INSPECTION 1. (a) (b) P12487 INSPECT WATER PUMP ASSY Visually check the drain hole for coolant leakage. Turn the pulley, and check that the water pump bearing moves smoothly and noiselessly. If the bearing moves roughly or noisily, replace the water pump assy. (c) Visually check the air holes for coolant leakage. If leakage is found, replace the water pump assy. if engine coolant has leaked onto the timing belt, replace the timing belt. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2816 16-28 COOLING - WATER PUMP ASSY (3MZ-FE) WATER PUMP ASSY (3MZ-FE) 1602G-13 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. DRAIN ENGINE COOLANT (See page 16-26 ) REMOVE FRONT WHEEL RH REMOVE FRONT FENDER APRON SEAL RH REMOVE V BELT NO. 1 (See page 14-125 ) REMOVE VANE PUMP V BELT (See page 14-125 ) REMOVE ENGINE MOVING CONTROL ROD (See page 14-149 ) REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-149 ) REMOVE GENERATOR BRACKET NO.2 REMOVE CRANKSHAFT PULLEY (See page 14-173 ) REMOVE TIMING BELT NO.1 COVER REMOVE TIMING BELT NO.2 COVER REMOVE ENGINE MOUNTING BRACKET RH REMOVE TIMING BELT GUIDE NO.2 REMOVE TIMING BELT (See page 14-173 ) 15. (a) REMOVE TIMING BELT IDLER SUB-ASSY NO.2 Remove the bolt and timing belt idler. A05055 16. 17. REMOVE CAMSHAFT TIMING PULLEY (See page 14-173 ) REMOVE TIMING BELT NO.3 COVER 18. (a) REMOVE WATER PUMP ASSY Remove the 4 bolts, 2 nuts and water pump. A36739 19. (a) 20. 21. INSTALL WATER PUMP ASSY Install a new gasket and the water pump with the 4 bolts and 2 nuts. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) INSTALL TIMING BELT NO.3 COVER (See page 14-173 ) INSTALL CAMSHAFT TIMING PULLEY (See page 14-173 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2814 16-29 COOLING 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. - WATER PUMP ASSY (3MZ-FE) INSTALL TIMING BELT IDLER SUB-ASSY NO.2 Torque: 34 N⋅m (347 kgf⋅cm, 25 ft⋅lbf) INSPECT TIMING BELT (See page 14-173 ) INSTALL TIMING BELT (See page 14-173 ) INSTALL TIMING BELT TENSIONER ASSY (See page 14-173 ) INSTALL TIMING BELT GUIDE NO.2 (See page 14-173 ) INSTALL ENGINE MOUNTING BRACKET RH Torque: 54 N⋅m (551 kgf⋅cm, 40 ft⋅lbf) INSTALL TIMING BELT NO.2 COVER (See page 14-173 ) INSTALL TIMING BELT NO.1 COVER (See page 14-173 ) INSTALL CRANKSHAFT PULLEY (See page 14-173 ) INSTALL GENERATOR BRACKET NO.2 Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14-149 ) INSTALL ENGINE MOVING CONTROL ROD (See page 14-149 ) INSTALL VANE PUMP V BELT (See page 14-125 ) INSTALL V BELT NO. 1 (See page 14-125 ) INSPECT DRIVE BELT TENSION (See page 14-125 ) ADD ENGINE COOLANT (See page 16-26 ) CHECK FOR ENGINE COOLANT LEAKS (See page 16-20 ) INSTALL FRONT WHEEL RH 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2815 16-31 COOLING - THERMOSTAT (3MZ-FE) THERMOSTAT (3MZ-FE) 1602F-09 REPLACEMENT HINT: The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. 1. DRAIN ENGINE COOLANT (See page 16-26 ) 2. REMOVE RADIATOR HOSE OUTLET 3. REMOVE WATER INLET PIPE (a) Remove the bolt and inlet pipe. 4. REMOVE WATER INLET (a) Remove the 3 bolts and water inlet. 5. REMOVE THERMOSTAT 6. (a) (b) 15
15
Stud Bolt INSTALL THERMOSTAT Install a new gasket to the thermostat. Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat into the water inlet housing. HINT: The jiggle valve may be set within 15
of either side of the prescribed position. Jiggle Valve A51994 7. 8. (a) (b) (c) (d) 9. 10. INSTALL WATER INLET Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) INSTALL WATER INLET PIPE Install a new O-ring to the inlet pipe. Apply soapy water to the O-ring. Connect the inlet pipe to the water inlet. Install the bolt holding the inlet pipe to the cylinder head. Torque: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) ADD ENGINE COOLANT (See page 16-26 ) CHECK FOR ENGINE COOLANT LEAKS (See page 16-20 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2817 16-33 COOLING - RADIATOR ASSY (3MZ-FE) COMPONENTS 12.8 (130, 9) Radiator Support Upper 7.8 (80, 69 in.⋅lbf) 160Q3-03 ×6 Fan Motor Connector Fan Assy w/ Motor Radiator Assy Fan Motor Connector Radiator Support Lower Radiator Hose Inlet Radiator Hose Outlet Oil Cooler Outlet Hose No. 2 Oil Cooler Outlet Hose No. 3 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque A90981 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2819 16-34 COOLING - RADIATOR ASSY (3MZ-FE) Radiator Cap Radiator Tank Upper Lock Plate
O-Ring
O-Ring 8.34 (85, 74 in.⋅lbf) Core Cooler Pipe 14.71 (150, 11)
O-Ring
O-Ring Oil Cooler Assy 8.34 (85, 74 in.⋅lbf) Radiator Tank Lower Radiator Tank Lower N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part A90982 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2820 16-32 COOLING - RADIATOR ASSY (3MZ-FE) RADIATOR ASSY (3MZ-FE) 160Q2-03 ON-VEHICLE CLEANING 1. (a) INSPECT FINS BLOCKAGE If the fins are clogged, wash them with water or a steam cleaner. Dry with compressed air. NOTICE:
If the distance between the steam cleaner and the core is too close, the fins may become damaged. Keep the following injection distance. Standard: A73603

Distance Steam Cleaner Pressures 300 mm (11.81 in.) 2,942 to 4,903 kPa (30 to 50 kgf/cm2, 427 to 711 psi) 500 mm (19.69 in.) 4,903 to 7,845 kPa (50 to 80 kgf/cm2, 711 to 1,138 psi) If the fins are bent, straighten them with a screwdriver or pliers. Never apply water directly onto the electronic components. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2818 16-36 COOLING - RADIATOR ASSY (3MZ-FE) 160Q5-03 OVERHAUL 1. (a) (b) REMOVE DRAIN PLUG Remove the drain plug. Remove the O-ring. 2. Part A Dimension B Claw SST Stopper Bolt Overhaul Handle A87082 Tank Lock Plate SST Stopper Bolt ASSEMBLE SST SST 09230-01010 (a) Install the claw to the overhaul handle, inserting it into the hole in part A as shown in the illustration. (b) While gripping the handle, adjust the stopper bolt so that dimension B is as shown in the illustration. Dimension B: 0.2 to 0.3 mm (0.008 to 0.012 in.) NOTICE: If the stopper bolt is not adjusted, the claw may be damaged. 3. UNCAULK LOCK PLATE Using SST to release the caulking, grip the handle until stopped by the stopper polite uncaulk the lock plate. SST 09230-01010 (09231-01010, 09231-01030) A87097 4. (b) REMOVE RADIATOR TANK UPPER AND TANK LOWER Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a plastic-faced hammer and remove the tank. Remove the O-ring. 5. (a) (b) (c) (d) REMOVE OIL COOLER ASSY Remove the cooler pipe Loosen the 2 nuts and 2 plate washers. Remove the oil cooler Remove the 2 O-rings from the oil cooler. (a) Tap A93953 A94326 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2822 16-37 COOLING O-Ring Cooler Pipe Oil Cooler Assy Plate Washer Nut Radiator Tank Lower O-Ring 6. (a) (b) (c) (d) (e) 30 - RADIATOR ASSY (3MZ-FE) INSTALL OIL COOLER ASSY Clean the O-ring contact surface of the lower tank and oil cooler. Install 2 new O-rings to the oil cooler. Install the oil cooler to the lower tank. Install the plate washer and nut. Torque: 8.34 N·m (85 kgf·cm, 74 in.·lbf) Install the pipe. Torque: 14.71 N·m (150 kgf·cm, 11 ft·lbf) 26.9 mm (1.059 in.) A94637 Lock Plate Lock Plate Core A87087 7. INSPECT LOCK PLATE FOR DAMAGE Inspect the lock plate for damage. HINT:
If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. Therefore, first correct any deformation with pliers or similar object.
Water leakage will result if the bottom of the lock plate groove is damaged or dented. Repair or replace if necessary. NOTICE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced. 8. (a)  Normal X Twisted O-Ring INSTALL RADIATOR TANK UPPER AND TANK LOWER After checking that there are no foreign objects in the lock plate groove, install a new O-ring without twisting it. HINT: When cleaning the lock plate groove, lightly rub it with sandpaper without scratching it. X Twisted A87088 CORRECT INCORRECT Tap Tank (b) (c) Install the tank without damaging the O-ring. Tap the lock plate with a plastic-faced hammer so that there is no gap between the lock plate and the tank. Lock Plate A87089 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2823 16-38 COOLING 9. Part A (a) Dimension B Punch Assembly 5 SST (b) Stopper Bolt Overhaul Handle 3 10. (a) 7 2 4 RADIATOR ASSY (3MZ-FE) ASSEMBLE SST SST 09230-01010, 09231-14010 Install the punch assembly to the overhaul handle, inserting it into the hole in part A as shown in the illustration. While gripping the handle, adjust the stopper bolt so that dimension B is as shown in the illustration. Dimension B: 8.4 mm (0.331 in.) A87090 1 6 - 8 CAULK LOCK PLATE Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, fully caulk the lock plate by gripping the handle until stopped by the stopper plate. SST 09230-01010 SST Stopper Bolt Tank Lock Plate A93955 HINT: Rib
Do not tap the areas protruding around the pipes, brackets or tank ribs.
The points shown in the illustration and oil cooler near here (A/T) cannot be tapped with the SST. Use pliers or similar objects and be careful not to damage the core plates. Bracket A87103 A93956 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2824 16-39 COOLING - RADIATOR ASSY (3MZ-FE) (b) Check the lock plate height (H) after completing the caulking. Plate height (H): 7.40 to 7.80 mm (0.2913 to 0.3071 in.) If not within the specified height, adjust the stopper bolt of the handle again and caulk again. H A87105 11. (a) (b) INSTALL DRAIN PLUG Install a new O-ring to the drain plug. Install the drain plug. 12. (a) SST (b) (c) INSPECT FOR WATER LEAKS Plug the inlet and outlet pipes of the radiator with SST. SST 09230-01010 Using a radiator cap tester, apply pressure to the radiator. Test pressure: 177 kPa (1.8 kgf/cm2, 26 psi) Submerge the radiator in water. A93957 Tank Lock Plate (d) Inspect for leaks. HINT: On radiators with resin tanks, there is a clearance between the tank and lock plate where a minute amount of air will remain, giving the appearance of an air leak when the radiator is submerged in water. Therefore, before doing the water leak test, first swish the radiator in water until all air bubbles disappear. O-Ring A87096 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2825 16-35 COOLING - RADIATOR ASSY (3MZ-FE) 160UB-01 REPLACEMENT HINT: The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. 1. DRAIN ENGINE COOLANT (See page 16-26 ) 2. DISCONNECT RADIATOR RESERVE TANK HOSE OR PIPE 3. DISCONNECT RADIATOR HOSE INLET 4. DISCONNECT RADIATOR HOSE OUTLET 5. DISCONNECT OIL COOLER OUTLET HOSE NO. 2 6. DISCONNECT OIL COOLER OUTLET HOSE NO. 3 7. REMOVE RADIATOR SUPPORT UPPER (a) Remove the radiator support upper with the 2 bolts. 8. REMOVE RADIATOR ASSY (a) Disconnect the fan motor connector. (b) Disconnect the ECT switch No. 1 connector. (c) Remove the radiator from the body. 9. REMOVE RADIATOR SUPPORT LOWER 10. REMOVE FAN ASSY W/MOTOR (a) Remove the 6 bolts and fan from the radiator. 11. INSTALL FAN ASSY W/MOTOR (a) Install the fan w/ to the radiator with the 6 bolts. Torque: 7.8 N·m (80 kgf·cm, 69 in.⋅lbf) 12. INSTALL RADIATOR ASSY (a) Install the radiator to the body. (b) Connect the ECT switch No. 1 connector. (c) Connect the fan motor connector. 13. INSTALL RADIATOR SUPPORT UPPER (a) Install the radiator support upper with the 2 bolts. Torque: 12.8 N·m (130 kgf·cm, 9 ft·lbf) 14. ADD ENGINE COOLANT (See page 16-26 ) 15. CHECK FOR ENGINE COOLANT LEAKS (See page 16-20 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2821 17-1 LUBRICATION - LUBRICATION SYSTEM (2AZ-FE) LUBRICATION SYSTEM (2AZ-FE) 1701Z-09 ON-VEHICLE INSPECTION 1. (a) CHECK ENGINE OIL LEVEL Warm up the engine, stop the engine and wait 5 minutes. The oil level should be between the dipstick’s low level mark and full level mark. If the oil level is low, check for leakage and add oil up to the full level mark. NOTICE: Do not fill with engine oil above the full level mark. 2. (a) Recommended Viscosity (SAE) 5W-30
C -29 -18
F -20 0 -7 20 4 16 40 60 27 38 80 100 A66623 CHECK ENGINE OIL QUALITY Check the oil for deterioration, entry of water, discoloring or thinning. If the quality is visibly poor, replace the oil. Oil grade: API grade SL, Energy-Conserving or ILSAC, multigrade engine oil is recommended. SAE 5W-30 is the best choice for your vehicle, for good fuel economy, and good starting in cold weather. 3. REMOVE OIL PRESSURE SWITCH ASSY (a) Disconnect the oil pressure switch connector. (b) Remove the oil pressure switch. 4. (a) INSTALL OIL PRESSURE GAUGE Install the oil pressure gauge. Oil Pressure Switch B11410 Oil Pressure Gauge B11411 5. WARM UP ENGINE 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2826 17-2 LUBRICATION 6. LUBRICATION SYSTEM (2AZ-FE) CHECK OIL PRESSURE Specification: Item Oil Pressure Idle 29 kPa (0.3 kgf/cm2, 4.3 psi) or more 3,000 rpm 245 to 539 kPa (2.5 to 5.5 kgf/cm2, 36 to 78 psi) or more INSTALL OIL PRESSURE SWITCH Remove the oil pressure gauge. Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent (c) Install the oil pressure switch. Torque: 15 N⋅m (153 kgf⋅cm, 11 ft⋅lbf) NOTICE: A50082 Do not start the engine for at least 1 hour after installation of the switch. (d) Connect the oil pressure switch connector. START ENGINE AND CHECK FOR ENGINE OIL LEAKS Adhesive 8. - 7. (a) (b) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2827 17-3 LUBRICATION - OIL FILTER SUB-ASSY (2AZ-FE) OIL FILTER SUB-ASSY (2AZ-FE) 1701X-10 REPLACEMENT CAUTION:
Prolonged and repeated contact of mineral oil with the skin will deplete the skin’s natural fats, leading to dryness, irritation and dermatitis. In addition, used engine oil contains harmful contaminants which may cause skin cancer.
Wear protective clothing and gloves to minimize the length and frequency of contact between the skin and used oil. If contact does occur, wash your skin thoroughly with soap and water or waterless hand cleaner. Do not use gasoline, thinners or solvents to wash the skin.
In order to preserve the environment, dispose of used oil and used oil filters only at designated disposal site. 1. DRAIN ENGINE OIL (a) Remove the oil filler cap. (b) Remove the oil drain plug and drain the oil into a container. 2. (a) 3. (a) (b) SST REMOVE OIL FILTER SUB-ASSY Using SST, remove the oil filter. SST 09228-06501 INSTALL OIL FILTER SUB-ASSY Check and clean the oil filter installation surface. Apply clean engine oil to the gasket of a new oil filter. B11412 (c) (d) SST B11413 4. (a) Lightly screw the oil filter into place by hand,Tighten it until the gasket contacts the seat. Using SST, tighten the oil filter. SST 09228-06501 (1) Depending on the work space available, choose from the following.
If enough space is available, use SST to tighten the oil filter. Torque: 17.5 N⋅m (178 kgf⋅cm, 13 ft⋅lbf)
If not enough space is available to use SST, tighten the oil filter a 3/4 turn by hand. ADD ENGINE OIL Clean and install the oil drain plug with a new gasket. Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2828 17-4 LUBRICATION (b) - OIL FILTER SUB-ASSY (2AZ-FE) Fill with fresh engine oil. Specification: Item Capacity Drain and refill w/ oil filter change 3.8 liters (4.0 US qts, 3.3 lmp. qts) Drain and refill w/o oil filter change 3.6 liters (3.8 US qts, 3.2 lmp. qts) Dry fill (c) 5. 4.5 liters (4.8 US qts, 4.0 lmp. qts) Install the oil filler cap. CHECK FOR ENGINE OIL LEAKS 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2829 17-19 LUBRICATION - LUBRICATION SYSTEM (3MZ-FE) LUBRICATION SYSTEM (3MZ-FE) 17020-12 ON-VEHICLE INSPECTION 1. (a) CHECK ENGINE OIL LEVEL Warm up the engine, stop the engine and wait for 5 minutes. The oil level should be between the dipstick’s low level mark and full level mark. If the oil level is low, check for leakage and add oil up to the full level mark. NOTICE: Do not fill with engine oil above the full level mark. 2. (a) Recommended Viscosity (SAE) 5W-30
C -29 -18
F -20 0 -7 20 4 16 40 60 27 38 80 100 A66623 CHECK ENGINE OIL QUALITY Check the oil for deterioration, entry of water, discoloring or thinning. If the quality is visibly poor, replace the oil. Oil grade: API grade SL, Energy-Conserving or ILSAC, multigrade engine oil is recommended. SAE 5W-30 is the best choice for your vehicle, for good fuel economy, and good starting in cold weather. 3. REMOVE OIL PRESSURE SWITCH ASSY (a) Disconnect the oil pressure switch connector. (b) Using a 24 mm deep socket wrench, remove the oil pressure switch. 4. (a) INSTALL OIL PRESSURE GAUGE Install the oil pressure gauge. Oil Pressure Switch A52637 Oil Pressure Gauge B04132 5. WARM UP ENGINE 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2844 17-20 LUBRICATION 6. LUBRICATION SYSTEM (3MZ-FE) CHECK OIL PRESSURE Specification: Item Oil Pressure Idle 29 kPa (0.3 kgf/cm2, 4.3 psi) or more 3,000 rpm 245 to 539 kPa (2.5 to 5.5 kgf/cm2, 36 to 78 psi) or more INSTALL OIL PRESSURE SWITCH Remove the oil pressure gauge. Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent (c) Using a 24 mm deep socket wrench, install the oil pressure switch. Torque: 15 N⋅m (152 kgf⋅cm, 11 ft⋅lbf) A50082 NOTICE: Do not start the engine for at least 1 hour after installation of the switch. (d) Connect the oil pressure switch connector. START ENGINE AND CHECK FOR ENGINE OIL LEAKS Adhesive 8. - 7. (a) (b) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2845 17-23 LUBRICATION - OIL PUMP ASSY (3MZ-FE) OIL PUMP ASSY (3MZ-FE) 170HG-04 COMPONENTS 8.0 (82, 71 in.⋅lbf) 8.0 (82, 71 in.⋅lbf) Vane Pump Assy 43 (438, 32) V Belt No. 1 V-Bank Cover Sub-assy 32 (326, 24) Pump Bracket Vane Pump V Belt Front Apron Seal RH 43 (438, 32) Generator Bracket No. 2 18 (184, 13) 10 (102, 7.0) 8.0 (82, 71 in.⋅lbf) Generator Assy Fan Belt Adjusting Bar Bracket 26 (265, 19) 25 (255, 18) Compressor and Magnetic Clutch 25 (255, 18) Compressor Mounting Bracket No. 1 Exhaust Pipe Support Bracket No. 1 Exhaust Pipe Sub-assy
Gasket Front No. 3 25 (255, 18) Engine Under Cover No. 1 56 (571, 41) 21 (214, 15)
Gasket
Gasket 48 (490, 35) 56 (571, 41) Exhaust Pipe Assy Front N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque 56 (571, 41)
Non-reusable A92869 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2848 17-24 LUBRICATION 64 (653, 47) - OIL PUMP ASSY (3MZ-FE) 23 (235, 17) Engine Moving Control Rod Engine Mountin Stay No. 2 RH 64 (653, 47) 95 (969, 70) 87 (887, 64) 95 (969, 70) 75 (765, 55) Front Frame Assy 87 (887, 64) 52 (530, 38) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque A90976 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2849 17-25 LUBRICATION - OIL PUMP ASSY (3MZ-FE) Engine Wire Protector Bushing Collar Timing Belt No. 3 Cover Camshaft Timing Pulley Gasket 125 (1275, 92) 9.0 (92, 80 in.⋅lbf) ×6 Timing Belt Idler Sub-assy No. 2 43 (438, 32) 125 (1275, 92) Timing Belt No. 2 Cover Engine Wire 9.0 (92, 80 in.⋅lbf) Engine Mounting Bracket RH Timing Belt Idler Sub-assy No. 1 28 (286, 21) 34 (347, 25) Crankshaft Pulley Crankshaft Timing Pulley Timing Belt Timing Belt Guide No. 2 220 (2250, 162) ×4 Timing Belt No. 1 Cover Timing Belt Tensioner Assy 27 (275, 20) Timing Belt Plate 9.0 (92, 80 in.⋅lbf) 8.0 (82, 71 in.⋅lbf) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque A90975 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2850 17-26 LUBRICATION - OIL PUMP ASSY (3MZ-FE) Oil Pump Assy 43 (438, 32) Compressor Mounting Bracket No. 1 20 (204, 15)
O-Ring 8.0 (82, 71 in.⋅lbf) Crankshaft Position Sensor 25 (255, 18) 8.0 (82, 71 in.⋅lbf)
Oil Pump Seal 20 (204, 15) Oil Pan Sub-assy 20 (204, 15) 8.0 (82, 71 in.⋅lbf) 20 (204, 15) 20 (204, 15) 8.0 (82, 71 in.⋅lbf) 20 (204, 15)
Gasket 20 (204, 15) 37 (379, 27) Oil Strainer Sub-assy 8.0 (82, 71 in.⋅lbf) 8.0 (82, 71 in.⋅lbf)
Gasket 8.0 (82, 71 in.⋅lbf) 45 (459, 33) Oil Pan Drain Plug 8.0 (82, 71 in.⋅lbf) N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part Oil Pan Sub-assy No. 2 A92865 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2851 17-27 LUBRICATION - OIL PUMP ASSY (3MZ-FE) Oil Pump Cover 10 (102, 7) x 10 Driven Rotor Drive Rotor Oil Pump Assy Oil Pump Relief Valve Oil Pump Relief Valve Spring Oil Pump Relief Valve Plug 49 (500, 36) N·m (kgf·cm, ft·lbf) : Specified torque A80109 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2852 17-34 LUBRICATION - OIL PUMP ASSY (3MZ-FE) 170JK-02 OVERHAUL 1. (a) REMOVE OIL PUMP RELIEF VALVE Remove the plug, spring and relief valve. 2. (a) (b) INSPECT OIL PUMP RELIEF VALVE Apply a light coat of engine oil to the oil pump relief valve Check that the valve falls smoothly into the valve hole by its own weight. If it does not, replace the relief valve. If necessary, replace the oil pump assy. A33002 3. (a) 4. (a) INSPECT OIL PUMP COVER Remove the 10 screws and the oil pump cover. INSPECT OIL PUMP ROTOR Apply a light coat of engine oil to the oil pump rotor set and place them into the oil pump body. Check that the rotors revolve smoothly. If the result is not as specified, replace the oil pump assy. (b) Check the tip clearance. (1) Using a feeler gauge, measure the clearance between the drive and driven rotor tips. Standard: 0.060 to 0.180 mm (0.0024 to 0.0071 in.) Maximum: 0.30 mm (0.0118 in.) If the tip clearance is greater than the maximum, replace the oil pump assy. A33003 (c) Check the body clearance between the driven rotor and pump body. (1) Using a feeler gauge, measure the clearance between the driven rotor and body. Standard: 0.250 to 0.325 mm (0.0098 to 0.0128 in.) Maximum: 0.50 mm (0.0197 in.) If the body clearance is greater than the maximum, replace the oil pump assy. A33004 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2859 17-35 LUBRICATION - OIL PUMP ASSY (3MZ-FE) (d) Check the side clearance. (1) Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight edge. Standard: 0.030 to 0.090 mm (0.0012 to 0.0035 in.) Maximum: 0.15 mm (0.0059 in.) If the side clearance is greater than the maximum, replace the oil pump assy. A33005 5. REMOVE OIL PUMP ROTOR Marks 6. (a) INSTALL OIL PUMP ROTOR Apply a light coat of engine oil to the oil pump gear set and place it into the pump body with the marks facing the pump body cover side. A51993 7. (a) 8. (a) (b) INSTALL OIL PUMP COVER Install the oil pump cover with the 10 screws. Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) INSTALL OIL PUMP RELIEF VALVE Apply a light coat of engine oil to the relief valve, and insert the relief valve and spring into the pump body hole. Install the plug. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2860 17-28 LUBRICATION - OIL PUMP ASSY (3MZ-FE) 170JJ-03 REPLACEMENT 1. 2. 3. 4. (a) 5. 6. 7. 8. 9. 10. 11. REMOVE FRONT WHEEL REMOVE ENGINE UNDER COVER NO.1 REMOVE FRONT FENDER APRON SEAL RH DRAIN ENGINE OIL Install a new gasket after draining engine oil. Torque: 45 N⋅m (459 kgf⋅cm, 33 ft⋅lbf) REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14-125 ) REMOVE VANE PUMP V BELT (See page 14-125 ) REMOVE ENGINE MOVING CONTROL ROD (See page 14-149 ) REMOVE ENGINE MOUNTING STAY NO.2 RH REMOVE GENERATOR BRACKET NO.2 REMOVE EXHAUST PIPE SUPPORT BRACKET NO.1 REMOVE EXHAUST PIPE ASSY FRONT (See page 15-5 ) 12. (a) SEPARATE COMPRESSOR AND MAGNETIC CLUTCH Remove the 2 bolts, nut and drive belt adjusting bar bracket. (b) Remove the 2 nuts and the generator bracket adjusting bar together with the wire harness clamp bracket. Disconnect the compressor, magnetic clutch connector and wire harness clamp. E34923 (c) A36746 13. (a) REMOVE COMPRESSOR MOUNTING BRACKET NO.1 Remove the 2 bolts and mounting bracket. A36749 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2853 17-29 LUBRICATION 14. 15. - OIL PUMP ASSY (3MZ-FE) REMOVE OIL LEVEL GAGE SUB-ASSY REMOVE OIL LEVEL GAGE GUIDE 16. (a) REMOVE ENGINE MOUNTING Remove the 4 nuts and bolt, and disconnect the engine mounting insulator FR. NOTICE: Do not remove the engine mounting insulator. A93314 (b) Remove the 4 bolts, nut and engine mounting bracket RH. A52015 17. 18. 19. 20. 21. 22. (a) 23. 24. 25. 26. 27. 28. (a) REMOVE CRANKSHAFT PULLEY (See page 14-173 ) REMOVE TIMING BELT NO.1 COVER (See page 14-173 ) REMOVE TIMING BELT NO.2 COVER (See page 14-173 ) REMOVE TIMING BELT GUIDE NO.2 REMOVE TIMING BELT (See page 14-173 ) REMOVE TIMING BELT IDLER SUB-ASSY NO.1 Using a socket hexagon wrench 10, remove the pivot bolt, timing belt idler No. 1 and plate washer. REMOVE TIMING BELT IDLER SUB-ASSY NO.2 REMOVE CAMSHAFT TIMING PULLEY (See page 14-173 ) REMOVE TIMING BELT NO.3 COVER (See page 14-173 ) REMOVE CRANKSHAFT TIMING PULLEY (See page 14-173 ) REMOVE OIL PAN SUB-ASSY NO.2 (See page 14-173 ) REMOVE OIL STRAINER SUB-ASSY Remove the bolt and 2 nuts, then remove the oil strainer and the gasket. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2854 17-30 LUBRICATION 29. (a) - OIL PUMP ASSY (3MZ-FE) REMOVE OIL PAN SUB-ASSY Uniformly loosen and remove the 15 bolts and 2 nuts, as shown in the illustration. B04136 (b) Using a screwdriver, remove the oil pan by prying between the cylinder block and the oil pan. NOTICE: Be careful not to damage the contact surfaces of the oil pan and cylinder block. B04137 30. (a) (b) (c) REMOVE OIL PUMP ASSY Remove the 9 bolts. Using a screwdriver, remove the oil pump by prying between the oil pump and the main bearing cap. Remove the O-ring. A51990 31. (a) SST A62376 INSTALL OIL PUMP ASSY Using SST and a hammer, install a new oil seal. Tap the surface of the SST with the hammer until the oil seal’s surface is flush with the oil pump body edge. SST 09223-00010 NOTICE:
Be careful not to tap the oil seal at an angle.
Keep the gap between the oil pump body edge and the oil seal free from contamination. (b) Apply a small amount of MP grease to the oil seal lip. (c) Remove any old seal packing material from the contact surface. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2855 17-31 LUBRICATION (d) - OIL PUMP ASSY (3MZ-FE) Apply a light coat of engine oil to a new O-ring and place it on the cylinder block. A36784 (e) Apply a continuous bead of seal packing (seal width: 2 to 3 mm (0.08 to 0.12 in.)) as shown in the illustration. Seal packing: Part No. 08226-00080 or equivalent NOTICE:
Remove any oil from contact surface.
Apply seal packing to the inner side of the bolt holes.
Install the oil pump within 3 minutes after applying seal packing.
Do not expose the seal to engine oil for at least 2 hours after installing the oil pump. B A C Seal Packing Seal Packing A Seal Width 2 to 3 mm B C A90857 (f) Align the key of the oil pump drive gear with the key way located on the crankshaft, and slide the oil pump into place. (g) Install the oil pump by tightening the 9 bolts uniformly. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) for bolt A 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) for bolt B 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) for bolt C A94216 A B C A A B A A A A51990 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2856 17-32 LUBRICATION - OIL PUMP ASSY (3MZ-FE) 32. 33. (a) INSTALL OIL PAN SUB-ASSY (See page 14-173 ) INSTALL OIL STRAINER SUB-ASSY Install a new gasket and the oil strainer with the bolt and 2 nuts. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 34. INSTALL OIL PAN SUB-ASSY NO.2 (See page 14-173 ) 35. INSTALL CRANKSHAFT POSITION SENSOR Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 36. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (See page 14-149 ) 37. INSTALL OIL LEVEL GAGE GUIDE 38. INSTALL OIL LEVEL GAGE SUB-ASSY 39. INSTALL TIMING BELT IDLER SUB-ASSY NO.1 (a) Using a socket hexagon wrench 10, install the plate washer and timing belt idler No. 1 with the pivot bolt. Torque: 34 N⋅m (347 kgf⋅cm, 25 ft⋅lbf) 40. INSTALL TIMING BELT IDLER SUB-ASSY NO.2 Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) 41. INSTALL TIMING BELT NO.3 COVER (See page 14-173 ) 42. INSTALL CAMSHAFT TIMING PULLEY (See page 14-173 ) 43. INSTALL TIMING BELT (See page 14-173 ) 44. INSTALL CHAIN TENSIONER ASSY NO.1 (See page 14-173 ) 45. INSTALL TIMING BELT GUIDE NO.2 (See page 14-41 ) 46. INSTALL TIMING BELT NO.2 COVER (a) Visually check for cracks and breaks on the gasket of the timing belt cover. If there is a trace that water is entering at the visual check, replace the timing belt cover. (b) Install the timing belt cover. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) 47. INSTALL TIMING BELT NO.1 COVER (See page 14-173 ) A C 48. (a) INSTALL ENGINE MOUNTING Install the engine mounting bracket RH with the 4 bolts and nut. Torque: 54 N⋅m (551 kgf⋅cm, 40 ft⋅lbf) for bolt A 54 N⋅m (551 kgf⋅cm, 40 ft⋅lbf) for nut B 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) for bolt C (b) Install the engine mounting insulator RH with the 4 nuts. Torque: 95 N⋅m (969 kgf⋅cm, 70 ft⋅lbf) for nut A 87 N⋅m (887 kgf⋅cm, 64 ft⋅lbf) for nut B B A A A52939 A B HINT: First, loosely install the nut labeled (A) with your hand. Then use a wrench to install the 3 nuts labeled (B). Finally, use a wrench to tighten nut (A). B B A52028 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2857 17-33 LUBRICATION (c) A - OIL PUMP ASSY (3MZ-FE) Install the engine mounting insulator FR with the nut. Torque: 87 N⋅m (887 kgf⋅cm, 64 ft⋅lbf) for nut A 52 N⋅m (530 kgf⋅cm, 38 ft⋅lbf) for nut B B B B A93314 49. INSTALL CRANKSHAFT PULLEY (See page 14-173 ) 50. INSTALL GENERATOR BRACKET NO.1 (a) Visually check for cracks and breaks on the gasket of the timing belt cover. If there is a trace that water is entering at the visual check, replace the timing belt cover. (b) Install the timing belt cover. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) 51. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (a) Install the compressor with the 3 bolts. Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf) (b) Install the adjusting bar bracket with the bolt and nut. Torque:25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf) for bolt 52. INSTALL ENGINE MOUNTING STAY NO.2 RH Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) 53. (a) B A A 54. 55. 56. 57. A INSTALL ENGINE MOVING CONTROL ROD Install the control rod and bracket with the 4 bolts. Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) for bolt A 23 N⋅m (235 kgf⋅cm, 17 ft⋅lbf) for bolt B A90268 INSTALL VANE PUMP V BELT (See page 14-125 ) INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14-125 ) ADD ENGINE OIL CHECK FOR ENGINE OIL LEAKS 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2858 17-21 LUBRICATION - OIL FILTER SUB-ASSY (3MZ-FE) OIL FILTER SUB-ASSY (3MZ-FE) 1701H-10 REPLACEMENT CAUTION:
Prolonged and repeated contact of mineral oil with the skin will deplete the skin’s natural fats, leading to dryness, irritation and dermatitis. In addition, used engine oil contains harmful contaminants which may cause skin cancer.
Wear protective clothing and gloves to minimize the length and frequency of contact between the skin and used oil. If contact does occur, wash your skin thoroughly with soap and water or waterless hand cleaner. Do not use gasoline, thinners or solvents to wash the skin.
In order to preserve the environment, dispose of used oil and used oil filters only at designated disposal site. 1. REMOVE ENGINE UNDER COVER NO.1 2. DRAIN ENGINE OIL (a) Remove the oil filler cap. (b) Remove the oil drain plug and drain the oil into a container. 3. (a) REMOVE OIL FILTER SUB-ASSY Using SST, remove the oil filter. SST 09228-07501 4. (a) (b) (c) INSTALL OIL FILTER SUB-ASSY Check and clean the oil filter installation surface. Apply clean engine oil to the gasket of a new oil filter. Lightly screw the oil filter into place by hand, Tighten it until the gasket contacts the seat. Using SST, tighten the oil filter. SST 09228-06501 (1) Depending on the work space available, choose from the following.
If enough space is available, use SST to tighten the oil filter. Torque: 17.5 N⋅m (178 kgf⋅cm, 13 ft⋅lbf)
If not enough space is available to use SST, tighten the oil filter a 3/4 turn by hand. SST A51980 (d) 3/4 turn A52007 5. (a) ADD ENGINE OIL Clean and install the oil drain plug with a new gasket. Torque: 45 N⋅m (459 kgf⋅cm, 33 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2846 17-22 LUBRICATION (b) - OIL FILTER SUB-ASSY (3MZ-FE) Fill with fresh engine oil. Specification: Item Capacity Drain and refill w/ oil filter change 4.7 liters (5.0 US qts, 4.1 lmp. qts) Drain and refill w/o oil filter change 4.5 liters (4.8 US qts, 4.0 lmp. qts) Dry fill (c) 6. 7. 5.5 liters (5.8 US qts, 4.8 lmp. qts) Install the oil filler cap. CHECK FOR ENGINE OIL LEAKS INSTALL ENGINE UNDER COVER NO.1 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2847 17-5 LUBRICATION - OIL PUMP ASSY (2AZ-FE) OIL PUMP ASSY (2AZ-FE) 170JG-02 COMPONENTS 7.0 (71, 62 in.⋅lbf) Engine Cover Sub-assy No. 1 Fan and Generator V Belt 43 (438, 31) Vane Pump Assy 52 (530, 38) 21 (214, 15) Generator Assy Engine Under Cover No. 1 Front Fender Apron Seal RH  Exhaust Pipe Gasket 56 (571, 41)  Exhaust Pipe Assy Front N⋅m (kgf⋅cm, ft⋅lbf) Exhaust Pipe Gasket 48 (489, 35) : Specified torque  Non-reusable part A90974 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2830 17-6 LUBRICATION - OIL PUMP ASSY (2AZ-FE) 9.0 (92, 80 in.⋅lbf) Ignition Coil Assy Engine Wire Ventilation Hose No. 1 Ventilation Hose No. 2 9.0 (92, 80 in.⋅lbf) Chain Tensioner Assy No. 1 11 (112, 8.0) 11 (112, 8.0) ×2 ×8 Timing Chain or Belt Cover Sub-assy 9.0 (92, 80 in.⋅lbf) Cylinder Head Cover Sub-assy  Gasket Gasket V-Ribbed Belt Tensioner Assy 43 (438, 32) ×8 52 (530, 38) 60 (612, 44) 9.0 (92, 80 in.⋅lbf)  Oil Seal ×2 Crankshaft Position Sensor 25 (255, 18) Chain Sub-assy Crankshaft Pulley 180 (1835, 133) Crankshaft Timing Sprocket Chain Tensioner Slipper 19 (194, 14) TIming Chain Guide 9.0 (92, 80 in.⋅lbf) Chain Vibration Damper No. 1 ×2 9.0 (92, 80 in.⋅lbf) Oil Pan Sub-assy  Gasket Crankshaft Position Sensor Plate No. 1 Spring × 12 No. 2 Chain Sub-assy Oil Pump Drive Shaft Sprocket N⋅m (kgf⋅cm, ft⋅lbf)  Non-reusable ×2 9.0 (92, 80 in.⋅lbf) Chin Tensioner Plate 12 (122, 9.0) Oil Pump Assy 19 (194, 14) 30 (306, 22) Oil Pump Driven Shaft Sprocket : Specified torque A90972 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2831 17-7 LUBRICATION - OIL PUMP ASSY (2AZ-FE) Engine Moving Control Rod w/ Bracket 64 (653, 47) Engine Moving Bracket RH Engine Mounting Bracket No. 2 RH 52 (530, 38) Engine Mounting Stay No. 2 RH 95 (969, 70) 54 (551, 40) Engine Mounting Bracket (4WD) ×3 34 (347, 25) 64 (653, 47) 75 (765, 55) 64 (653, 47) 95 (696, 70) 64 (653, 47) 87 (897, 64) Front Frame Assy N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque A90973 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2832 17-8 LUBRICATION - OIL PUMP ASSY (2AZ-FE) Oil Pump Strainer Set 9.0 (92, 80 in.⋅lbf) 9.0 (92, 80 in.⋅lbf)  Gasket Oil Pump Relief Valve Plug Oil Pump Relief Valve Spring Drive Rotor Oil Pump Cover Driven Rotor Oil Pump Relief Valve Oil Pump Assy N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque  Non-reusable part A87112 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2833 17-16 LUBRICATION - OIL PUMP ASSY (2AZ-FE) 170JI-03 OVERHAUL 1. (a) REMOVE OIL PUMP STRAINER SET Remove the 2 nuts and oil pump strainer. 2. (a) (b) REMOVE OIL PUMP RELIEF VALVE Using a socket wrench (27 mm), remove the plug. Remove the valve spring and relief valve. 3. (a) REMOVE OIL PUMP COVER Remove the 5 bolts and oil pump cover. B11430 A52074 B11431 4. (a) INSPECT OIL PUMP RELIEF VALVE Check the relief valve. (1) Coat the valve with engine oil and check that the valve falls smoothly into the valve hole by its own weight. If it does not, replace the relief valve. If necessary, replace the oil pump assy. B11419 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2841 17-17 LUBRICATION - OIL PUMP ASSY (2AZ-FE) 5. (a) Driven Rotor Drive Rotor B11420 INSPECT OIL PUMP ROTOR Check the side clearance. (1) Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight edge. Standard: 0.030 to 0.085 mm (0.0012 to 0.0033 in.) Maximum: 0.16 mm (0.0063 in.) If the side clearance is greater than the maximum, replace the oil pump assy. (b) Driven Rotor Groove Check the tip clearance. (1) Using a feeler gauge, measure the clearance between the driven rotor tips. Standard: 0.080 to 0.160 mm (0.0031 to 0.0063 in.) Maximum: 0.35 mm (0.0138 in.) If the tip clearance is greater than the maximum, replace the oil pump assy. Drive Tip B11421 (c) Check the body clearance. (1) Using a feeler gauge, measure the clearance between the driven rotor and pump body. Standard: 0.100 to 0.170 mm (0.0039 to 0.0067 in.) Maximum: 0325 mm (0.01280 in.) (d) Remove the oil pump rotors. If the body clearance is greater than the maximum, replace the oil pump assy. B11422 6. REMOVE OIL PUMP ROTOR 7. (a) (b) Marks INSTALL OIL PUMP ROTOR Coat the drive rotor and driven rotor with engine oil. Place the drive and driven rotors into the pump body with the marks facing the pump body cover side. B11423 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2842 17-18 LUBRICATION - OIL PUMP ASSY (2AZ-FE) 8. (a) INSTALL OIL PUMP COVER Install the pump body cover with the 5 bolts. Torque: 8.8 N⋅m (90 kgf⋅cm, 79 in.⋅lbf) 9. (a) (b) (c) INSTALL OIL PUMP RELIEF VALVE Coat the relief valve with engine oil. Insert the relief valve and spring into the pump body hole. Using a socket wrench (27 mm), install the plug. 10. (a) (b) INSTALL OIL PUMP STRAINER SET Place a new gasket on the oil pump. Install the oil strainer with the 2 nuts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) B11431 A52074 B11430 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2843 17-9 LUBRICATION - OIL PUMP ASSY (2AZ-FE) 170JH-03 REPLACEMENT 1. 2. 3. 4. (a) REMOVE FRONT WHEEL RH REMOVE ENGINE UNDER COVER NO.1 REMOVE FRONT FENDER APRON SEAL RH DRAIN ENGINE OIL Install a new gasket and the drain plug after draining engine oil. Torque: 25 N⋅m (255 kgf⋅cm, 18 ft⋅lbf) 5. REMOVE EXHAUST PIPE ASSY FRONT 6. REMOVE ENGINE MOVING CONTROL ROD W/BRACKET (See page 14-24 ) 7. REMOVE ENGINE MOUNTING STAY NO.2 RH (See page 14-24 ) 8. REMOVE ENGINE MOUNTING BRACKET NO.2 RH (See page 14-24 ) 9. REMOVE FAN AND GENERATOR V BELT (See page 14-5 ) 10. REMOVE ENGINE COVER SUB-ASSY NO.1 11. DISCONNECT ENGINE WIRE 12. REMOVE GENERATOR ASSY 13. REMOVE VANE PUMP ASSY (See page 51-8 ) NOTICE: Do not disconnect the hose. 14. REMOVE IGNITION COIL ASSY 15. DISCONNECT VENTILATION HOSE 16. DISCONNECT VENTILATION HOSE NO.2 17. REMOVE CYLINDER HEAD COVER SUB-ASSY (See page 14-41 ) 18. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See page 14-6 ) 19. REMOVE CRANKSHAFT PULLEY (See page 14-41 ) 20. REMOVE CRANKSHAFT POSITION SENSOR (See page 14-41 ) 21. (a) REMOVE OIL PAN SUB-ASSY Remove the 12 bolts and 2 nuts. A64641 (b) Insert the blade of SST between the crankcase and oil pan. Cut through the sealer and remove the oil pan. SST 09032-00100 NOTICE: Be careful not to damage the contact surface of the cylinder block and oil pan. A00019 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2834 17-10 LUBRICATION 22. 23. - OIL PUMP ASSY (2AZ-FE) REMOVE CHAIN TENSIONER ASSY NO.1 (See page 14-41 ) REMOVE V-RIBBED BELT TENSIONER ASSY (See page 14-24 ) Engine Hanger No.1 24. Engine Hanger No.2 INSTALL ENGINE HANGER NO.1 A52507 25. REMOVE ENGINE MOUNTING INSULATOR (a) Attach the engine chain hoist to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part. (b) Remove the bolt and disconnect the engine mounting insulator FR. A52441 (c) Remove the bolt and disconnect the steering gear return hose clamp from the frame. (d) Remove the 4 nuts from the engine mounting insulator RH. Raise the engine and remove the engine mounting insulator RH. A59901 (e) A59900 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2835 17-1 1 LUBRICATION 26. (a) - OIL PUMP ASSY (2AZ-FE) REMOVE ENGINE MOUNTING BRACKET RH Remove the 3 bolts and engine mounting bracket. A52481 27. 28. 29. 30. 31. 32. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSY (See page 14-41 ) REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1 REMOVE CHAIN TENSIONER SLIPPER (See page 14-68 ) REMOVE CHAIN VIBRATION DAMPER NO.1 (See page 14-68 ) REMOVE CHAIN SUB-ASSY (See page 14-68 ) REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET 90 33. (a) REMOVE NO.2 CHAIN SUB-ASSY Turn the crankshaft counterclockwise 90, and align the adjusting hole of the oil pump drive sprocket gear with the groove of the oil pump. (b) Insert a bar (φ 4.0 mm (0.16 in.)) into the adjusting hole of the oil pump drive sprocket to temporarily lock the sprocket in position. Remove the nut. Groove A52508 Groove A52509 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2836 17-12 LUBRICATION - OIL PUMP ASSY (2AZ-FE) (c) (d) Remove the bolt, chain tensioner plate and spring. Remove the chain tensioner, oil pump drive sprocket and chain. 34. (a) REMOVE OIL PUMP ASSY Remove the 3 bolts, oil pump and gasket. B11415 A32684 35. (a) INSTALL OIL PUMP ASSY Install a new gasket and oil pump with the 3 bolts. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) 36. (a) (b) INSTALL NO.2 CHAIN SUB-ASSY Set the crankshaft key in the horizontal left position. Turn the cutout of the drive shaft to the top. (c) Align the mark links (yellow colored links) of the chain with the timing marks of the gear as shown in the illustration. Insert the gear together with chain into the crankshaft and oil pump shaft. Temporarily tighten the oil pump drive shaft gear with the nut. B11424 Mark Link Timing Mark (d) (e) Timing Mark Mark Link A94198 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2837 17-13 LUBRICATION Chain Tensioner Plate - OIL PUMP ASSY (2AZ-FE) (f) Insert the damper spring into the adjusting hole, and install the chain tensioner plate with the bolt. Torque: 12 N⋅m (122 kgf⋅cm, 9 ft⋅lbf) (g) Align the adjusting hole of the sprocket with the groove of the oil pump. Insert a bar (φ 4 mm (0.16 in.)) into the adjusting hole of the sprocket to temporarily lock the gear in position. Install the nut. Torque: 30 N⋅m (306 kgf⋅cm, 22 ft⋅lbf) Bolt Spring A94215 (h) Groove A52512 (i) 90 Rotate the crankshaft 90clockwise and align the crankshaft key with the top. A36525 37. 38. (a) 39. 40. 41. 42. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET INSTALL CHAIN VIBRATION DAMPER NO.1 Install the chain vibration damper with the 2 bolts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) INSTALL CHAIN SUB-ASSY (See page 14-68 ) INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 (See page 14-41 ) INSTALL TIMING CHAIN OR BELT COVER SUB-ASSY (See page 14-41 ) INSTALL V-RIBBED BELT TENSIONER ASSY (See page 14-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2838 17-14 LUBRICATION - OIL PUMP ASSY (2AZ-FE) 43. (a) INSTALL ENGINE MOUNTING BRACKET RH Install the engine mounting bracket with the 3 bolts. Torque: 54 N⋅m (551 kgf⋅cm, 40 ft⋅lbf) 44. (a) INSTALL ENGINE MOUNTING INSULATOR Raise the engine and install the engine mounting insulator RH. Install the engine mounting insulator RH with the 4 nuts. Torque: 95 N⋅m (969 kgf⋅cm, 70 ft⋅lbf) for nut A 87 N⋅m (887 kgf⋅cm, 64 ft⋅lbf) for nut B A52481 A (b) B B B A59900 (c) Install the steering gear return hose clamp to the frame with the bolt. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) (d) Install the engine mounting insulator FR with the bolt. Torque: 87 N⋅m (887 kgf⋅cm, 64 ft⋅lbf) A59901 A52441 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2839 17-15 LUBRICATION 6.0 mm Seal Width: 3.0 to 4.0 mm Seal Packing A94202 9 11 1 8 12 7 OIL PUMP ASSY (2AZ-FE) 45. INSTALL OIL PAN SUB-ASSY NOTICE:
Remove any oil from the contact surface.
Install the oil pan within 3 minutes after applying seal packing.
Do not start the engine for at least 2 hours after installing. (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan. (b) Apply seal packing in a continuous bead (Seal Width: 3.0 to 4.0 mm (0.12 to 0.16 in.)) as shown in the illustration, and install the oil pan. Seal packing: Part No. 08826-00080 or equivalent (c) 10 - Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) 13 6 14 5 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 4 3 2 A64641 INSTALL CRANKSHAFT POSITION SENSOR (See page 14-41 ) INSTALL CRANKSHAFT PULLEY (See page 14-41 ) INSTALL CHAIN TENSIONER ASSY NO.1 (See page 14-68 ) INSTALL CYLINDER HEAD COVER SUB-ASSY INSTALL IGNITION COIL ASSY INSTALL VANE PUMP ASSY INSTALL GENERATOR ASSY INSTALL ENGINE WIRE INSTALL FAN AND GENERATOR V BELT (See page 14-5 ) INSTALL ENGINE MOUNTING BRACKET NO.2 RH INSTALL ENGINE MOUNTING STAY NO.2 RH INSTALL ENGINE MOVING CONTROL ROD W/BRACKET (See page 14-24 ) INSTALL EXHAUST PIPE ASSY FRONT (See page 15-2 ) INSTALL FRONT WHEEL RH ADD ENGINE OIL CHECK FOR ENGINE OIL LEAKS 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2840 18-1 1 IGNITION - VVT SENSOR (3MZ-FE) VVT SENSOR (3MZ-FE) 180BK-01 REPLACEMENT HINT: A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). 1. REMOVE AIR CLEANER ASSY 2. (a) (b) 3. (a) Bank 1 (b) (c) REMOVE VVT SENSOR Disconnect the sensor connector. Remove the bolt and sensor. INSTALL VVT SENSOR Apply a light coat of engine oil to a new O-ring. Install the O-ring onto the sensor. Install the sensor with the bolt. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) Connect the sensor connector. Bank 2 A79541 A78529 4. A86853 INSTALL AIR CLEANER ASSY (See page 14-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2871 18-12 IGNITION - CRANKSHAFT POSITION SENSOR (3MZ-FE) CRANKSHAFT POSITION SENSOR (3MZ-FE) 180BL-01 REPLACEMENT HINT: A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). 1. (a) REMOVE ENGINE UNDER COVER NO.1 Remove the 6 screws, 2 clips and under cover. 2. (a) REMOVE FRONT FENDER APRON SEAL RH Remove the clip, 2 bolts and apron seal. 3. (a) (b) 4. (a) REMOVE CRANKSHAFT POSITION SENSOR Disconnect the sensor connector. Remove the bolt and sensor. INSTALL CRANKSHAFT POSITION SENSOR Install the sensor with the bolt. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) Connect the sensor connector. A90206 A80512 (b) A79763 5. (a) 6. (a) INSTALL FRONT FENDER APRON SEAL RH Install the clip, 2 bolts and apron seal. INSTALL ENGINE UNDER COVER NO.1 Install the 6 screws, 2 clips and under cover. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2872 18-9 IGNITION - IGNITION SYSTEM (3MZ-FE) 18097-02 INSPECTION NOTICE: In this section, the terms “cold” and “hot” refer to the temperature of the coils. “Cold” means approximately -10C (14F) to 50C (122F). “Hot” means approximately 50C (122F) to 100C (212F). 1. INSPECT SPARK PLUG NOTICE:
Do not use a wire brush for cleaning.
Do not attempt to adjust the electrode gap of a used spark plug. (a) Megaohmmeter Ground I39522 Check the electrode. (1) Using a megaohmmeter, measure the insulation resistance. Correct insulation resistance: 10 MΩ or higher If the resistance is less than the specified value, proceed to step (d). HINT: If a megaohmmeter is not available, do the following simple inspection instead. (b) B02629 Alternative inspection method: (1) Quickly accelerate the engine to 4,000 rpm 5 times. (2) Remove the spark plug. (3) Visually check the spark plug. (4) If the electrode is dry, the spark plug is functioning. Proceed to step 2. (5) If the electrode is damp, proceed to step (c), (d) and (e). (6) Install the spark plug. (c) Check the spark plug for any damage on its thread and insulator. If there is damage, replace the spark plug. Recommended spark plug: DENSO made SK20R11 NGK made IFR6A11 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2869 18-10 IGNITION - IGNITION SYSTEM (3MZ-FE) (d) 1.0 to 1.1 mm B02630 B62019 2. (a) Check the spark plug electrode gap. Maximum electrode gap for used spark plug: 1.3 mm (0.051 in.) If the gap is greater than the maximum, replace the spark plug. Correct electrode gap for new spark plug: 1.0 to 1.1 mm (0.039 to 0.043 in.) NOTICE: If adjusting the gap of a new spark plug, bend only the base of the ground electrode. Do not touch the tip. Never attempt to adjust the gap on a used plug. (e) Clean the spark plugs. If the electrode has traces of wet carbon, clean the electrode with a spark plug cleaner and then dry it. Air pressure: 588 kPa (6 kgf/cm2, 85 psi) Duration: 20 seconds or less HINT: Only use the spark plug cleaner when the electrode is free of oil. If the electrode has traces of oil, use gasoline to clean off the oil before using the spark plug cleaner. INSPECT VVT SENSOR Using an ohmmeter, measure the resistance between the terminals. Standard: Temperature Specified Condition Cold 835 to 1,400 Ω Hot 1,060 to 1,645 Ω If the result is not as specified, replace the sensor. 3. INSPECT CRANKSHAFT POSITION SENSOR (a) Using an ohmmeter, measure the resistance between the terminals. Standard: Temperature Specified Condition Cold 1,630 to 2,740 Ω Hot 2,065 to 3,225 Ω If the result is not as specified, replace the sensor. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2870 18-7 IGNITION - IGNITION SYSTEM (3MZ-FE) IGNITION SYSTEM (3MZ-FE) 1807T-08 ON-VEHICLE INSPECTION NOTICE: In this section, the terms “cold” and “hot” refer to the temperature of the coils. “Cold” means approximately -10C (14F) to 50C (122F). “Hot” means approximately 50C (122F) to 100C (212F). 1. INSPECT IGNITION COIL ASSY (WITH IGNITER) AND PERFORM SPARK TEST (a) Check for DTCs. NOTICE: If a DTC is present, perform a troubleshooting in accordance with the procedure for that DTC. (b) Check if sparks occur. (1) Remove the V-bank cover (see page 14-24 ). (2) Remove the intake air surge tank (see page 14-24 ). (3) Remove the ignition coils. (4) Using a 16 mm (0.63 in.) plug wrench, remove the spark plugs. (5) Install the spark plugs to each ignition coil and connect the ignition coil connectors. (6) Disconnect the 6 injector connectors. (7) Ground the spark plugs. (8) Check if sparks occur at each spark plug while the engine is being cranked. NOTICE:
Be sure to ground the spark plug when checking.
Replace the ignition coil if given physical impact is given to the coil.
Do not crank the engine for more than 2 seconds. If sparks do not occur, do the following test: SPARK TEST NG CHECK IF WIRE HARNESS SIDE CONNECTOR OF IGNITION COIL (WITH IGNITER) IS SECURE OK PERFORM SPARK TEST WITH A DIFFERENT IGNITION COIL (WITH IGNITER) NG OK 1. Replace current ignition coil (with igniter) with a different, functioning ignition coil (with igniter). Connect securely. If sparks occur, replace faulty ignition coil (with igniter). 2. Perform spark test again. NG CHECK POWER SUPPLY TO IGNITION COIL (WITH IGNITER) 1. Turn ignition switch ON. 2. Check that there is battery voltage at ignition coil positive (+) terminal. OK CHECK RESISTANCE OF VVT SENSOR (See page 18-1 1) Cold Hot 835 to 1,400 Ω 1,060 to 1,645 Ω Standard: NG Check wiring between ignition switch to ignition coil (with igniter). Replace VVT sensor. NG OK Continue on next page Author
: Date
: 2867 18-8 IGNITION - Continued from previous page OK CHECK RESISTANCE OF CRANKSHAFT POSITION SENSOR (See page 18-12 ) Cold Hot Standard: 1,630 to 2,740 Ω 2,065 to 3,225 Ω OK CHECK IGT SIGNAL FROM ECM (See page 05-541 ) OK IGNITION SYSTEM (3MZ-FE) NG NG Replace crankshaft position sensor. Check ECM (see page 05-394 ). REPAIR WIRING BETWEEN IGNITION COIL AND ECM (9) Using a 16 mm (0.63 in.) plug wrench, install the spark plugs. Torque: 25 N⋅m (255 kgf⋅cm, 18.5 ft⋅lbf) (10) Install the ignition coil. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) (11) Install the intake air surge tank (see page 14-24 ). (12) Install the V-bank cover (see page 14-24 ). Author
: Date
: 2868 18-3 IGNITION - IGNITION SYSTEM (2AZ-FE) 18092-02 INSPECTION NOTICE: In this section, the terms “cold”and “hot” refer to the temperature of the coils. “Cold” means approximately -10C (14F) to 50C (122F). ”Hot” means approximately 50C (122F) to 100C (212F). 1. INSPECT SPARK PLUG NOTICE:
Do not use a wire brush for cleaning.
Do not attempt to adjust the electrode gap of a used spark plug. Megaohmmeter Ground I39522 (a) Check the electrode. (1) Using a megaohmmeter, measure the insulation resistance. Correct insulation resistance: 10 MΩ or higher If the resistance is less than the specified value, proceed to step (d). HINT: If a megaohmmeter is not available, do the following simple inspection instead. (b) B02629 Alternative inspection method: (1) Quickly accelerate the engine to 4,000 rpm 5 times. (2) Remove the spark plug. (3) Visually check the spark plug. (4) If the electrode is dry, the spark plug is functioning. Proceed to step 2. (5) If the electrode is damp, proceed to step (c), (d), and (e). (6) Install the spark plug. (c) Check the spark plug for any damage on its thread and insulator. If there is damage, replace the spark plug. Recommended spark plug: DENSO made SK20R11 NGK made IFR6A11 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2863 18-4 IGNITION - IGNITION SYSTEM (2AZ-FE) (d) 1.0 to 1.1 mm B02630 B62019 2. (a) Check the spark plug electrode gap. Maximum electrode gap for used spark plug: 1.3 mm (0.051 in.) If the gap is greater than the maximum, replace the spark plug. Correct electrode gap for new spark plug: 1.0 to 1.1 mm (0.039 to 0.043 in.) NOTICE: If adjusting the gap of a new spark plug, bend only the base of the ground electrode. Do not touch the tip. Never attempt to adjust the gap on a used plug. (e) Clean the spark plugs. If the electrode has traces of wet carbon, clean the electrode with a spark plug cleaner and then dry it. Air pressure: 588 kPa (6 kgf/cm2, 85 psi) Duration: 20 seconds or less HINT: Only use the spark plug cleaner when the electrode is free of oil. If the electrode has traces of oil, use gasoline to clean off the oil before using the spark plug cleaner. INSPECT CAMSHAFT POSITION SENSOR Using an ohmmeter, measure the resistance between the terminals. Standard: Temperature Specified Condition Cold 835 to 1,400 Ω Hot 1,060 to 1,645 Ω If the result is not as specified, replace the sensor. 3. INSPECT CRANKSHAFT POSITION SENSOR (a) Using an ohmmeter, measure the resistance between the terminals. Standard: Temperature Specified Condition Cold 985 to1,600 Ω Hot 1,265 to 1,890 Ω If the result is not as specified, replace the sensor. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2864 18-1 IGNITION - IGNITION SYSTEM (2AZ-FE) IGNITION SYSTEM (2AZ-FE) 18091-05 ON-VEHICLE INSPECTION NOTICE: In this section, the terms “cold” and “hot” refer to the temperature of the coils. ”Cold”means approximately -10C (14F) to 50C (122F). ”Hot” means approximately 50C (122F) to 100C (212F). 1. INSPECT IGNITION COIL ASSY (WITH IGNITER) AND PERFORM SPARK TEST (a) Check for DTCs. NOTICE: If a DTC is present, perform a troubleshooting in accordance with the procedure for that DTC. (b) Check if sparks occur. (1) Remove the engine cover No. 1 (see page 14-24 ). (2) Remove the ignition coils. (3) Using a 16 mm (0.63 in.) plug wrench, remove the spark plugs. (4) Install the spark plugs to each ignition coil and connect the ignition coil connectors. (5) Disconnect the 4 injector connectors. (6) Ground the spark plugs. (7) Check if sparks occur at each spark plug while the engine is being cranked. NOTICE:
Be sure to ground the spark plug when checking.
Replace the ignition coil if given physical impact is given to the coil.
Do not crank the engine for more than 2 seconds. If the sparks do not occur, do the following test: SPARK TEST NG CHECK IF WIRE HARNESS SIDE CONNECTOR OF IGNITION COIL (WITH IGNITER) IS SECURE OK PERFORM SPARK TEST WITH A DIFFERENT IGNITION COIL (WITH IGNITER) NG OK Connect securely. If sparks occur, replace faulty ignition coil (with igniter). 1. Replace current ignition coil (with igniter) with a different, functioning ignition coil (with igniter). 2. Perform spark test again. NG CHECK POWER SUPPLY TO IGNITION COIL (WITH IGNITER) 1. Turn ignition switch ON. 2. Check that there is battery voltage at ignition coil positive (+) terminal. OK CHECK RESISTANCE OF CAMSHAFT POSITION SENSOR (See page 18-5 ) Hot Cold 835 to 1,400 Ω 1,060 to 1,645 Ω Standard: NG NG Check wiring between ignition switch to ignition coil (with igniter). Replace camshaft position sensor. OK Continue on next page Author
: Date
: 2861 18-2 IGNITION - IGNITION SYSTEM (2AZ-FE) Continued from previous page OK CHECK RESISTANCE OF CRANKSHAFT POSITION SENSOR (See page 18-6 ) Cold Hot Standard: 985 to 1,600 Ω 1,265 to 1,890 Ω OK CHECK IGT SIGNAL FROM ECM (See page 05-174 ) OK NG NG Replace crankshaft position sensor. Check ECM (see page 05-32 ). REPAIR WIRING BETWEEN IGNITION COIL AND ECM (8) Using a 16 mm (0.63 in.) plug wrench, install the spark plugs. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) (9) Install the ignition coils. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) (10) Install the engine cover No. 1. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) Author
: Date
: 2862 18-5 IGNITION - CAMSHAFT POSITION SENSOR (2AZ-FE) CAMSHAFT POSITION SENSOR (2AZ-FE) 18094-02 REPLACEMENT HINT: A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). 1. REMOVE AIR CLEANER ASSY (See page 14-24 ) 2. (a) (b) REMOVE CAMSHAFT POSITION SENSOR Disconnect the sensor connector. Remove the bolt and sensor. A85637 3. (a) (b) 4. INSTALL CAMSHAFT POSITION SENSOR Apply a light coat of engine oil to a new O-ring. Install the O-ring onto the sensor. Install the sensor with the bolt. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) INSTALL AIR CLEANER ASSY (See page 14-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2865 18-6 IGNITION - CRANKSHAFT POSITION SENSOR (2AZ-FE) CRANKSHAFT POSITION SENSOR (2AZ-FE) 18093-02 REPLACEMENT HINT: A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). 1. (a) REMOVE ENGINE UNDER COVER NO.1 Remove the 6 screws, 2 clips and under cover. 2. (a) REMOVE FRONT FENDER APRON SEAL RH Remove the clip, 2 bolts and apron seal. 3. (a) (b) 4. (a) REMOVE CRANKSHAFT POSITION SENSOR Disconnect the sensor connector. Remove the bolt, clamp and sensor. INSTALL CRANKSHAFT POSITION SENSOR Install the sensor and clamp with the bolt. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) Connect the sensor connector. A90206 A80512 (b) A85638 5. (a) 6. (a) INSTALL FRONT FENDER APRON SEAL RH Install the clip, 2 bolts and apron seal. INSTALL ENGINE UNDER COVER NO.1 Install the 6 screws, 2 clips and under cover. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2866 19-1 STARTING & CHARGING - STARTING SYSTEM (2AZ-FE) STARTING SYSTEM (2AZ-FE) 190VG-01 INSPECTION 1. INSPECT STARTER ASSY NOTICE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. (a) Do the pull-in test. (1) Disconnect the lead wire from terminal C. (2) Connect the battery to the magnetic switch as shown in the illustration on the left. Check that the clutch pinion gear extends. If the clutch pinion gear does not move, replace the magnetic switch assy. Terminal C Terminal 50 A60459 Disconnect Terminal C (b) Do the hold-in test. (1) Maintain the battery connections in step (a), but disconnect the negative (-) lead from terminal C. Check that the pinion gear remains extended. If the clutch pinion gear returns inward, replace the magnetic switch assy. A81044 (c) Check the clutch pinion gear return. (1) Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear returns. If the clutch pinion gear does not return, replace the magnetic switch assy. Disconnect A81045 (d) Terminal 30 Terminal 50 Do the no-load performance test. (1) Connect the lead wire to terminal C. Make sure that the lead is not grounded. Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) (2) Clamp the starter in a vise. (3) Connect the battery and an ammeter to the starter as shown in the illustration. A60462 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2873 19-2 STARTING & CHARGING - STARTING SYSTEM (2AZ-FE) (4) Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter reads the specified current. Specified current: 90 A or less at 11.5 V 2. (a) INSPECT RELAY (Marking: STARTER) Check the resistance of the STARTER relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1Ω (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay. A92673 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2874 19-3 STARTING & CHARGING - STARTER ASSY (2AZ-FE) STARTER ASSY (2AZ-FE) 190RU-03 COMPONENTS Starter Armature Assy Starter Commutator End Frame Assy 6.0 (61, 53 in.⋅lbf)
Snap Ring Washer Starter Commutator End Frame Cover Magnetic Switch Assy 7.5 (76, 66 in.⋅lbf) 10 (102, 7) Starter Yoke Assy Planetary Gear Starter Drive Housing Assy (w/ Clutch & Drive Lever & Center Bearing) Starter Armature Plate N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part A92671 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2875 19-5 STARTING & CHARGING - STARTER ASSY (2AZ-FE) 190RW-03 OVERHAUL 1. (a) REMOVE MAGNETIC SWITCH ASSY Remove the nut and disconnect the lead wire from the magnetic switch. (b) Remove the 2 screws holding the magnetic switch to the starter drive housing. Remove the magnetic switch. Remove the return spring and plunger from the drive housing. A79718 (c) (d) A79719 2. (a) REMOVE STARTER YOKE ASSY Remove the 2 through bolts, and pull out the yoke together with the commutator end frame. (b) Remove the yoke from the commutator end frame. A79720 A79721 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2877 19-6 STARTING & CHARGING - STARTER ASSY (2AZ-FE) 3. (a) REMOVE STARTER AMATURE PLATE Remove the armature plate from the yoke. 4. REMOVE STARTER COMMUTATOR END FRAME COVER Using a screwdriver, remove the frame cover. A79722 (a) A79723 5. (a) Snap Ring Pliers (b) REMOVE STARTER ARMATURE ASSY Using snap ring pliers, remove the snap ring and plate washer. Remove the armature from the commutator end frame. 6. (a) REMOVE PLANETARY GEAR Remove the 3 planetary gears from the drive housing. A82440 A81167 7. (a) INSPECT MAGNETIC SWITCH ASSY Check the plunger. (1) Push in the plunger and check that it returns quickly to its original position. If necessary, replace the magnetic switch assy. A58586 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2878 19-7 STARTING & CHARGING - STARTER ASSY (2AZ-FE) (b) Terminal C Terminal 50 Check if the pull-in coil has an open circuit. (1) Check the resistance between terminals 50 and C. Standard: Below 1 Ω If the result is not as specified, replace the magnetic switch assy. Below 1 Ω A79725 (c) Body Below 2 Ω Check if the hold-in coil has an open circuit. (1) Check the resistance between terminal 50 and the switch body. Standard: Below 2 Ω If the result is not as specified, replace the magnetic switch assy. Terminal 50 A79726 8. (a) INSPECT STARTER ARMATURE ASSY Check the commutator for contamination and burns on its surface. If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. (b) Check if the commutator has an open circuit. (1) Check the resistance between the segments of the commutator. Standard: Below 1 Ω If the result is not as specified, replace the armature assy. Below 1 Ω Segment A58372 (c) 10 kΩ or Higher Commutator Check if the commutator is grounded. (1) Check the resistance between the commutator and armature coil core. Standard: 10 kΩ or higher If the result is not as specified, replace the armature assy. Coil Core A58373 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2879 19-8 STARTING & CHARGING - STARTER ASSY (2AZ-FE) (d) Depth Using a vernier caliper, measure the commutator’s depth. Specified depth: 3.1 mm (0.122 in.) Maximum depth: 3.8 mm (0.150 in.) If the depth is greater than the maximum, replace the starter armature. A58584 9. Length INSPECT STARTER COMMUTATOR END FRAME ASSY (a) Using a vernier caliper, measure the brush length. Standard length: 9.0 mm (0.354 in.) Minimum length: 4.0 mm (0.157 in.) If the length is less than the minimum, replace the end frame assy. A76677 (b) Check the brush insulation. (1) Check the resistance between the positive (+) and negative (-) brush. Standard: 10 kΩ or higher If the result is not as specified, repair or replace the end frame assy. 10 kΩ or Higher A79766 10. (a) INSPECT STARTER DRIVE HOUSING ASSY Check the starter clutch. (1) Rotate the clutch pinion gear counterclockwise and check that it turns freely. Try to rotate the clutch pinion gear clockwise and check that it locks. If necessary, replace the drive housing assy. Lock Free A81655 Apply Grease 11. (a) (b) INSTALL PLANETARY GEAR Apply grease to the planetary gears and pin parts of the planetary shaft. Install the 3 planetary gears. A81656 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2880 19-9 STARTING & CHARGING 12. (a) (b) (c) Snap Ring Pliers - STARTER ASSY (2AZ-FE) INSTALL STARTER ARMATURE ASSY Apply grease to the plate washer and the armature shaft. Install the armature to the starter commutator end frame. Using snap ring pliers, install the plate washer and a new snap ring. A82440 (d) Using a vernier caliper, measure the length of the snap ring. Maximum length: 5.0 mm (0.197 in.) If the length is greater than the maximum, replace it with a new snap ring. Length A58810 13. (a) INSTALL STARTER COMMUTATOR END FRAME COVER Install the end frame cover to the commutator end frame. A81178 Key 14. (a) INSTALL STARTER ARMATURE PLATE Align the keyway of the starter plate with the key inside the field frame, and install the plate. 15. INSTALL STARTER COMMUTATOR END FRAME ASSY Align the rubber of the end frame with the cutout of the yoke. Install the end frame to the yoke. Keyway A73991 Rubber Cutout (a) (b) A79727 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2881 19-10 STARTING & CHARGING Cutout - STARTER ASSY (2AZ-FE) 16. (a) INSTALL STARTER YOKE ASSY Align the protrusion of the yoke with the cutout of the drive housing. (b) Install the yoke with the 2 through bolts. Torque: 6.0 N⋅m (61 kgf⋅cm, 53 in.⋅lbf) 17. (a) (b) INSTALL MAGNETIC SWITCH ASSY Apply grease to the plunger and the hook. Hang the plunger hook of the magnetic switch to the drive lever. Install the plunger and return spring. Protrusion A79728 A79720 (c) A79729 (d) Install the magnetic switch with the 2 screws. Torque: 7.5 N⋅m (76 kgf⋅cm, 66 in.⋅lbf) (e) Connect the lead wire to the magnetic switch with the nut. Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) A79719 A79718 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2882 19-4 STARTING & CHARGING - STARTER ASSY (2AZ-FE) 190VH-01 REPLACEMENT NOTICE: Before changing the starter, check the following again:
Connector connection
Accessory installation 1. REMOVE BATTERY 2. REMOVE BATTERY TRAY 3. (a) (b) (c) (b) (c) REMOVE STARTER ASSY Disconnect the starter connector. Open the terminal cap, remove the nut and disconnect the starter wire. Remove the 2 bolts and starter. (a) (c) A60064 4. (a) (b) (c) 5. 6. (a) (b) INSTALL STARTER ASSY Install the starter with the 2 bolts. Torque: 37 N⋅m (377 kgf⋅cm, 27 ft⋅lbf) Install the starter wire with the nut. Torque: 9.8 N⋅m (100 kgf⋅cm, 7 ft⋅lbf) Connect the starter connector. INSTALL BATTERY TRAY INSTALL BATTERY Install the battery clamp with the bolt and nut. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in⋅lbf) Connect the cables to the battery terminals. Torque: 3.5 N⋅m (36 kgf⋅cm, 31 in.⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2876 19-12 STARTING & CHARGING - CHARGING SYSTEM (2AZ-FE) 190RZ-03 ON-VEHICLE INSPECTION 1. CHECK BATTERY ELECTROLYTE LEVEL (a) Check the electrolyte quantity of each cell. Maintenance-free battery: If it is under the lower level, replace the battery. Except Maintenance-free battery: If it is under the lower level, add distilled water. 2. Except Maintenance-free battery: CHECK BATTERY SPECIFIC GRAVITY (a) Check the specific gravity of each cell. Standard specific gravity: 1.25 to 1.29 at 20°C (68°F) If the specific gravity is less than the specification, charge the battery. 3. Maintenance-free battery: CHECK BATTERY VOLTAGE (a) After the vehicle has run for 20 minutes, stop the engine. (b) Turn the ignition switch ON, and operate the headlight, blower fan and defogger for 1 minute. (c) Turn the ignition switch OFF. (d) Measure the battery voltage. Standard voltage: 12.5 to 12.9 V at 20°C (68°F) If the voltage is less than specification, charge the battery. 4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES (a) Check that the battery terminals are not loose or corroded. If the terminals are corroded, clean the terminals. (b) Check the fusible link and fuses for resistance of below 1 Ω. 5. (a) REPLACE BELT B00543 INSPECT DRIVE BELT Check the belt for wear, cracks and other signs of damage. If any defect is found, replace the drive belt. HINT: Replace the drive belt if the following defects are found:
If the belt has worn out until the wire can be seen.
If the cracks reach the wire more than one place.
If the belt has chunks missing from the ribs. (b) Check that the belt fits properly in the ribbed grooves. HINT: With your hand, confirm that the belt has not slipped out of the groove on the bottom of the pulley. CORRECT INCORRECT B75171 6. (a) 7. (a) 8. VISUALLY CHECK GENERATOR WIRING Check that the wiring is in good condition. LISTEN FOR ABNORMAL NOISES FROM GENERATOR Check that there is no abnormal noise from the generator while the engine is running. INSPECT CHARGE WARNING LAMP CIRCUIT 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2884 19-13 STARTING & CHARGING - CHARGING SYSTEM (2AZ-FE) (a) Turn the ignition switch ON. Check that the charge warning lamp turns on. (b) Start the engine and check that the lamp turns off. If the lamp does not operate as specified, troubleshoot the charge warning lamp circuit. 9. INSPECT CHARGING CIRCUIT WITHOUT LOAD HINT: If a battery/generator tester is available, connect the tester to the charging circuit according to the manufacturer’s instrucBattery tions. (a) If a tester is not available, connect an ammeter and voltGenerator meter to the charging circuit as follows. Voltmeter (1) Disconnect the wire from terminal B of the generator and connect it to the negative (-) lead of the ammeA91025 ter. (2) Connect the ammeter’s positive (+) lead to terminal B of the generator. (3) Connect the voltmeter’s positive (+) lead to terminal B of the generator. (4) Ground the voltmeter’s negative (-) lead. (b) Check the charging circuit. (1) Keep the engine speed at 2,000 rpm, check the reading on the ammeter and voltmeter. Standard amperage: 10 A or less Standard voltage: 13.2 to 14.8 V If the result is not as specified, replace the generator. 10. INSPECT CHARGING CIRCUIT WITH LOAD (a) With the engine running at 2,000 rpm, turn on the high-beam headlamps and turn the heater blower switch to the HI position. (b) Check the reading on the ammeter. Standard amperage: 30 A or more HINT:
If the ammeter reading is less than the standard amperage, repair the generator.
If the battery is fully charged, the indication will sometimes be less than the standard amperage. Ammeter Disconnect Wire from Terminal B 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2885 19-1 1 STARTING & CHARGING - CHARGING SYSTEM (2AZ-FE) CHARGING SYSTEM (2AZ-FE) 1902O-06 PRECAUTION CAUTION:
Check that the battery cables are connected to the correct terminals.
Disconnect the battery cables when the battery is given a quick charge.
Do not perform tests with a high voltage insulation resistance tester.
Never disconnect the battery while the engine is running.
Check that the charging cable is tightened on terminal B of the generator and the fuse box. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2883 19-14 STARTING & CHARGING - GENERATOR ASSY (2AZ-FE) GENERATOR ASSY (2AZ-FE) 190VI-01 COMPONENTS 100 A
Generator Drive End Frame Bearing Washer 2.3 (23, 20 in.⋅lbf) x4 Generator Pulley Generator Rotor Assy Retainer Plate 110 (1,122, 81) Drive End Frame Assy Generator 4.6 (47, 41 in.⋅lbf) Generator Brush Holder Assy 5.8 (59, 51 in.⋅lbf) Terminal Insulator x4 1.8 (18, 16 in.⋅lbf) Generator Rear End Cover Generator Rectifier End Frame N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part A92688 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2886 19-15 STARTING & CHARGING - GENERATOR ASSY (2AZ-FE) 130 A
Generator Drive End Frame Bearing Generator Bearing Cover 2.3 (23, 20 in.⋅lbf) Generator Washer x4
Generator Rotor Bearing Generator Pulley Generator Rotor Assy Retainer Plate 110 (1,122, 81) Drive End Frame Assy Generator 4.6 (47, 41 in.⋅lbf) Terminal Insulator Generator Plate Seal Generator Brush Holder Assy 5.8 (59, 51 in.⋅lbf) x4 1.8 (18, 16 in.⋅lbf) Generator Rear End Cover Generator Plate Seal Generator Rectifier End Frame N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part A92683 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2887 19-17 STARTING & CHARGING - GENERATOR ASSY (2AZ-FE) 190VK-01 OVERHAUL 1. SST (1-A) SST (1-B) REMOVE GENERATOR PULLEY SST 09820-63010 (09820-06010, 09820-06020) HINT: Hold SST (1-A, B) 09820-06010 SST (2) 09820-06020 (a) Turn A92680 Hold SST (1-A) with a torque wrench, and tighten SST (1-B) clockwise to the specified torque. Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) NOTICE: Check that SST is secured to the rotor shaft. (b) Mount SST (2) in a vise. (c) Insert SST (1-A, B) into SST (2), and attach the pulley nut to SST (2). SST (2) Insert SST (1) A81659 (d) To loosen the pulley nut, turn SST (1-A) in the direction shown in the illustration. NOTICE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half turn. (e) Remove the generator from SST (2). SST(1-A) Turn A81660 (f) (g) SST (1-A) SST (1-B) Turn SST (1-B) and remove SST (1-A, B). Remove the pulley nut and pulley. Turn Hold A81661 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2889 19-18 STARTING & CHARGING - GENERATOR ASSY (2AZ-FE) 2. (a) (b) REMOVE GENERATOR REAR END COVER Place the generator on the pulley. Remove the 3 nuts and rear end cover. 3. (a) REMOVE TERMINAL INSULATOR Remove the terminal insulator from the rectifier end frame. 4. (a) REMOVE GENERATOR BRUSH HOLDER ASSY 100 A: Remove the 2 screws and brush holder. (b) 130 A: Remove the brush holder. (1) Remove the plate seal. (2) Remove the 2 screws and brush holder. (3) Remove the plate seal. 5. (a) REMOVE GENERATOR COIL ASSY Remove the 4 bolts. Pulley A81662 A81146 100 A A81147 130 A A79736 A81148 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2890 19-19 STARTING & CHARGING GENERATOR ASSY (2AZ-FE) (b) Using SST, remove the rectifier end frame. SST 09950- 40011 (09951- 04020, 09952- 04010, 09953- 04020, 09954- 04010, 09955- 04071, 09957-04010, 09958-04011) 6. (a) REMOVE GENERATOR ROTOR ASSY Remove the washer and rotor. Turn SST - Hold A81663 Washer A81664 7. (a) INSPECT GENERATOR BRUSH HOLDER ASSY 100 A: Using a vernier caliper, measure the exposed brush length. Standard exposed brush length: 10.5 mm (0.413 in.) Minimum exposed brush length: 4.5 mm (0.177 in.) If the exposed brush length is less than the minimum, replace the brush holder assy. Length A79305 (b) 130 A: Using a vernier caliper, measure the exposed brush length. Standard exposed brush length: 10.5 mm (0.413 in.) Minimum exposed brush length: 4.5 mm (0.177 in.) If the exposed brush length is less than the minimum, replace the brush holder assy. Length B16374 8. INSPECT GENERATOR ROTOR ASSY (a) Check that the bearing is not rough or worn. 100 A: If necessary, replace the rotor assy. 130 A: If necessary, replace the rotor bearing. A79306 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2891 19-20 STARTING & CHARGING - GENERATOR ASSY (2AZ-FE) (b) Check if the rotor has open circuit. (1) Measure the resistance between the slip ring. Resistance: 2.3 to 2.7 Ω at 20
C (68
F) If the resistance is not as specified, replace the rotor assy. Slip Ring 2.3 to 2.7 Ω at 20
C (68
F) A81665 Slip Ring (c) Check the rotor for ground. (1) Measure the resistance between the slip ring and rotor core. Standard: 1 MΩ or higher If the resistance is not as specified, replace the rotor assy. (d) Check that the slip rings are not rough or scored. If rough or scored, replace the rotor assy. Rotor Core 1 MΩ or Higher A81666 (e) Using vernier calipers, measure the slip ring diameter. Standard diameter: 14.2 to 14.4 mm (0.559 to 0.567 in.) Minimum diameter: 14.0 mm (0.551 in.) If the diameter is less than the minimum, replace the rotor assy. Diameter A75676 9. 130 A: REMOVE GENERATOR ROTOR BEARING (a) Using SST, remove the bearing cover (outside) and bearing. SST 09820-00021 NOTICE: Be careful not to damage the fan. (b) Remove the bearing cover (inside). SST Hold A75678 10. SST (a) (b) (c) Generator Pulley 130 A: INSTALL GENERATOR ROTOR BEARING Place the generator rotor on the generator pulley. Install the bearing cover (inside). Using SST and a press, press in a new bearing. SST 09820-00031 A75679 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2892 19-21 STARTING & CHARGING (d) SST - GENERATOR ASSY (2AZ-FE) Using SST, push in the bearing cover (outside). SST 09285-76010 A75680 11. INSPECT GENERATOR DRIVE END FRAME BEARING (a) Check that the bearing is not rough or worn. If necessary, replace the bearing. A81155 12. (a) REMOVE GENERATOR DRIVE END FRAME BEARING Remove the 4 screws and retainer plate. (b) Using SST and a wooden block, tap out the bearing. SST 09950- 60010 (09951- 00250), 09950- 70010 (09951-07100) 13. (a) INSTALL GENERATOR DRIVE END FRAME BEARING Using SST and a press, press in a new bearing. SST 09950- 60010 (09951- 00470), 09950- 70010 (09951-07100) A81156 Wooden Block SST A81667 SST A81668 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2893 19-22 STARTING & CHARGING - GENERATOR ASSY (2AZ-FE) (b) Install the retainer plate with the 4 screws. Torque: 2.3 N⋅m (23 kgf⋅cm, 20 in.⋅lbf) 14. (a) (b) INSTALL GENERATOR ROTOR ASSY Place the generator drive end frame on the pulley. Install the rotor and washer. 15. (a) INSTALL GENERATOR RECTIFIER END FRAME 100 A: Using deep socket wrench 21 and a press, press in the coil carefully. 130 A: Using deep socket wrench 20 and a press, press in the coil carefully. A81669 Washer Pulley A81670 Deep Socket Wrench 20 or 21 (b) A81671 (c) Tighten the 4 bolts. Torque: 5.8 N⋅m (59 kgf⋅cm, 51 in.⋅lbf) 16. (a) INSTALL GENERATOR BRUSH HOLDER ASSY 100 A: Install the brush holder. (1) While pushing the 2 brushes to inside the brush holder, insert a pin (φ1.0 mm (0.039 in.)) into the brush holder hole. A81148 100 A Pin (φ1.0 mm (0.039 in.)) A79315 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2894 19-23 STARTING & CHARGING 100 A - GENERATOR ASSY (2AZ-FE) (2) Install the brush holder with the 2 screws. Torque: 1.8 N⋅m (18 kgf⋅cm, 16 in.⋅lbf) (3) Pull out the pin (φ1.0 mm (0.039 in.)) from the brush holder. Pin (φ1.0 mm (0.039 in.)) A81672 (b) 130 A Pin A79736 130 A: Install the brush holder (1) Install the plate seal (inside). (2) Place the brush holder with the pin facing upward. NOTICE: Be careful of the generator brush holder installing direction. (3) Tighten the 2 screws. Torque: 1.8 N⋅m (18 kgf⋅cm, 16 in.⋅lbf) (4) Align the pins of the brush holder with the holes of the plate seal (outside), and install the plate seal (outside). 17. INSTALL TERMINAL INSULATOR (a) Install the terminal insulator. NOTICE: pay attention to the mounting direction of the terminal insulator. A81146 18. (a) INSTALL GENERATOR REAR END COVER Install the rear end cover with the 3 nuts. Torque: 4.6 N⋅m (47 kgf⋅cm, 41 in.⋅lbf) A81164 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2895 19-24 STARTING & CHARGING 19. SST (1-A) SST (1-B) - GENERATOR ASSY (2AZ-FE) INSTALL GENERATOR PULLEY SST 09820-63010 (09820-06010, 09820-06020) HINT: Hold SST 1-A and B 09820-06010 SST 2 09820-06020 (a) Turn A92680 Install the pulley to the rotor shaft by tightening the generator pulley nut by hand. (b) Hold SST (1-A) with a torque wrench, and tighten SST (1-B) clockwise with the specified torque. Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) NOTICE: Check that SST is secured to the rotor shaft. (c) (d) Mount SST (2) in a vise. Insert SST (1-A) and (B) into SST (2), and attach the generator pulley nut to SST (2) (e) Tighten the pulley nut by turning SST (1-A) in the direction shown in the illustration. Torque: 111 N⋅m (1,125 kgf⋅cm, 81 ft⋅lbf) Remove the generator from SST (2). SST (2) Insert SST (1) A81659 (f) SST (1-A) Turn A81673 (g) (h) SST (1-A) SST (1-B) Turn SST (1-B), and remove SST (1-A), (B). Turn the pulley, and check that the pulley moves smoothly. Turn Hold A81661 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2896 19-16 STARTING & CHARGING - GENERATOR ASSY (2AZ-FE) 190VJ-01 REPLACEMENT 1. REMOVE V BELT (See page 14-5 ) 2. (a) (a) (b) (c) (c) (d) (d) (b) REMOVE GENERATOR ASSY Remove the bolt, and disconnect the wire clip on the wire connectors from the generator. Disconnect the wire clamp from the wire clip. Remove the cap and nut, and disconnect the generator wire. Disconnect the generator connector. A92678 (e) 3. (a) A B A92679 (b) (c) (e) (c) (d) (e) (b) (d) 4. Remove the 2 bolts and generator. INSTALL GENERATOR ASSY Install the generator. Torque: 52 N⋅m (530 kgf⋅cm, 38 ft⋅lbf) for bolt A 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) for bolt B NOTICE: Be careful not to put the wire harness between the engine and the generator when install the generator. Connect the generator connector. Connect the generator wire with the nut, and install the cap. Torque: 9.8 N⋅m (100 kgf⋅cm, 7.0 ft⋅lbf) Install the wire clamp to the wire clip. Install the wire clip on the wire connectors to the generator. A92678 INSTALL V BELT (See page 14-5 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2888 19-25 STARTING & CHARGING - STARTING SYSTEM (3MZ-FE) STARTING SYSTEM (3MZ-FE) 190VL-01 INSPECTION 1. INSPECT STARTER ASSY NOTICE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. (a) Do the pull-in test. (1) Disconnect the lead wire from terminal C. (2) Connect the battery to the magnetic switch as shown in the illustration on the left. Check that the clutch pinion gear extends. If the clutch pinion gear does not move, replace the magnetic switch assy. Terminal C Terminal 50 A60459 Disconnect Terminal C (b) Do the hold-in test. (1) Maintain the battery connections in step (a), but disconnect the negative (-) lead from terminal C. Check that the pinion gear remains extended. If the clutch pinion gear returns inward, replace the magnetic switch assy. A81044 (c) Check the clutch pinion gear return. (1) Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear returns. If the clutch pinion gear does not return, replace the magnetic switch assy. Disconnect A81045 (d) Terminal 30 Terminal 50 Do the no-load performance test. (1) Connect the lead wire to terminal C. Make sure that the lead is not grounded. Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) (2) Clamp the starter in a vise. (3) Connect the battery and an ammeter to the starter as shown in the illustration. A60462 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2897 19-26 STARTING & CHARGING - STARTING SYSTEM (3MZ-FE) (4) Check that the starter rotates smoothly and steadily with the clutch pinion gear extended. Check that the ammeter reads the specified current. Specified current: 90 A or less at 11.5 V 2. (a) INSPECT RELAY (Marking: STARTER) Check the resistance of the STARTER relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1Ω (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay. A92673 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2898 19-27 STARTING & CHARGING - STARTER ASSY (3MZ-FE) STARTER ASSY (3MZ-FE) 190S7-03 COMPONENTS Starter Armature Assy Starter Commutator End Frame Assy 6.0 (61, 53 in.⋅lbf)
Snap Ring Washer Starter Commutator End Frame Cover Magnetic Switch Assy 7.5 (76, 66 in.⋅lbf) 10 (102, 7) Starter Yoke Assy Planetary Gear Starter Drive Housing Assy (w/ Clutch & Drive Lever & Center Bearing) Starter Armature Plate N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part A92671 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2899 19-29 STARTING & CHARGING - STARTER ASSY (3MZ-FE) 190O9-04 OVERHAUL 1. (a) REMOVE MAGNETIC SWITCH ASSY Remove the nut and disconnect the lead wire from the magnetic switch. (b) Remove the 2 screws holding the magnetic switch to the starter drive housing. Remove the magnetic switch. Remove the return spring and plunger from the drive housing. A79718 (c) (d) A79719 2. (a) REMOVE STARTER YOKE ASSY Remove the 2 through bolts, and pull out the yoke together with the commutator end frame. (b) Remove the yoke from the commutator end frame. A79720 A79721 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2901 19-30 STARTING & CHARGING - STARTER ASSY (3MZ-FE) 3. (a) REMOVE STARTER AMATURE PLATE Remove the armature plate from the field frame. 4. REMOVE STARTER COMMUTATOR END FRAME COVER Using a screwdriver, remove the frame cover. A79722 (a) A79723 5. (a) Snap Ring Pliers (b) REMOVE STARTER ARMATURE ASSY Using snap ring pliers, remove the snap ring and plate washer. Remove the armature from the commutator end frame. 6. (a) REMOVE PLANETARY GEAR Remove the 3 planetary gears from the drive housing. A82440 A81167 7. (a) INSPECT MAGNETIC SWITCH ASSY Check the plunger. (1) Push in the plunger and check that it returns quickly to its original position. If necessary, replace the magnetic switch assy. A58586 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2902 19-31 STARTING & CHARGING - STARTER ASSY (3MZ-FE) (b) Terminal C Terminal 50 Check if the pull-in coil has an open circuit. (1) Check the resistance between terminals 50 and C. Standard: Below 1 Ω If the result is not as specified, replace the magnetic switch assy. Below 1 Ω A79725 (c) Check if the hold-in coil has an open circuit. (1) Check the resistance between terminal 50 and the switch body. Standard: Below 2 Ω If the the result is not as specified, replace the magnetic switch assy. Body Below 2 Ω Terminal 50 A79726 8. (a) INSPECT STARTER ARMATURE ASSY Check the commutator for contamination and burns on its surface. If the surface is dirty or burnt, correct it with sandpaper (No. 400) or a lathe. (b) Check if the commutator has an open circuit. (1) Check the resistance between the segments of the commutator. Standard: Below 1 Ω If the result is not as specified, replace the armature assy. Below 1 Ω Segment A58372 (c) 10 kΩ or Higher Commutator Check if the commutator is grounded. (1) Check the resistance between the commutator and armature coil core. Standard: 10 kΩ or higher If the result is not as specified, replace the armature assy. Coil Core A58373 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2903 19-32 STARTING & CHARGING - STARTER ASSY (3MZ-FE) (d) Depth Using a vernier caliper, measure the commutator’s depth. Specified depth: 3.1 mm (0.122 in.) Maximum depth: 3.8 mm (0.150 in.) If the depth is greater than the maximum, replace the starter armature. A58584 9. Length INSPECT STARTER COMMUTATOR END FRAME ASSY (a) Using a vernier caliper, measure the brush length. Standard length: 9.0 mm (0.354 in.) Minimum length: 4.0 mm (0.157 in.) If the length is less than the minimum, replace the end frame assy. A76677 (b) Check the brush insulation. (1) Check the resistance between the positive (+) and negative (-) brush. Standard: 10 kΩ or higher If the result is not as specified, repair or replace the end frame assy. 10 kΩ or Higher A79766 10. (a) INSPECT STARTER DRIVE HOUSING ASSY Check the starter clutch. (1) Rotate the clutch pinion gear counterclockwise and check that it turns freely. Try to rotate the clutch pinion gear clockwise and check that it locks. If necessary, replace the drive housing assy. Lock Free A81655 Apply Grease 11. (a) (b) INSTALL PLANETARY GEAR Apply grease to the planetary gears and pin parts of the planetary shaft. Install the 3 planetary gears. A81656 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2904 19-33 STARTING & CHARGING 12. (a) (b) (c) Snap Ring Pliers - STARTER ASSY (3MZ-FE) INSTALL STARTER ARMATURE ASSY Apply grease to the plate washer and the armature shaft. Install the armature to the starter commutator end frame. Using snap ring pliers, install the plate washer and a new snap ring. A82440 (d) Using a vernier caliper, measure the length of the snap ring. Maximum length: 5.0 mm (0.197 in.) If the length is greater than the maximum, replace it with a new snap ring. Length A58810 13. (a) INSTALL STARTER COMMUTATOR END FRAME COVER Install the end frame cover to the commutator end frame. A81178 Key 14. (a) INSTALL STARTER ARMATURE PLATE Align the keyway of the starter plate with the key inside the yoke, and install the plate. 15. INSTALL STARTER COMMUTATOR END FRAME ASSY Align the rubber of the end frame with the cutout of the yoke. Install the end frame to the yoke. keyway A73991 Rubber Cutout (a) (b) A79727 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2905 19-34 STARTING & CHARGING Cutout - STARTER ASSY (3MZ-FE) 16. (a) INSTALL STARTER YOKE ASSY Align the protrusion of the yoke with the cutout of the drive housing. (b) Install the yoke with the 2 through bolts. Torque: 6.0 N⋅m (61 kgf⋅cm, 53 in.⋅lbf) 17. (a) (b) INSTALL MAGNETIC SWITCH ASSY Apply grease to the plunger and the hook. Hang the plunger hook of the magnetic switch to the drive lever. Install the plunger and return spring. Protrusion A79728 A79720 (c) A79729 (d) Install the magnetic switch with the 2 screws. Torque: 7.5 N⋅m (76 kgf⋅cm, 66 in.⋅lbf) (e) Connect the lead wire to the magnetic switch with the nut. Torque: 10 N⋅m (102 kgf⋅cm, 7 ft⋅lbf) A79719 A79718 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2906 19-28 STARTING & CHARGING - STARTER ASSY (3MZ-FE) 190VM-01 REPLACEMENT NOTICE: Before changing the starter, check the following again:
Connector connection
Accessory installation 1. REMOVE BATTERY 2. REMOVE BATTERY TRAY Terminal Cap (b) 3. (a) (b) REMOVE STARTER ASSY Disconnect the starter connector. Open the terminal cap, remove the nut and disconnect the starter wire. (c) 4. (a) Remove the 2 bolts and starter. INSTALL STARTER ASSY Install the starter with the 2 bolts. Torque: 37 N⋅m (377 kgf⋅cm, 27 ft⋅lbf) (b) Install the terminal nut and cover the nut with the cap. Torque: 9.8 N⋅m (100 kgf⋅cm, 7 ft⋅lbf) Connect the starter wire. (a) A78527 A78528 Terminal Cap (b) (c) (c) A78527 5. 6. (a) (b) INSTALL BATTERY TRAY INSTALL BATTERY Install the battery clamp with the bolt and nut. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) Connect the cables to the battery terminals. Torque: 3.5 N⋅m (36 kgf⋅cm, 31 in.⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2900 19-36 STARTING & CHARGING - CHARGING SYSTEM (3MZ-FE) 190SA-03 ON-VEHICLE INSPECTION 1. CHECK BATTERY ELECTROLYTE LEVEL (a) Check the electrolyte quantity of each cell. Maintenance-free battery: If it is under the lower level, replace the battery. Except Maintenance-free battery: If it is under the lower level, add distilled water. 2. Except Maintenance-free battery: CHECK BATTERY SPECIFIC GRAVITY (a) Check the specific gravity of each cell. Standard specific gravity: 1.25 to 1.29 at 20°C (68°F) If the specific gravity is less than the specification, charge the battery. 3. Maintenance-free battery: CHECK BATTERY VOLTAGE (a) After the vehicle has run for 20 minutes, stop the engine. (b) Turn the ignition switch ON, and operate the headlight, blower fan and defogger for 1 minute. (c) Turn the ignition switch OFF. (d) Measure the battery voltage. Standard voltage: 12.5 to 12.9 V at 20°C (68°F) If the voltage is less than specification, charge the battery. 4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES (a) Check that the battery terminals are not loose or corroded. If the terminals are corroded, clean the terminals. (b) Check the fusible link and fuses for resistance of below 1 Ω. 5. (a) REPLACE BELT B00543 INSPECT DRIVE BELT Check the belt for wear, cracks and other signs of damage. If any defect is found, replace the drive belt. HINT: Replace the drive belt if the following defects are found:
If the belt has worn out until the wire can be seen.
If the cracks reach the wire more than one place.
If the belt has chunks missing from the ribs. (b) Check that the belt fits properly in the ribbed grooves. HINT: With your hand, confirm that the belt has not slipped out of the groove on the bottom of the pulley. CORRECT INCORRECT B75171 6. (a) 7. (a) 8. VISUALLY CHECK GENERATOR WIRING Check that the wiring is in good condition. LISTEN FOR ABNORMAL NOISES FROM GENERATOR Check that there is no abnormal noise from the generator while the engine is running. INSPECT CHARGE WARNING LAMP CIRCUIT 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2908 19-37 STARTING & CHARGING - CHARGING SYSTEM (3MZ-FE) (a) Turn the ignition switch ON. Check that the charge warning lamp turns on. (b) Start the engine and check that the lamp turns off. If the lamp does not operate as specified, troubleshoot the charge warning lamp circuit. 9. INSPECT CHARGING CIRCUIT WITHOUT LOAD HINT: If a battery/generator tester is available, connect the tester to the charging circuit according to the manufacturer’s instrucBattery tions. (a) If a tester is not available, connect an ammeter and voltmeter to the charging circuit as follows. Generator Voltmeter (1) Disconnect the wire from terminal B of the generator and connect it to the negative (-) lead of the ammeA91071 ter. (2) Connect the ammeter’s positive (+) lead to terminal B of the generator. (3) Connect the voltmeter’s positive (+) lead to terminal B of the generator. (4) Ground the voltmeter’s negative (-) lead. (b) Check the charging circuit. (1) Keep the engine speed at 2,000 rpm, check the reading on the ammeter and voltmeter. Standard amperage: 10 A or less Standard voltage: 13.2 to 14.8 V If the result is not as specified, replace the generator. 10. INSPECT CHARGING CIRCUIT WITH LOAD (a) With the engine running at 2,000 rpm, turn on the high-beam headlamps and turn the heater blower switch to the HI position. (b) Check the reading on the ammeter. Standard amperage: 30 A or more HINT:
If the ammeter reading is less than the standard amperage, repair the generator.
If the battery is fully charged, the indication will sometimes be less than the standard amperage. Ammeter Disconnect Wire from Terminal B 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2909 19-35 STARTING & CHARGING - CHARGING SYSTEM (3MZ-FE) CHARGING SYSTEM (3MZ-FE) 190NY-04 PRECAUTION CAUTION:
Check that the battery cables are connected to the correct terminals.
Disconnect the battery cables when the battery is given a quick charge.
Do not perform tests with a high voltage insulation resistance tester.
Never disconnect the battery while the engine is running.
Check that the charging cable is tightened on terminal B of the generator and the fuse box. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2907 19-38 STARTING & CHARGING - GENERATOR ASSY (3MZ-FE) GENERATOR ASSY (3MZ-FE) 190VN-01 COMPONENTS 100 A
Generator Drive End Frame Bearing Washer 2.3 (23, 20 in.⋅lbf) x4 Generator Pulley Generator Rotor Assy Retainer Plate 110 (1,122, 81) Drive End Frame Assy Generator 4.6 (47, 41 in.⋅lbf) Generator Brush Holder Assy 5.8 (59, 51 in.⋅lbf) Terminal Insulator x4 1.8 (18, 16 in.⋅lbf) Generator Rear End Cover Generator Rectifier End Frame N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part A92688 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2910 19-39 STARTING & CHARGING - GENERATOR ASSY (3MZ-FE) 130 A
Generator Drive End Frame Bearing Generator Bearing Cover 2.3 (23, 20 in.⋅lbf) Generator Washer x4
Generator Rotor Bearing Generator Pulley Generator Rotor Assy Retainer Plate 110 (1,122, 81) Drive End Frame Assy Generator 4.6 (47, 41 in.⋅lbf) Terminal Insulator Generator Plate Seal Generator Brush Holder Assy 5.8 (59, 51 in.⋅lbf) x4 1.8 (18, 16 in.⋅lbf) Generator Rear End Cover Generator Plate Seal Generator Rectifier End Frame N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part A92683 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2911 19-42 STARTING & CHARGING - GENERATOR ASSY (3MZ-FE) 190VO-01 OVERHAUL 1. SST (1-A) SST (1-B) REMOVE GENERATOR PULLEY SST 09820-63010 (09820-06010, 09820-06020) HINT: Hold SST (1-A, B) 09820-06010 SST (2) 09820-06020 (a) Turn A92680 Hold SST (1-A) with a torque wrench, and tighten SST (1-B) clockwise to the specified torque. Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) NOTICE: Check that SST is secured to the rotor shaft. (b) Mount SST (2) in a vise. (c) Insert SST (1-A, B) into SST (2), and attach the pulley nut to SST (2). SST (2) Insert SST (1) A81659 (d) To loosen the pulley nut, turn SST (1-A) in the direction shown in the illustration. NOTICE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half turn. (e) Remove the generator from SST (2). SST(1-A) Turn A81660 (f) (g) SST (1-A) SST (1-B) Turn SST (1-B) and remove SST (1-A, B). Remove the pulley nut and pulley. Turn Hold A81661 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2914 19-43 STARTING & CHARGING - GENERATOR ASSY (3MZ-FE) 2. (a) (b) REMOVE GENERATOR REAR END COVER Place the generator on the pulley. Remove the 3 nuts and rear end cover. 3. (a) REMOVE TERMINAL INSULATOR Remove the terminal insulator from the rectifier end frame. 4. (a) REMOVE GENERATOR BRUSH HOLDER ASSY 100 A: Remove the 2 screws and brush holder. (b) 130 A: Remove the brush holder. (1) Remove the plate seal. (2) Remove the 2 screws and brush holder. (3) Remove the plate seal. 5. (a) REMOVE GENERATOR RECTIFIER END FRAME Remove the 4 bolts. Pulley A81662 A81146 100 A A81147 130 A A79736 A81148 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2915 19-44 STARTING & CHARGING GENERATOR ASSY (3MZ-FE) (b) Using SST, remove the rectifier end frame. SST 09950- 40011 (09951- 04020, 09952- 04010, 09953- 04020, 09954- 04010, 09955- 04071, 09957-04010, 09958-04011) 6. (a) REMOVE GENERATOR ROTOR ASSY Remove the washer and rotor. Turn SST - Hold A81663 Washer A81664 7. (a) INSPECT GENERATOR BRUSH HOLDER ASSY 100 A: Using a vernier caliper, measure the exposed brush length. Standard exposed brush length: 10.5 mm (0.413 in.) Minimum exposed brush length: 4.5 mm (0.177 in.) If the exposed brush length is less than the minimum, replace the brush holder assy. Length A79305 (b) 130 A: Using a vernier caliper, measure the exposed brush length. Standard exposed brush length: 10.5 mm (0.413 in.) Minimum exposed brush length: 4.5 mm (0.177 in.) If the exposed brush length is less than the minimum, replace the brush holder assy. Length B16374 8. INSPECT GENERATOR ROTOR ASSY (a) Check that the bearing is not rough or worn. 100 A: If necessary, replace the rotor assy. 130 A: If necessary, replace the rotor bearing. A79306 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2916 19-45 STARTING & CHARGING - GENERATOR ASSY (3MZ-FE) (b) Check if the rotor has open circuit. (1) Measure the resistance between the slip ring. Resistance: 2.3 to 2.7 Ω at 20
C (68
F) If the resistance is not as specified, replace the generator rotor. Slip Ring 2.3 to 2.7 Ω at 20
C (68
F) A81665 Slip Ring (c) Check the rotor for ground. (1) Measure the resistance between the slip ring and rotor core. Standard: 1 MΩ or higher If the resistance is not as specified, replace the rotor assy. (d) Check that the slip rings are not rough or scored. If rough or scored, replace the rotor assy. Rotor Core 1 MΩ or Higher A81666 (e) Using vernier calipers, measure the slip ring diameter. Standard diameter: 14.2 to 14.4 mm (0.559 to 0.567 in.) Minimum diameter: 14.0 mm (0.551 in.) If the diameter is less than the minimum, replace the rotor assy. Diameter A75676 9. 130 A: REMOVE GENERATOR ROTOR BEARING (a) Using SST, remove the bearing cover (outside) and bearing. SST 09820-00021 NOTICE: Be careful not to damage the fan. (b) Remove the bearing cover (inside). SST Hold A75678 10. SST (a) (b) (c) Generator Pulley 130 A: INSTALL GENERATOR ROTOR BEARING Place the generator rotor on the generator pulley. Install the bearing cover (inside). Using SST and a press, press in a new bearing. SST 09820-00031 A75679 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2917 19-46 STARTING & CHARGING (d) SST - GENERATOR ASSY (3MZ-FE) Using SST, push in the bearing cover (outside). SST 09285-76010 A75680 11. INSPECT GENERATOR DRIVE END FRAME BEARING (a) Check that the bearing is not rough or worn. If necessary, replace the bearing. A81155 12. (a) REMOVE GENERATOR DRIVE END FRAME BEARING Remove the 4 screws and retainer plate. (b) Using SST and a wooden block, tap out the bearing. SST 09950- 60010 (09951- 00250), 09950- 70010 (09951-07100) 13. (a) INSTALL GENERATOR DRIVE END FRAME BEARING Using SST and a press, press in a new bearing. SST 09950- 60010 (09951- 00470), 09950- 70010 (09951-07100) A81156 Wooden Block SST A81667 SST A81668 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2918 19-47 STARTING & CHARGING - GENERATOR ASSY (3MZ-FE) (b) Install the retainer plate with the 4 screws. Torque: 2.3 N⋅m (23 kgf⋅cm, 20 in.⋅lbf) 14. (a) (b) INSTALL GENERATOR ROTOR ASSY Place the drive end frame on the pulley. Install the rotor and washer. 15. (a) INSTALL GENERATOR RECTIFIER END FRAME 100 A: Using deep socket wrench 21 and a press, press in the coil carefully. 130 A: Using deep socket wrench 20 and a press, press in the coil carefully. A81156 Washer Pulley A81670 Deep Socket Wrench 20 or 21 (b) A81671 (c) Tighten the 4 bolts. Torque: 5.8 N⋅m (59 kgf⋅cm, 51 in.⋅lbf) 16. (a) INSTALL GENERATOR BRUSH HOLDER ASSY 100 A: Install the brush holder. (1) While pushing the 2 brushes to inside the brush holder, insert a pin (φ1.0 mm (0.039 in.)) into the brush holder hole. A81148 100 A Pin (φ1.0 mm (0.039 in.)) A79315 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2919 19-48 STARTING & CHARGING 100 A - GENERATOR ASSY (3MZ-FE) (2) Install the generator brush holder with the 2 screws. Torque: 1.8 N⋅m (18 kgf⋅cm, 16 in.⋅lbf) (3) Pull out the pin (φ1.0 mm (0.039 in.)) from the generator brush holder. Pin (φ1.0 mm (0.039 in.)) A81672 130 A (b) Pin A79736 130 A: Install the brush holder. (1) Install the plate seal (inside). (2) Place the brush holder with the pin facing upward. NOTICE: Be careful of the generator brush holder installing direction. (3) Tighten the 2 screws. Torque: 1.8 N⋅m (18 kgf⋅cm, 16 in.⋅lbf) (4) Align the pins of the brush holder with the holes of the plate seal (outside), and install the plate seal (outside). 17. INSTALL TERMINAL INSULATOR (a) Install the terminal insulator. NOTICE: pay attention to the mounting direction of the terminal insulator. A81146 18. (a) INSTALL GENERATOR REAR END COVER Install the rear end cover with the 3 nuts. Torque: 4.6 N⋅m (47 kgf⋅cm, 41 in.⋅lbf) A81164 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2920 19-49 STARTING & CHARGING 19. SST (1-A) SST (1-B) - GENERATOR ASSY (3MZ-FE) INSTALL GENERATOR PULLEY SST 09820-63010 (09820-06010, 09820-06020) HINT: Hold SST 1-A and B 09820-06010 SST 2 09820-06020 (a) Turn A92680 Install the pulley to the rotor shaft by tightening the generator pulley nut by hand. (b) Hold SST (1-A) with a torque wrench, and tighten SST (1-B) clockwise with the specified torque. Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) NOTICE: Check that SST is secured to the rotor shaft. (c) (d) Mount SST (2) in a vise. Insert SST (1-A) and (B) into SST (2), and attach the generator pulley nut to SST (2). (e) Tighten the pulley nut by turning SST (1-A) in the direction shown in the illustration. Torque: 111 N⋅m (1,125 kgf⋅cm, 81 ft⋅lbf) Remove the generator from SST (2). SST (2) Insert SST (1) A81659 (f) SST (1-A) Turn A81673 SST (1-A) SST (1-B) (g) (h) Turn SST (1-B), and remove SST (1-A), (B). Turn the pulley, and check that the pulley moves smoothly. Turn Hold A81661 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2921 19-40 STARTING & CHARGING - GENERATOR ASSY (3MZ-FE) 190O5-04 REPLACEMENT (a) (c) 1. (a) (b) (c) REMOVE GENERATOR ASSY Remove the wire harness clamp. Disconnect the generator connector. Open the terminal cap, remove the nut and disconnect the generator wire. (d) (e) Loosen bolts A and B. Loosen bolt C to lessen the tension of the V belt. (f) Remove bolts A and B, and the generator. 2. (a) INSTALL GENERATOR ASSY Temporarily install the generator with bolts A and B. (b) A79746 A B C A81657 A B A79747 A B A79747 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2912 19-41 STARTING & CHARGING (b) (c) A (d) B 3. C (e) (f) INSPECT V BELT (See page 14-121 ) A81657 - GENERATOR ASSY (3MZ-FE) Adjust the V belt tension by tightening bolt C (see page 14-125 ). Tighten bolts A and B. Torque: 58 N⋅m (592 kgf⋅cm, 43 ft⋅lbf) for bolt A 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) for bolt B Install the generator wire with the nut. Torque: 9.8 N⋅m (100 kgf⋅cm, 7.0 ft⋅lbf) Connect the generator connector. Install the wire harness clamp. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2913 26-2 FRONT SUSPENSION - FRONT SUSPENSION SYSTEM 260DX-07 HOW TO PROCEED WITH TROUBLESHOOTING HINT: This is the repair procedure for vehicle pull. START * ROAD TEST Does the vehicle pull? Preliminary Check  Tire pressure  Vehicle height  Brake dragging NO Is the steering off center? NO COMPLETE YES YES Adjust front tie rods. YES Are the tires uni-directional type? NO NO ROAD TEST Does the vehicle still pull? Cross switch front tire & wheel assemblies (left & right). YES YES Does the vehicle pull in the same direction as before? NO Choose the position of front tire & wheel assemblies where there is least amount of pull. Check front wheel alignment. Is it within specification? YES NO Is the pull stronger than before? YES NO Reverse the front left side tire and rebalance it. Adjust front wheel alignment. ROAD TEST Does the vehicle still pull? YES NO ROAD TEST Does the vehicle still pull? YES Does the vehicle pull to the left? COMPLETE YES Increase right front camber and decrease left front camber until pull is eliminated. NO NO NO NOTICE : Do not exceed 1° of cross camber. Do not exceed adjustment range. Increase left front camber and decrease right front camber until pull is eliminated. ROAD TEST Does the vehicle still pull? YES Contact your local retail tire distributor. *Select a flat road where the vehicle can be driven in a straight line for 100 meters at a constant speed of 56km/h (35mph). Please confirm safety and set the steering wheel straight ahead. Drive the vehicle in a straight line for 100 meters at a constant speed of 56km/h (35mph) without holding the steering wheel. (1) The vehicle can keep straight but the steering wheel has some angle. STEERING OFF CENTER (See page 50-4 ) (2) The vehicle cannot keep straight. VEHICLE PULL 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2923 26-1 FRONT SUSPENSION - FRONT SUSPENSION SYSTEM FRONT SUSPENSION SYSTEM 260H6-04 PROBLEM SYMPTOMS TABLE Use the table below to help determine the cause of the problem. The numbers indicate the priority of the possible cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Bottoming Sways/pitches Suspected Area See page 1. Vehicle (Overloaded) 2. Spring (Weak) 3. Shock absorber (Worn) 26-12 26-12 1. Tire (Worn or improperly inflated) 2. Stabilizer bar (Bent or broken) 28-1 26-22 26-25 26-12 3. Shock absorber (Worn) 1. 2. 3. 4. Tire (Worn or improperly inflated) Wheel (Out of balance) Shock absorber (Worn) Wheel alignment (Incorrect) 5. 6. 7. 8. Ball joint (Worn) Hub bearing (Worn) Steering linkage (Loose or worn) Steering gear (Out of adjustment or broken) Front wheel shimmy 1. Tire (Worn or improperly inflated) 2. Wheel alignment (Incorrect) 3. Shock absorber (Worn) 4. Suspension parts (Worn) 28-1 26-7 27-5 26-12 - 1. 2. 3. 4. 5. 26-2 26-2 26-2 26-2 26-2 Abnormal tire wear Vehicle pull 28-1 28-1 26-12 26-7 27-5 26-20 30-3 51-3 Tire Tire pressure (incorrect) Wheel alignment (Incorrect) Brake (Dragging) Steering wheel (Off center) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2922 26-7 FRONT SUSPENSION - FRONT WHEEL ALIGNMENT FRONT WHEEL ALIGNMENT 260H7-03 ADJUSTMENT 1. INSPECT TIRE (SEE PAGE 26-7 ) 2. MEASURE VEHICLE HEIGHT Vehicle height: A B FF C 4WD DC D G31173 A B Front A - B Rear D - C FF 120.1 mm (4.73 in.) 40.5 mm (1.59 in.) 4WD 110.1 mm (4.33 in.) 30.5 mm (1.20 in.) Measuring points: A: Ground clearance of front wheel center B: Ground clearance of lower suspension arm No.2 bush set bolt center C: Ground clearance of strut rod set bolt center D: Ground clearance of rear wheel center NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specified value. HINT: Bounce the vehicle at the corners up and down to stabilize the suspension and inspect the vehicle height. 3. D Front INSPECT TOE-IN Toe-in: Toe-in (total) C SA3213 If the toe-in is not within the specified range, adjust it at the rack ends. 4. ADJUST TOE-IN (a) Remove the rack boot set clips. (b) Loosen the tie rod end lock nuts. (c) G23792 A + B: 0° ± 10’ (0° ± 0.16°) C - D: 0 ± 2 mm (0 ± 0.08 in.) Turn the right and left rack ends by equal amounts to adjust the toe-in. HINT: Try to adjust the toe-in to the center of the specified value. (d) Make sure that the lengths of the right and left rack ends are the same. Rack and length difference: 1.5 mm (0.059 in.) or less (e) Torque the tie rod end lock nuts. Torque: 74 N·m (755 kgf·cm, 55 ft·lbf) (f) Place the boots on the seats and install the clips. HINT: Make sure that the boots are not twisted. (g) Perform VSC system calibration (see page 05-765 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2928 26-8 FRONT SUSPENSION FRONT WHEEL ALIGNMENT 5. (a) INSPECT WHEEL ANGLE Turn the steering wheel fully left and right to measure the turning angle. Wheel turning angle: Front A B - B A Front A: Inside B: Outside F46953 Inside wheel Outside wheel: Reference FF 35
28’
2
(35.47

2
) 31
13’ (31.22
) 4WD 35
41’
2
(35.68

2
) 31
22’ (31.37
) If the right and left inside wheel angles differ from the specified value, check and adjust the right and left rack end lengths. 6. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION (a) Put the front wheel on the center of the alignment tester. (b) Set the camber - caster - kingpin gauge at the center of the axle hub or drive shaft. Camber, caster and steering axis inclination: Gauge Alignment Tester FF 4WD Right-left error -0 °40’ ± 45’ (-0.67 ° ± 0.75°) 45’ (0.75°) or less -0 °35’ ± 45’ (-0.58 ° ± 0.75°) 45’ (0.75°) or less Right-left error 2°45’ ± 45’ (2.75° ± 0.75°) 45’ (0.75°) or less 2°45’ ± 45’ (2.75° ± 0.75°) 45’ (0.75°) or less 10°45’ ± 45’ (10.75° ± 0.75°) 45’ (0.75°) or less 10°35’ ± 45’ (10.58° ± 0.75°) 45’ (0.75°) or less Camber Z03382 Caster Steering axis inclination Right-left error C83886 If the caster and steering axis inclination are not within the specified values after the camber has been correctly adjusted, recheck the suspension parts for damage and/or wear. 7. ADJUST CAMBER NOTICE: Inspect toe-in after the camber has been adjusted. (a) Remove the front wheel. (b) Remove the 2 nuts on the lower side of the shock absorber. HINT: When removing the nuts, keep the bolts from rotating. (c) Clean the installation surface of the shock absorber and the steering knuckle. (d) Temporarily install the 2 nuts. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2929 26-9 FRONT SUSPENSION (e) (f) 1 2 G32193 - FRONT WHEEL ALIGNMENT Fully push or pull the front axle hub in the direction of the required adjustment. Tighten the nuts. Torque: 230 N⋅m (2,350 kgf⋅cm, 170 ft⋅lbf) HINT: When installing the nuts, keep the bolts from rotating and then torque the nuts. (g) Install the front wheel. Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) NOTICE: Keep the bolts from rotating and torque the nuts. (h) Install the front wheel. Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) (i) Check the camber. If the measured value is not within the specified range, calculate the required adjustment amount using the formula below. (Camber adjustment amount) = Center of the specified range medium - Measured value Check installed bolts combination. Select appropriate bolts from the table below to adjust the camber to within the specified range. Move the axle toward (+) in step (e) Refer to table (1) (Move the axle toward positive side) Move the axle toward (-) in step (e) Refer to table (2) (Move the axle toward negative side) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2930 26-10 FRONT SUSPENSION - FRONT WHEEL ALIGNMENT Table (1) (Move the axle toward positive side) Installed 1 Bolt Adjusting 2 Value -1
30’ to -1
15’ No Dot No Dot No Dot No Dot 1 Dot 2 Dots 3 Dots No Dot 1 Dot 2 Dots 3 Dots 3 Dots 3 Dots 3 Dots G -1
15’ to -1
00’ G A G A B G A B C G A B C D G A B C D E F -1
00’ to -0
45’ -0
45’ to -0
30’ -0
30’ to -0
15’ -0
15’ to 0
0
to 0
15’ A B C D E 0
15’ to 0
30 B C D F 0
30’ to 0
45’ C D E E F 0
45’ to 1
00’ D E F 1
00’ to 1
15’ E F 1
15’ to 1
30’ F Selected Bolt Combination A B C D E F G 90105-17012 90105-17012 90105-17012 90105-17013 90105-17014 90105-17015 90105-17012 90105-17013 90105-17014 90105-17015 90105-17015 90105-17015 90105-17015 90105-17012 1 2 Bolt Distinguishing Mark No Dot 90105-17012 1 Dot 90105-17013 2 Dots 3 Dots 90105-17014 90105-17015 F47223 The body and suspension may be damaged if the camber is not correctly adjusted according to the above table. NOTICE: Replace the nut with a new one when replacing the bolt. (j) Repeat the steps mentioned above. At step (b), replace 1 or 2 selected bolts. HINT: Replace one bolt at a time when replacing 2 bolts. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2931 26-1 1 FRONT SUSPENSION - FRONT WHEEL ALIGNMENT Table (2) (Move the axle toward negative side) Installed 1 Bolt Adjusting 2 Value -1
30’ to -1
15’ No Dot No Dot No Dot No Dot 1 Dot 2 Dots 3 Dots No Dot 1 Dot 2 Dots 3 Dots 3 Dots 3 Dots 3 Dots -1
15’ to -1
00’ E F -1
00’ to -0
45’ D E F -0
45’ to -0
30’ C D E F -0
30’ to -0
15’ B C D E F -0
15’ to 0
A B C D E F G A B C D E G A B C D G A B C G A B G A F 0
to 0
15’ 0
15’ to 0
30 0
30’ to 0
45’ 0
45’ to 1
00’ 1
00’ to 1
15’ 1
15’ to 1
30’ G Selected Bolt Combination A B C D E F G 90105-17012 90105-17012 90105-17012 90105-17013 90105-17014 90105-17015 90105-17012 90105-17013 90105-17014 90105-17015 90105-17015 90105-17015 90105-17015 90105-17012 1 2 Bolt Distinguishing Mark No Dot 90105-17012 1 Dot 90105-17013 2 Dots 3 Dots 90105-17014 90105-17015 F47223 The body and suspension may be damaged if the camber is not correctly adjusted according to the above table. NOTICE: Replace the nut with a new one when replacing the bolt. (k) Repeat the steps mentioned above. At step (b), replace 1 or 2 selected bolts. HINT: Replace one bolt at a time when replacing 2 bolts. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2932 26-17 FRONT SUSPENSION - SHOCK ABSORBER ASSY FRONT LH 260H9-02 DISPOSAL HINT: Dispose of the RH side by following the same procedures as with the LH side. 1. (a) (b) DISPOSE OF SHOCK ABSORBER ASSY FRONT LH Fully extend the shock absorber rod. Using a drill, make a hole in the cylinder as shown in the illustration to discharge the gas inside. CAUTION:
Be careful when drilling because shards of metal may fly about. Always use the proper safety equipment.
The gas is colorless, odorless and non-poisonous. G29259 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2938 26-12 FRONT SUSPENSION - SHOCK ABSORBER ASSY FRONT LH SHOCK ABSORBER ASSY FRONT LH 260H8-02 REPLACEMENT HINT:


1. COMPONENTS: See page 26-3 Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. REMOVE FRONT WHEEL 2. (a) SEPARATE FRONT STABILIZER LINK ASSY LH Remove the nut and separate the front stabilizer link assy LH from the shock absorber assy front LH. HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud. C83858 G25726 3. REMOVE FRONT SHOCK ABSORBER WITH COIL SPRING (a) Loosen the lock nut. NOTICE:
Do not loosen or remove the lock nut except when disassmbling the shock absorber assy front LH with coil spring.
Do not remove the lock nut. G29254 (b) Remove the bolt and disconnect the front flexible hose No. 1 and speed sensor front LH wire harness. (c) Remove the 2 nuts and bolts on the lower side of front shock absorber with coil spring. F40138 HINT: When removing the bolts, keep the bolt from rotating and loosen the nut. C83886 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2933 26-13 FRONT SUSPENSION - SHOCK ABSORBER ASSY FRONT LH (d) Remove the 3 nuts on the upper side of the front shock absorber with coil spring. (e) Remove the front shock absorber with coil spring. NOTICE: Make sure that the front speed sensor is disconnected from the front shock absorber. G29255 4. (a) SST SST G29256 FIX FRONT SHOCK ABSORBER WITH COIL SPRING As shown in the illustration to the left, secure the front shock absorber with coil spring in a vise by clamping onto a double nutted bolt affixed to the bracket at the bottom of the absorber. F47185 5. (a) REMOVE SHOCK ABSORBER ASSY FRONT LH Using SST, compress the front coil spring LH. SST 09727-30021 (09727-00010, 09727-00021) NOTICE: Do not use an impact wrench. It will damage the SST. HINT: Use 2 of the same type of SST. (b) Remove the front suspension support sub-assy LH, front suspension support bearing LH, front coil spring seat upper LH, front coil spring insulator upper LH, front coil spring LH, front spring bumper LH and front coil spring insulator lower LH from the shock absorber assy front LH. 6. INSPECT SHOCK ABSORBER ASSY FRONT LH (a) Compress and extend the shock absorber rod 4 times or more. Then check that there is no abnormal resistance or sound and operation resistance is normal. If there is any abnormality, replace the shock absorber assy front LH with a new one. NOTICE: When disposing of the shock absorber assy front LH, see G29257 DISPOSAL on page 26-17 . 7. INSTALL SHOCK ABSORBER ASSY FRONT LH (a) Install the front coil spring insulator lower LH onto the shock absorber assy front LH. (b) Install the front spring bumper LH to the piston rod. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2934 26-14 FRONT SUSPENSION - SHOCK ABSORBER ASSY FRONT LH (c) SST C83860 F47700 Using SST, compress the front coil spring LH. SST 09727-30021 (09727-00010, 09727-00021) NOTICE: Do not use an impact wrench. It will damage the SST. HINT: Use 2 of the same type of SST. (d) Install the front coil spring LH to the shock absorber assy front LH. HINT: Fit the lower end of the front coil spring LH in the gap of the spring lnsulator lower LH. (e) Install the front coil spring insulator upper LH with the mark facing to the outside of the vehicle as shown in the illustration. (f) Install the front coil spring seat upper LH to the shock absorber assy front LH with the mark facing to the outside of the vehicle. (g) Install a new front suspension support bearing LH. Outside Outside Mark G25037 G25727 Outside 5 G25038 5 Mark G25729 F40162 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2935 26-15 FRONT SUSPENSION Outside Outside Mark (h) (i) (j) - SHOCK ABSORBER ASSY FRONT LH Install the front suspension support sub-assy LH with the mark facing to the outside of the vehicle. Temporarily tighten a new lock nut. Remove the SST slowly in order to release the coil spring. SST 09727-30021 (09727-00010, 09727-00021) G29258 8. G29255 INSTALL FRONT SHOCK ABSORBER WITH COIL SPRING (a) Install the front shock absorber with coil spring . (b) Install the 3 nuts to the upper side of front shock absorber with coil spring. Torque: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf) NOTICE: Do not tighten the lock nuts until installing the bolts and nuts (lower side). (c) Install the 2 bolts and 2 nuts to the lower side of front shock absorber with coil spring. Torque: 230 N⋅m (2,350 kgf⋅cm, 170 ft⋅lbf) HINT: When installing the nuts, keep the bolts from rotating and torque the nut. C83886 (d) Install the front flexible hose No. 1 and speed sensor wire harness front LH with the bolt. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) (e) Fully tighten the lock nut. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) F40138 G29254 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2936 26-16 FRONT SUSPENSION 9. (a) - SHOCK ABSORBER ASSY FRONT LH INSTALL FRONT STABILIZER LINK ASSY LH Install the front stabilizer link assy LH with the nut. Torque: 74 N⋅m (755 kgf⋅cm, 55 ft⋅lbf) HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud. F40136 10. 11. INSTALL FRONT WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (SEE PAGE 26-7 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2937 26-20 FRONT SUSPENSION - LOWER BALL JOINT ASSY FRONT LH LOWER BALL JOINT ASSY FRONT LH 260HB-02 REPLACEMENT HINT:


1. 2. 3. 4. 5. 6. 7. 8. COMPONENTS: See page 26-3 . Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. REMOVE FRONT WHEEL REMOVE FRONT AXLE HUB LH NUT (SEE PAGE 30-21 ) SST 09930-00010 SEPARATE SPEED SENSOR FRONT LH (SEE PAGE 30-21 ) SEPARATE FRONT DISC BRAKE CALIPER ASSY LH (SEE PAGE 30-38 ) REMOVE FRONT DISC SEPARATE TIE ROD END SUB-ASSY LH (SEE PAGE 30-21 ) SST 09628-6201 1 SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH (SEE PAGE 30-21 ) REMOVE FRONT AXLE ASSY LH (SEE PAGE 30-38 ) 9. (a) (b) REMOVE LOWER BALL JOINT ASSY FRONT LH Remove the cotter pin and castle nut. Using SST, remove the lower ball joint assy front LH. SST 09628-6201 1 C95204 10. (a) INSPECT LOWER BALL JOINT ASSY FRONT LH As shown in the illustration, flip the ball joint stud back and forth 5 times. (b) Using a torque wrench and nut, turn the ball joint continuously at a rate of 3 to 5 seconds per turn and take the torque reading on the 5th turn. Turning torque: 0.98 to 3.43 N·m (10 to 35 kgf·cm, 8.7 to 30 in.·lbf) If the value is not within the specification, replace the lower ball ZX1712 joint assy front LH with a new one. 11. INSTALL LOWER BALL JOINT ASSY FRONT LH (a) Install the lower ball joint assy front LH to the steering knuckle with the castle nut. Torque: 123 N⋅m (1,250 kgf⋅cm, 91 ft⋅lbf) NOTICE: Prevent oil from adhering to the screw and tapered parts. (b) Install a new cotter pin to the steering knuckle. NOTICE: If the holes for the cotter pin are not aligned, tighten the nut up to 60 further. 12. INSTALL FRONT AXLE ASSY LH (SEE PAGE 30-38 ) 13. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH (SEE PAGE 30-21 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2941 26-21 FRONT SUSPENSION 14. 15. 16. 17. 18. 19. 20. 21. - LOWER BALL JOINT ASSY FRONT LH INSTALL TIE ROD END SUB-ASSY LH (SEE PAGE 30-21 ) INSTALL FRONT DISC INSTALL FRONT DISC BRAKE CALIPER ASSY LH (SEE PAGE 30-38 ) INSTALL SPEED SENSOR FRONT LH (SEE PAGE 30-21 ) INSTALL FRONT AXLE HUB LH NUT (SEE PAGE 30-21 ) INSTALL FRONT WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (SEE PAGE 26-7 ) CHECK ABS SPEED SENSOR SIGNAL (SEE PAGE 05-765 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2942 26-3 FRONT SUSPENSION - FRONT SUSPENSION FRONT SUSPENSION 260DY-05 COMPONENTS 80 (816, 59)
49 (500, 36) Front Suspension Support Sub-assy LH Front Stabilizer Link Assy LH Front Suspension Support
Bearing LH 74 (755, 55) Front Coil Spring Seat Upper LH Front Shock Absorber w/ Coil Spring Front Coil Spring Insulator Upper LH Front Spring Bumper LH 230 (2,350, 170) Speed Sensor front LH Front Coil Spring Insulator Lower LH 19 (194, 14) Front Flexible Hose No.1 Front Coil Spring LH Shock Absorber Assy Front LH Front Axle Assy LH N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part G29262 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2924 26-4 FRONT SUSPENSION - FRONT SUSPENSION Tie Rod Assy LH 74 (755, 55) Speed Sensor Front LH Front Stabilizer Link Assy LH 230 (2,350, 170) 8.0 (82, 71 in.⋅lbf) 104 (1,060, 77) 123 (1,250, 91) Front Disc
Cotter Pin 104 (1,060, 77) Front Brake Caliper Assy Front Axle Assy LH
294 (3,000, 217) Front Suspension Member Dynamic Damper Transverse Engine Engine Mounting Insulator 3MZ-FE: 29 (296, 21) 49 (500, 36)
Cotter Pin 200 (2,040, 148) 200 (2,040, 148) Lower Ball Joint Assy Front LH Front Lower Arm Bush Stopper Front Frame Assy 87 (887, 64) 206 (2,100, 152) 127 (1,300, 94) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part Front Suspension Arm Sub-assy Lower No.1 LH G32192 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2925 26-5 FRONT SUSPENSION - FRONT SUSPENSION FF: 16 (163, 12) Front Stabilizer Bracket No.1 RH 74 (755, 55) Front Stabilizer Bar Bush No.1 16 (163, 12) Front Stabilizer Link Assy RH Front Stabilizer Bracket No.1 LH Stabilizer Bar Front Front Stabilizer Bar Bush No.1 Front Stabilizer Link Assy 74 (755, 55) 74 (755, 55) 230 (2,350, 170) 70 (715, 52) Power Steering Link Assy Front Stabilizer Bracket No.2 RH Front Stabilizer Bracket No.2 LH 49 (500, 36)
Cotter Pin Front Frame Assy N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part F45482 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2926 26-6 FRONT SUSPENSION 4WD: 3MZ-FE Exhaust Manifold Heat Insulator No.1 - FRONT SUSPENSION 8.5 (87, 75 in.⋅lbf) Exhaust Pipe Sub-assy Front No.3 Gasket 49 (500, 36) 56 (571, 41) Exhaust Manifold Converter Sub-assy Gasket Manifold Stay 56 (571, 41) 34 (347, 25) 48 (489, 35) 34 (347, 25) 16 (163, 12) 16 (163, 12) Front Stabilizer Bracket No.1 LH Front Stabilizer Bracket No.1 RH Front Stabilizer Bar Bush No.1 Front Stabilizer Link Assy RH Front Stabilizer Bar Bush No.1 Stabilizer Bar Front Front Stabilizer Link Assy LH 74 (755, 55) Front Stabilizer Bracket No.2 RH 70 (715, 52) 74 (755, 55) 74 (755, 55) Power Steering Link Assy 230 (2,350, 170) Front Stabilizer Bracket No.2 LH 70 (715, 52) Front Frame Assy 49 (500, 36) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part
Cotter Pin F45483 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2927 26-18 FRONT SUSPENSION - FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH 260HA-02 REPLACEMENT HINT:


1. 2. COMPONENTS: See page 26-3 . Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 ) REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (2AZ-FE ENGINE TYPE) (SEE PAGE 14-24 ) 3. (a) REMOVE TRANSVERSE ENGINE MOUNTING INSULATOR Remove the 3 nuts and the transverse engine mounting insulator. C83387 4. (a) (b) REMOVE FRONT SUSPENSION ARM SUB- ASSY LOWER NO.1 LH Remove the 3 bolts and the nut on the suspension arm lower No.1 LH and remove it from the front frame assy. Remove the front lower arm bush stopper. C65934 5. 1 2 (a) (b) 3 C65934 C66233 (c) INSTALL FRONT SUSPENSION ARM SUB- ASSY LOWER NO.1 LH Install the front lower arm bush stopper. Install the suspension arm lower No.1 LH to the front frame assy with the 3 bolts and the nut. Tighten the 3 bolts in numerical order as shown in the illustration. Torque: (bolt 1, 2) 200 N⋅m (2,040 kgf⋅cm, 148 ft⋅lbf) (bolt 3) 206 N⋅m (2,100 kgf⋅cm, 152 ft⋅lbf) HINT: Start tightening the bolts from the front side of the vehicle. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2939 FRONT SUSPENSION 6. (a) - FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH 26-19 INSTALL TRANSVERSE ENGINE MOUNTING INSULATOR Install the transverse engine mounting insulator with the 3 nuts. Torque: 87 N⋅m (887 kgf⋅cm, 64 ft⋅lbf) C83387 7. 8. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 ) INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (2AZ-FE ENGINE TYPE) (SEE PAGE 14-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2940 26-25 FRONT SUSPENSION - STABILIZER BAR FRONT (4WD) STABILIZER BAR FRONT (4WD) 260HD-04 REPLACEMENT HINT:


1. COMPONENTS: See page 28-1 . Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. REMOVE FRONT WHEEL 2. REMOVE FRONT STABILIZER LINK ASSY LH (a) Remove the 2 nuts and the front stabilizer link assy LH. HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud. F40143 3. REMOVE FRONT STABILIZER LINK ASSY RH HINT: Remove the RH side following the same procedures as with the LH side. 4. (a) 5. INSPECT FRONT STABILIZER LINK ASSY LH As shown in the illustration, flip the ball joint stud back and forth 5 times. (b) Using a torque wrench and nut, turn the nut continuously at a rate of 2 to 4 seconds per turn and take the torque reading on the 5th turn. Turning torque: 0.05 to 1.96 N·m (0.5 to 20 kgf·cm, 0.4 to 17.4 in.·lbf) If the value is not within the specification, replace the front stabiC66721 lizer link assy LH with a new one. REMOVE EXHAUST PIPE SUB-ASSY FRONT NO.3 (3MZ-FE ENGINE TYPE) (SEE PAGE 15-5 ) 6. (a) REMOVE FRONT STABILIZER BRACKET NO.1 LH Remove the 2 bolts and front stabilizer bracket No.1 LH. F40144 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2946 26-26 FRONT SUSPENSION - STABILIZER BAR FRONT (4WD) 7. REMOVE FRONT STABILIZER BRACKET NO.1 RH HINT: Remove the RH side following the same procedures as with the LH side. 8. REMOVE FRONT STABILIZER BRACKET NO.2 LH (a) Remove the front stabilizer bracket No.2 LH from the stabilizer bar bush. 9. REMOVE FRONT STABILIZER BRACKET NO.2 RH HINT: Remove the RH side following the same procedures with the LH side. 10. SEPARATE TIE ROD END SUB-ASSY LH (SEE PAGE 30-21 ) SST 09628-6201 1 11. SEPARATE TIE ROD END SUB-ASSY RH SST 09628-6201 1 HINT: Separate the RH side following the same procedures as with the LH side. 12. SEPARATE STEERING INTERMEDIATE SHAFT SUB-ASSY (SEE PAGE 51-28 ) 13. DISCONNECT RETURN TUBE ASSY (SEE PAGE 51-28 ) SST 09023-12701 14. DISCONNECT PRESSURE FEED TUBE ASSY (SEE PAGE 51-28 ) SST 09023-12701 15. REMOVE POWER STEERING LINK ASSY (SEE PAGE 51-28 ) 16. REMOVE FRONT STABILIZER BAR BUSH NO.1 (a) Remove the 2 bushes from the stabilizer. 17. REMOVE MANIFOLD STAY (3MZ-FE ENGINE TYPE) (SEE PAGE 15-5 ) 18. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1 (3MZ-FE ENGINE TYPE) (SEE PAGE 15-5 ) 19. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 15-5 ) 20. REMOVE STABILIZER BAR FRONT (a) Remove the stabilizer bar front from the vehicle. 21. INSTALL STABILIZER BAR FRONT (a) Install the stabilizer bar front from the vehicle. 22. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 15-5 ) 23. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 (3MZ-FE ENGINE TYPE) (SEE PAGE 15-5 ) 24. INSTALL MANIFOLD STAY (3MZ-FE ENGINE TYPE) (SEE PAGE 15-5 ) Outer side Cutout Rear side 25. INSTALL FRONT STABILIZER BAR BUSH NO.1 HINT:
Install the bushing to the outer side of the bush stopper on the stabilizer bar.
Place the cutout of the stabilizer bush facing the rear side as shown in the illustration. Bush stopper G31174 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2947 26-27 FRONT SUSPENSION 26. 27. 28. - STABILIZER BAR FRONT (4WD) INSTALL POWER STEERING LINK ASSY (SEE PAGE 51-28 ) INSTALL PRESSURE FEED TUBE ASSY (SEE PAGE 51-28 ) SST 09023-12701 INSTALL RETURN TUBE ASSY (SEE PAGE 51-28 ) SST 09023-12701 CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSY (SEE PAGE 51-28 ) INSTALL TIE ROD END SUB-ASSY LH (SEE PAGE 30-21 ) INSTALL TIE ROD END SUB-ASSY RH 29. 30. 31. HINT: Install the RH side following the same procedures as with the LH side. 32. INSTALL FRONT STABILIZER BRACKET NO.2 LH (a) Install the front stabilizer bracket No. 2 to the stabilizer bar bush No.1. 33. INSTALL FRONT STABILIZER BRACKET NO.2 RH HINT: Install the RH side following the same procedures as with the LH side. 34. INSTALL FRONT STABILIZER BRACKET NO.1 LH (a) Install the front stabilizer bracket No. 1 LH with the 2 bolts. Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf) F40144 35. INSTALL FRONT STABILIZER BRACKET NO.1 RH HINT: Install the RH side following the same procedures as with the LH side. 36. INSTALL EXHAUST PIPE SUB-ASSY FRONT NO.3 (3MZ-FE ENGINE TYPE) (SEE PAGE 15-5 ) 37. INSTALL FRONT STABILIZER LINK ASSY LH (a) Install the front stabilizer link assy LH with the 2 nuts. Torque: 74 N⋅m (755 kgf⋅cm, 55 ft⋅lbf) HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud. F40143 38. INSTALL FRONT STABILIZER LINK ASSY RH HINT: Install the RH side following the same procedures as with the LH side. 39. INSTALL FRONT WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) 40. BLEED POWER STEERING FLUID (SEE PAGE 51-3 ) 41. CHECK POWER STEERING FLUID LEAKAGE 42. INSPECT AND ADJUST STEERING WHEEL CENTER POINT 43. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (SEE PAGE 26-7 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2948 26-22 FRONT SUSPENSION - STABILIZER BAR FRONT (FF) STABILIZER BAR FRONT (FF) 260HC-04 REPLACEMENT HINT:


1. COMPONENTS: See page 26-3 . Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. REMOVE FRONT WHEEL 2. REMOVE FRONT STABILIZER LINK ASSY LH (a) Remove the 2 nuts and the front stabilizer link assy LH. HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud. F40143 3. REMOVE FRONT STABILIZER LINK ASSY RH HINT: Remove the RH side by following the same procedures as with the LH side. 4. (a) C66721 INSPECT FRONT STABILIZER LINK ASSY LH As shown in the illustration, flip the ball joint stud back and forth 5 times . (b) Using a torque wrench and nut, turn the nut continuously at a rate of 2 to 4 seconds per turn and take the torque reading on the 5th turn. Turning torque: 0.05 to 1.96 N·m (0.5 to 20 kgf·cm, 0.4 to 17.4 in.·lbf) If the value is not within the specification, replace the front stabilizer link assy LH with a new one. 5. REMOVE FRONT STABILIZER BRACKET NO.1 LH (a) Remove the 2 bolts and the front stabilizer bracket No. 1 LH. F40144 6. REMOVE FRONT STABILIZER BRACKET NO.1 RH HINT: Remove the RH side by following the same procedures as with the LH side. 7. REMOVE FRONT STABILIZER BRACKET NO.2 LH (a) Remove the front stabilizer bracket No. 2 LH from the stabilizer bar bush. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2943 26-23 FRONT SUSPENSION - STABILIZER BAR FRONT (FF) 8. REMOVE FRONT STABILIZER BRACKET NO.2 RH HINT: Remove the RH side following the same procedures as with as the LH side. 9. DISCONNECT TIE ROD END SUB-ASSY LH (SEE PAGE 30-21 ) SST 09628-6201 1 10. DISCONNECT TIE ROD END SUB-ASSY RH SST 09628-6201 1 HINT: Disconnect the RH side following the same procedures as with the LH side. 11. SEPARATE STEERING INTERMEDIATE SHAFT SUB-ASSY (SEE PAGE 51-28 ) 12. DISCONNECT STEERING GEAR OUTLET RETURN TUBE (SEE PAGE 51-28 ) SST 09023-12701 13. DISCONNECT PRESSURE FEED TUBE ASSY (SEE PAGE 51-28 ) SST 09023-12701 14. REMOVE POWER STEERING LINK ASSY (SEE PAGE 51-28 ) 15. REMOVE FRONT STABILIZER BAR BUSH NO.1 (a) Remove the 2 bushes from the stabilizer. 16. REMOVE STABILIZER BAR FRONT (a) Remove the stabilizer bar front from the vehicle. 17. INSTALL STABILIZER BAR FRONT (a) Install the stabilizer bar front to the vehicle. Outer side Cutout Rear side 18. INSTALL FRONT STABILIZER BAR BUSH NO.1 HINT:
Install the bush to the outer side of the bush stopper on the stabilizer bar.
Place the cutout of the stabilizer bush facing the rear side as shown in the illustration. Bush stopper G31174 19. 20. 21. INSTALL POWER STEERING LINK ASSY (SEE PAGE 51-28 ) INSTALL PRESSURE FEED TUBE ASSY (SEE PAGE 51-28 ) SST 09023-12701 INSTALL STEERING GEAR OUTLET RETURN TUBE (SEE PAGE 51-28 ) SST 09023-12701 CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSY (SEE PAGE 51-28 ) INSTALL TIE ROD END SUB-ASSY LH (SEE PAGE 30-21 ) INSTALL TIE ROD END SUB-ASSY RH 22. 23. 24. HINT: Install the RH side following the same procedures as with the LH side. 25. INSTALL FRONT STABILIZER BRACKET NO.2 LH (a) Install the front stabilizer bracket No. 2 to the stabilizer bar bush No.1. 26. INSTALL FRONT STABILIZER BRACKET NO.2 RH HINT: Install the RH side following the same procedure as with the LH side. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2944 26-24 FRONT SUSPENSION 27. (a) - STABILIZER BAR FRONT (FF) INSTALL FRONT STABILIZER BRACKET NO.1 LH Install the front stabilizer bracket No. 1 LH with the 2 bolts. Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf) F40144 28. INSTALL FRONT STABILIZER BRACKET NO.1 RH HINT: Install the RH side following the same procedures as with the LH side. 29. (a) INSTALL FRONT STABILIZER LINK ASSY LH Install the front stabilizer link assy LH with the 2 nuts. Torque: 74 N⋅m (755 kgf⋅cm, 55 ft⋅lbf) HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud. F40143 30. INSTALL FRONT STABILIZER LINK ASSY RH HINT: Install the RH side following the same procedures as with the LH side. 31. INSTALL FRONT WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) 32. BLEED POWER STEERING FLUID (SEE PAGE 51-3 ) 33. CHECK POWER STEERING FLUID LEAKAGE 34. INSPECT AND ADJUST STEERING WHEEL CENTER POINT 35. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (SEE PAGE 26-7 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2945 27-1 REAR SUSPENSION - REAR SUSPENSION SYSTEM REAR SUSPENSION SYSTEM 2701I-11 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. Symptom Bottoming Sways/pitches Suspected Area See page 1. Vehicle (Overloaded) 2. Spring (Weak) 3. Shock absorber (Worn) 27-7 27-7 1. Tire (Worn or improperly inflated) 2. Stabilizer bar (Bent or broken) 28-1 27-27 27-29 27-7 3. Shock absorber (Worn) Rear wheel shimmy 1. 2. 3. 4. Tire (Worn or improperly inflated) Wheel (Out of balance) Shock absorber (Worn) Wheel alignment (Incorrect) 28-1 28-1 27-7 26-7 27-5 30-3 5. Hub bearing (Worn) 1. Tire (Worn or improperly inflated) 2. Wheel alignment (Incorrect) 28-1 26-7 27-5 27-7 - Abnormal tire wear 3. Shock absorber (Worn) 4. Suspension parts (Worn) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2949 27-5 REAR SUSPENSION - REAR WHEEL ALIGNMENT REAR WHEEL ALIGNMENT 2701J-06 ADJUSTMENT 1. INSPECT TIRE (SEE PAGE 28-1 ) 2. MEASURE VEHICLE HEIGHT (SEE PAGE 26-7 ) NOTICE: Before inspecting wheel alignment, adjust the vehicle height to the specified value. A B 3. D INSPECT TOE-IN A + B: 0°18’ ± 12’ (0.3° ± 0.2°) C - D: 3 ± 2 mm (0.12 ± 0.08 in.) Toe-in (total) Front HINT:

Measure ”C - D” only when ”A + B” cannot be measured. If the toe-in is not within the specified range, inspect the suspension parts and replace them if necessary. C SA3213 4. (a) ADJUST TOE-IN (FF DRIVE TYPE) Measure the lengths of the right and left No.2 lower suspension arms. No. 2 lower suspension arm length difference: 1.5 mm (0.06 in.) or less If the left-right difference is larger than 1.5 mm (0.06 in.), adjust it by following the procedures below. C83001 (b) (c) Loosen the 2 lock nuts. Turn the right and left adjusting tubes by an equal amount to adjust toe-in. HINT:

(d) C83002 Try to adjust the toe-in to the center value. One turn of each adjusting tube will adjust toe-in by approximately 1.1 (111’), 11.1mm (0.437 in.). Torque the 2 lock nuts. Torque: 56 N⋅m (570 kgf⋅cm, 41 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2953 27-6 REAR SUSPENSION - REAR WHEEL ALIGNMENT 5. (a) ADJUST TOE-IN (4WD DRIVE TYPE) Measure the distance between each wheel disc and corner of the toe-adjusting cam, and then confirm that left and right distances are the same. No. 2 lower suspension arm length difference: 1.0 mm (0.04 in.) or less If the left-right difference is larger than 1.0 mm (0.04 in.), adjust it by following the procedures below. (b) Turn the adjust cams by an equal amount to adjust toe-in. HINT:
Try to adjust the toe-in to the center value.
The toe-in will change by the following specifications corresponding to each graduation of the cam. Approx. 3.3 mm (0.13 in.) (c) Tighten the nut. Torque: 100 N⋅m (1,020 kgf⋅cm, 74 ft⋅lbf) G25768 G25056 6. INSPECT CAMBER Camber Right-left error FF 4WD -1 °20’ ± 45’ (-1.33° ± 0.75°) 45’ (0.75°) or less -0 °45’ ± 45’ (-0.75° ± 0.75°) 45’ (0.75°) or less HINT: Camber is not adjustable. If the measurement is not within the specification, inspect the suspension parts for damage and/or wear, and replace them if necessary. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2954 27-16 REAR SUSPENSION - REAR SUSPENSION ARM ASSY NO.1 LH (FF) REAR SUSPENSION ARM ASSY NO.1 LH (FF) 270HY-01 REPLACEMENT HINT: COMPONENTS: See page 27-2 . 1. REMOVE REAR WHEEL 2. REMOVE STABILIZER BAR REAR (SEE PAGE 27-27 ) 3. (a) (b) REMOVE REAR SUSPENSION ARM ASSY NO.1 LH Support the rear axle carrier with a jack. Remove the bolt and disconnect the rear suspension arm assy No.1 (inner side). C82994 (c) Remove the bolt, nut and the rear suspension arm assy No.1 (outer side) from the rear axle carrier. NOTICE: When removing the bolt, keep the nut from rotating. C83800 G26318 4. (a) TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH Install the rear suspension arm assy No.1 (inner side) with the bolt, and temporarily tighten the bolt. C82994 Rear ÇÇ ÇÇ Paint Mark B53748 HINT: Ensure that the paint mark on the rear suspension arm assy No.1 faces the rear side of the vehicle. B73546 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2964 27-17 REAR SUSPENSION - REAR SUSPENSION ARM ASSY NO.1 LH (FF) (b) Connect the rear suspension arm assy No.1 (outer side) to the rear axle carrier with the bolt and nut and temporarily tighten the bolt and nut. NOTICE: When installing the bolt, fix the nut and temporarily tighten the bolt. C83800 5. G26318 STABILIZE SUSPENSION (SEE PAGE 27-13 ) 6. (a) FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH Fully tighten the bolt. Torque: 120 N⋅m (1,220 kgf⋅cm, 89 ft⋅lbf) C82994 (b) C82996 7. 8. 9. Fully tighten the bolt. Torque: 112 N⋅m (1,140 kgf⋅cm, 83 ft⋅lbf) G26319 INSTALL STABILIZER BAR REAR (SEE PAGE 27-27 ) INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT REAR WHEEL ALIGNMENT (SEE PAGE 27-5 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2965 27-25 REAR SUSPENSION - REAR SUSPENSION ARM ASSY NO.2 LH (4WD) REAR SUSPENSION ARM ASSY NO.2 LH (4WD) 270I1-01 REPLACEMENT HINT: COMPONENTS: See page 27-2 . 1. REMOVE REAR WHEEL 2. (a) (b) Matchmarks G25057 REMOVE REAR SUSPENSION ARM ASSY NO.2 LH Support the rear axle carrier with a jack. Place matchmarks on the adjust cams and rear suspension member sub-assy. (c) Remove the nut, camber adjust cam and toe adjust cam, and disconnect the rear suspension arm assy No.2 (inner side). NOTICE: When removing the nut, keep the bolt from rotating. (d) Remove the bolt, nut and the rear suspension arm assy No.2 (outer side) from the rear axle carrier. NOTICE: When removing the bolt, keep the nut from rotating. F46331 3. Matchmarks (a) TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH Install the rear suspension arm No.2 (inner side) to the rear suspension member sub-assy with the camber adjust cam and toe adjust cam, and temporarily tighten the nut. G25057 Rear ÇÇ ÇÇ Paint Mark HINT: Ensure that the paint mark on the rear suspension arm assy No.2 faces to the rear side of the vehicle. B53748 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2973 27-26 REAR SUSPENSION - REAR SUSPENSION ARM ASSY NO.2 LH (4WD) (b) Connect the rear suspension arm assy No.2 (outer side) to the rear axle carrier with the bolt and nut. NOTICE: When installing the bolt, fix the nut and temporarily tighten the bolt. F46331 4. STABILIZE SUSPENSION (SEE PAGE 27-13 ) 5. Matchmarks (a) (b) FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH Align the matchmarks on the adjust cams and rear suspension member sub-assy. Fully tighten the nut. Torque: 100 N⋅m (1,020 kgf⋅cm, 74 ft⋅lbf) G25057 (c) Fully tighten the bolt. Torque: 112 N⋅m (1,140 kgf⋅cm, 83 ft⋅lbf) F46330 6. 7. INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT REAR WHEEL ALIGNMENT (SEE PAGE 27-5 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2974 27-27 REAR SUSPENSION - STABILIZER BAR REAR (FF) STABILIZER BAR REAR (FF) 270EI-04 REPLACEMENT HINT: COMPONENTS: See page 27-2 . 1. REMOVE REAR WHEEL 2. REMOVE REAR STABILIZER LINK ASSY LH (a) Remove the 2 nuts and stabilizer link. HINT: If the ball joint turns together with the nut, use a hexagon wrench (5 mm) to hold the stud. C82629 3. REMOVE REAR STABILIZER LINK ASSY RH HINT: Remove the RH side using the same procedures as for the LH side. 4. (a) C66721 INSPECT REAR STABILIZER LINK ASSY LH As shown in the illustration, flip the ball joint stud back and forth 5 times. (b) Using a torque wrench and nut, turn the ball joint continuously at a rate of 3 to 5 seconds per turn and take the torque reading on the 5th turn. Turning torque: 1.0 N·m (10 kgf·cm, 9 in.·lbf) or less If the value is not within the specification, replace the rear stabilizer link assy with a new one. NOTICE:
Check that neither unusual drag nor rattle occurs during the rotation.
Check that neither cracks nor grease leakage exists on the dust cover. 5. REMOVE REAR STABILIZER BAR BRACKET NO.1 (a) Remove the 2 bolts and stabilizer bar bracket. C82630 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2975 27-28 REAR SUSPENSION 6. (a) - STABILIZER BAR REAR (FF) REMOVE STABILIZER BAR REAR Remove the stabilizer bar and 2 stabilizer bush. 7. (a) Outer Side (b) INSTALL STABILIZER BAR REAR Install the stabilizer bush to the outer side of the stopper ring on the stabilizer bar. Install the stabilizer bar. Rear Side Stopper Ring F47188 8. (a) INSTALL REAR STABILIZER BAR BRACKET NO.1 Install the stabilizer bar bracket with the 2 bolts. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) 9. (a) INSTALL REAR STABILIZER LINK ASSY LH Install the stabilizer link with the 2 nuts. Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) C82630 HINT: If the ball joint turns together with the nut, use a hexagon wrench (5 mm) to hold the stud. C82629 10. INSTALL REAR STABILIZER LINK ASSY RH HINT: Install the RH side using the same procedures as for the LH side. 11. INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) 12. INSPECT REAR WHEEL ALIGNMENT (SEE PAGE 27-5 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2976 27-29 REAR SUSPENSION - STABILIZER BAR REAR (4WD) STABILIZER BAR REAR (4WD) 270EJ-03 REPLACEMENT HINT: COMPONENTS: See page 27-2 . 1. REMOVE REAR WHEEL 2. REMOVE REAR STABILIZER LINK ASSY LH (a) Remove the 2 nuts and stabilizer link. HINT: If the ball joint turns together with the nut, use a hexagon wrench (5 mm) to hold the stud. C82631 3. REMOVE REAR STABILIZER LINK ASSY RH HINT: Remove the RH side using the same procedures as for the LH side. 4. (a) C66721 INSPECT REAR STABILIZER LINK ASSY LH As shown in the illustration, flip the ball joint stud back and forth 5 times. (b) Using a torque wrench and nut, turn the ball joint continuously at a rate of 3 to 5 seconds per turn and take the torque reading on the 5th turn. Turning torque: 1.0 N·m (10 kgf·cm, 9 in.·lbf) or less If the value is not within the specification, replace the rear stabilizer link assy with a new one. NOTICE:
Check that neither unusual drag nor rattle occurs during the rotation.
Check that neither cracks nor grease leakage exists on the dust cover. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2977 27-30 REAR SUSPENSION Left side: - STABILIZER BAR REAR (4WD) 5. (a) REMOVE STABILIZER BAR REAR Remove the 3 bolts and stabilizer bar. 6. (a) INSTALL STABILIZER BAR REAR Install the stabilizer bracket. (b) Install the stabilizer bar with the 3 bolts. Torque: Bolt A: 54 N⋅m (550 kgf⋅cm, 40 ft⋅lbf) Bolt B: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) G25065 Right side: F45738 Left side: G25072 G25990 Left side: (A) G25065 Right side: (B) (B) F45738 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2978 27-31 REAR SUSPENSION 7. (a) - STABILIZER BAR REAR (4WD) INSTALL REAR STABILIZER LINK ASSY LH Install the stabilizer link with the 2 nuts. Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) HINT: If the ball joint turns together with the nut, use a hexagon wrench (5 mm) to hold the stud. C82631 8. INSTALL REAR STABILIZER LINK ASSY RH HINT: Install the RH side using the same procedures as for the LH side. 9. INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) 10. INSPECT REAR WHEEL ALIGNMENT (SEE PAGE 27-5 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2979 27-12 REAR SUSPENSION - REAR SHOCK ABSORBER WITH COIL SPRING 2701L-11 DISPOSAL 1. (a) (b) A B F45737 DISPOSE OF SHOCK ABSORBER ASSY REAR LH Fully extend the shock absorber rod. Using a drill, make a hole in the cylinder somewhere between A and B as shown in the illustration to discharge the gas inside. CAUTION:
Be careful when drilling as shards of metal may fly about. Always use the proper safety equipment.
The gas is colorless, odorless and non-poisonous. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2960 27-7 REAR SUSPENSION - REAR SHOCK ABSORBER WITH COIL SPRING REAR SHOCK ABSORBER WITH COIL SPRING 270HX-01 OVERHAUL HINT: COMPONENTS: See page 27-2 . 1. REMOVE DECK SIDE TRIM COVER LH 2. REMOVE REAR WHEEL 3. (a) SEPARATE REAR STABILIZER LINK ASSY LH Support the rear axle carrier with a jack. (b) Remove the nut and disconnect the stabilizer link from the shock absorber. F46326 HINT: If the ball joint turns together with the nut, use a hexagon wrench (5 mm) to hold the stud. C83156 4. (a) REMOVE REAR SHOCK ABSORBER WITH COIL SPRING FF: Disconnect the skid control sensor connector. Remove the 2 bolts, and disconnect the flexible hose and skid control sensor wire from the shock absorber. G25060 (b) 4WD: Remove the 3 bolts, and disconnect the flexible hose and speed sensor from the shock absorber and rear axle carrier. G25070 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2955 27-8 REAR SUSPENSION - REAR SHOCK ABSORBER WITH COIL SPRING (c) Loosen the 2 nuts on the lower side of the shock absorber. HINT: Do not remove the 2 bolts and 2 nuts. C83160 G25778 (d) (e) (f) Remove the 3 nuts. Lower the rear axle carrier, and remove the 2 nuts and 2 bolts on the lower side of the shock absorber. Remove the shock absorber with coil spring. G28842 5. (a) 28 mm (1.1 in.) FIX REAR SHOCK ABSORBER WITH COIL SPRING Install the 2 nuts and bolt to the bracket at the lower part of the shock absorber, and secure it in a vise as shown in the illustration to the left. G25796 6. (a) REMOVE SHOCK ABSORBER ASSY REAR LH Loosen the nut while holding the LH support suspension with a bar taped up so as not to damage the stud bolts. NOTICE:
Do not damage the LH support suspension stud bolts.
Do not remove the nut. G28844 (b) Using SST, compress the coil spring. SST 09727- 30021 (09727- 00010, 09727- 00021, 09727-00031) NOTICE: Do not use an impact wrench. It will damage the SST. (c) Remove the nut, collar and LH support suspension. (d) Remove the coil spring, spring bumper and insulator lower. SST F45723 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2956 27-9 REAR SUSPENSION - REAR SHOCK ABSORBER WITH COIL SPRING 7. (a) INSPECT SHOCK ABSORBER ASSY REAR LH Compress and extend the shock absorber rod, and check that there is no abnormal resistance or unusual sound. If there is any abnormality, replace the shock absorber with a new one. NOTICE: When disposing of the shock absorber, see DISPOSAL on page 27-12 . G28843 8. (a) (b) INSTALL SHOCK ABSORBER ASSY REAR LH Install the spring bumper. Install the insulator lower, as shown in the illustration. G26304 (c) SST F41029 Using SST, compress the coil spring. SST 09727- 30021 (09727- 00010, 09727- 00021, 09727-00031) NOTICE: Do not use an impact wrench. It will damage the SST. (d) Install the coil spring to the shock absorber. HINT: Fit the lower end of the coil spring into the gap of the insulator lower. Lower Bracket (e) 3.5
5 HINT: Ensure that the stud bolt is positioned 3.5 to the front of the vehicle as shown in the illustration, and the deviation should be within
5. Front Outside LH Support Suspension Align the LH support suspension with the shock absorber lower bracket, as shown in the illustration. F45739 SST (f) Install the collar to the piston rod. (g) Temporarily install a new nut. (h) Remove the SST. HINT: After removing SST, recheck the direction of the LH support suspension. F02773 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2957 27-10 REAR SUSPENSION - REAR SHOCK ABSORBER WITH COIL SPRING (i) Fully tighten the nut while holding the LH support suspension with a bar taped up so as not to damage the stud bolts. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) NOTICE: Do not damage the LH support suspension stud bolts. G28844 9. (a) INSTALL REAR SHOCK ABSORBER WITH COIL SPRING Install the shock absorber with coil spring and tighten the 3 nuts. Torque: 58 N⋅m (590 kgf⋅cm, 43 ft⋅lbf) G28842 (b) Install the 2 bolts and nuts to the shock absorber with coil spring. Torque: 180 N⋅m (1,840 kgf⋅cm, 133 ft⋅lbf) NOTICE: When installing the nut, keep the bolt from rotating. C83160 G25778 (A) (c) FF: Install the flexible hose and skid control sensor wire with the 2 bolts. Connect the skid control sensor connector. Torque: Bolt A: 19 N⋅m (192 kgf⋅cm, 14 ft⋅lbf) Bolt B: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) (d) 4WD: Install the flexible hose and speed sensor with the 3 bolts. Torque: Bolt A: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) Bolt B: 19 N⋅m (192 kgf⋅cm, 14 ft⋅lbf) Bolt C: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) (B) G25060 (A) (B) (C) G25070 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2958 27-1 1 REAR SUSPENSION 10. (a) - REAR SHOCK ABSORBER WITH COIL SPRING INSTALL REAR STABILIZER LINK ASSY LH Install the stabilizer link to the shock absorber with the nut. Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) HINT: If the ball joint turns together with the nut, use a hexagon wrench (5 mm) to hold the stud. C83156 11. 12. 13. INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT REAR WHEEL ALIGNMENT (SEE PAGE 27-5 ) CHECK ABS SPEED SENSOR SIGNAL (SEE PAGE 05-765 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2959 27-13 REAR SUSPENSION - STRUT ROD ASSY REAR STRUT ROD ASSY REAR 270EE-03 REPLACEMENT HINT: COMPONENTS: See page 27-2 . 1. REMOVE REAR WHEEL 2. (a) REMOVE STRUT ROD ASSY REAR Support the rear axle carrier with a jack. (b) Remove the bolt and nut, and separate the parking brake cable. F46326 G25061 (c) Remove the bolt and nut, and disconnect the strut rod (front side). NOTICE: When removing the bolt, keep the nut from rotating. G25062 (d) Remove the bolt, nut and strut rod from the rear axle carrier. NOTICE: When removing the bolt, keep the nut from rotating. F46324 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2961 27-14 REAR SUSPENSION - STRUT ROD ASSY REAR 3. (a) TEMPORARILY TIGHTEN STRUT ROD ASSY REAR Install the strut rod (rear side), bolt and nut, and temporarily tighten the bolt. NOTICE: When installing the bolt, fix the nut and temporarily tighten the bolt. F46325 (b) Support the rear axle carrier. F46326 (c) Connect the strut rod (front side) with the bolt and nut. NOTICE: When installing the bolt, fix the nut and temporarily tighten the bolt. G25062 4. (a) STABILIZE SUSPENSION FF: Jack up the rear axle carrier, placing a wood block to avoid damage. Apply load to the suspension so that the installed bolt of the suspension arm assy No.1 (inner side of the vehicle) is horizontally aligned with the center of the rear axle hub. (b) 4WD: Jack up the rear axle carrier, placing a wood block to avoid damage. Apply load to the suspension so that the rear drive shaft assy is horizontally positioned. G25792 G25793 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2962 27-15 REAR SUSPENSION - STRUT ROD ASSY REAR 5. (a) FULLY TIGHTEN STRUT ROD ASSY REAR Fully tighten the bolt. Torque: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf) (b) Fully tighten the bolt. Torque: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf) (c) Install the parking brake cable with the bolt and nut. Torque: Bolt: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) Nut: 6.0 N⋅m (61 kgf⋅cm, 53 in.⋅lbf) F46324 G25062 G25061 6. 7. INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT REAR WHEEL ALIGNMENT (SEE PAGE 27-5 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2963 27-18 REAR SUSPENSION - REAR SUSPENSION ARM ASSY NO.1 LH (4WD) REAR SUSPENSION ARM ASSY NO.1 LH (4WD) 270HZ-01 REPLACEMENT HINT: COMPONENTS: See page 27-2 . 1. REMOVE REAR WHEEL 2. REMOVE EXHAUST PIPE ASSY (a) 2AZ-FE (see page 15-2 ) (b) 3MZ-FE (see page 15-5 ) 3. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY (SEE PAGE 30-12 ) SST 09325-20010 4. REMOVE STRUT ROD ASSY REAR (SEE PAGE 27-13 ) 5. (a) SEPARATE REAR SUSPENSION ARM ASSY NO.2 LH Remove the bolt, nut and the rear suspension arm assy No.2 (outer side) from the rear axle carrier. NOTICE: When removing the bolt, keep the nut from rotating. F46327 6. SEPARATE REAR SUSPENSION ARM ASSY NO.2 RH HINT: Separate the RH side using the same procedures as for the LH side. 7. (a) SEPARATE REAR SUSPENSION ARM ASSY NO.1 LH Remove the bolt, nut and the rear suspension arm assy No.1 (outer side) from the rear axle carrier. NOTICE: When removing the bolt, keep the nut from rotating. F46328 8. SEPARATE REAR SUSPENSION ARM ASSY NO.1 RH HINT: Separate the RH side using the same procedures as for the LH side. 9. REMOVE SPEED SENSOR REAR LH (SEE PAGE 30-60 ) 10. REMOVE SPEED SENSOR REAR RH HINT: Remove the RH side using the same procedures as for the LH side. 11. REMOVE REAR DRIVE SHAFT ASSY LH (SEE PAGE 30-45 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2966 27-19 REAR SUSPENSION - REAR SUSPENSION ARM ASSY NO.1 LH (4WD) 12. REMOVE REAR DRIVE SHAFT ASSY RH HINT: Remove the RH side using the same procedures as for the LH side. 13. (a) (b) (c) C82990 REMOVE REAR SUSPENSION MEMBER SUB-ASSY Support the rear suspension member with a jack. Remove the 4 nuts, 2 bolts and 2 retainers from the rear suspension member. Lower the rear suspension member. G25770 14. REMOVE REAR SUSPENSION ARM ASSY NO.1 LH (a) Remove the bolt, nut and rear suspension arm assy No.1. NOTICE: When removing the bolt, keep the nut from rotating. C82991 15. (a) INSTALL REAR SUSPENSION ARM ASSY NO.1 LH Install the rear suspension arm assy No.1 with the bolt and nut, and temporarily tighten the bolt. C82991 HINT: Ensure that the paint mark on the rear suspension arm assy No.1 faces the rear side of the vehicle. Rear ÇÇ ÇÇ Paint Mark B53748 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2967 27-20 REAR SUSPENSION - REAR SUSPENSION ARM ASSY NO.1 LH (4WD) (b) Set the rear suspension arm assy No.1 in the position shown in the illustration, and fully tighten the bolt. Torque: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf) 16. (a) (b) INSTALL REAR SUSPENSION MEMBER SUB-ASSY Raise the rear suspension member with a jack. Install the rear suspension member with the 4 nuts, 2 bolts and 2 retainers. Torque: Front side: 115 N⋅m (1,170 kgf⋅cm, 85 ft⋅lbf) Rear side: 181 N⋅m (1,850 kgf⋅cm, 134 ft⋅lbf) 30 mm (1.18 in.) G25794 C82990 G25770 17. INSTALL REAR DRIVE SHAFT ASSY LH (SEE PAGE 30-45 ) 18. INSTALL REAR DRIVE SHAFT ASSY RH HINT: Install the RH side using the same procedures as for the LH side. 19. INSTALL SPEED SENSOR REAR LH (SEE PAGE 30-60 ) 20. INSTALL SPEED SENSOR REAR RH HINT: Install the RH side using the same procedures as for the LH side. 21. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH (a) Install the rear suspension arm assy No.1 (outer side) to the rear axle carrier, and temporarily tighten the bolt. NOTICE: When installing the bolt, fix the nut and temporarily tighten the bolt. F46328 22. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 RH HINT: Temporarily tighten the RH side using the same procedures as for the LH side. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2968 27-21 REAR SUSPENSION - REAR SUSPENSION ARM ASSY NO.1 LH (4WD) 23. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH (a) Install the rear suspension arm No. 2 (outer side) to the rear axle carrier, and temporarily tighten the bolt. NOTICE: When installing the bolt, fix the nut and temporarily tighten the bolt. F46327 24. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 RH HINT: Temporarily tighten the RH side using the same procedures as for the LH side. 25. TEMPORARILY TIGHTEN STRUT ROD ASSY REAR (SEE PAGE 27-13 ) 26. STABILIZE SUSPENSION (SEE PAGE 27-13 ) 27. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH (a) Fully tighten the bolt. Torque: 112 N⋅m (1,140 kgf⋅cm, 83 ft⋅lbf) F46329 28. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 RH HINT: Fully tighten the RH side using the same procedures as for the LH side. 29. (a) FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH Fully tighten the bolt. Torque: 112 N⋅m (1,140 kgf⋅cm, 83 ft⋅lbf) F46330 30. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 RH HINT: Fully tighten the RH side using the same procedures as for the LH side. 31. FULLY TIGHTEN STRUT ROD ASSY REAR (SEE PAGE 27-13 ) 32. INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) 33. TEMPORARILY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSY (SEE PAGE 30-12 ) 34. FULLY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSY (SEE PAGE 30-12 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2969 27-22 REAR SUSPENSION 35. (a) (b) 36. 37. 38. - REAR SUSPENSION ARM ASSY NO.1 LH (4WD) INSTALL EXHAUST PIPE ASSY 2AZ-FE (see page 15-2 ) 3MZ-FE (see page 15-5 ) CHECK FOR EXHAUST GAS LEAKS INSPECT REAR WHEEL ALIGNMENT (SEE PAGE 27-5 ) CHECK ABS SPEED SENSOR SIGNAL (SEE PAGE 05-765 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2970 27-2 REAR SUSPENSION - REAR SUSPENSION REAR SUSPENSION 270EB-03 COMPONENTS FF:
49 (500, 36) x3 58 (590, 43) Rear Support To Rear Shock Absorber LH Collar Rear Suspension Member Sub-assy LH Support Assy Rear Suspension Rear Spring Bumper No.1 LH Rear Stabilizer Link Assy LH Stabilizer Bush Stabilizer Bar Rear Rear Coil Spring Rear LH 39 (400, 29) 120 (1,220, 89) Rear Coil Spring Insulator Lower LH Rear Stabilizer Bar Bracket No.1 56 (570, 41) 19 (194, 14) Shock Absorber Assy Rear LH Rear Suspension Arm Assy No.2 LH Rear Suspension Arm Assy No.1 LH 39 (400, 29) 112 (1,140, 83) 19 (192, 14) 120 (1,220, 89) Flexible Hose 180 (1,840, 133) 112 (1,140, 83) Skid Control Sensor Wire 80 (816, 59) 80 (816, 59) 5.0 (51, 44 in.⋅lbf) Parking Brake Cable Assy No.3 Strut Rod Assy Rear 6.0 (61, 53 in.⋅lbf) N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part 39 (400, 29) F45734 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2950 27-3 REAR SUSPENSION - REAR SUSPENSION 4WD: Rear Suspension Member Sub-assy
49 (500, 36) x3 58 (590, 43) LH Support Assy Rear Suspension Rear Support To Rear shock Absorber LH Collar 181 (1,850, 134) Rear Spring Bumper No.1 LH Retainer Retainer Coil Spring Rear LH Rear Coil Spring Insulator Lower LH 115 (1,170, 85) Rear Suspension Toe Adjust Cam Sub-assy Camber Adjust Cam No.2 100 (1,020, 74) Shock Absorber Assy Rear LH Rear Suspension Arm Assy No.2 LH Rear Suspension Arm Assy No.1 LH 5.0 (51, 44in.⋅lbf) 112 (1,140, 83) 80 (816, 59) 180 (1,840, 133) 112 (1,140, 83) Flexible Hose Speed Sensor Rear LH 8.0 (82, 71 in.⋅lbf) 80 (816, 59) 80 (816, 59) 19 (192, 14) 294 (3,000, 217) Strut Rod Assy Rear Parking Brake Cable Assy No.3 6.0 (61, 53 in.⋅lbf) 39 (400, 29) N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part F45735 F47189 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2951 27-4 REAR SUSPENSION - REAR SUSPENSION 4WD: Rear Stabilizer Link Assy RH Stabilizer Bar Rear 39 (400, 29) Rear Stabilizer Link Assy LH x2 19 (194, 14) 39 (400, 29) 54 (550, 40) N·m (kgf·cm, ft·lbf) : Specified torque G25082 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2952 27-23 REAR SUSPENSION - REAR SUSPENSION ARM ASSY NO.2 LH (FF) REAR SUSPENSION ARM ASSY NO.2 LH (FF) 270I0-01 REPLACEMENT HINT: COMPONENTS: See page 27-2 . 1. REMOVE REAR WHEEL 2. (a) (b) REMOVE REAR SUSPENSION ARM ASSY NO.2 LH Support the rear axle carrier with a jack. Remove the bolt, and disconnect the rear suspension arm assy No.2 (inner side). C82992 (c) Remove the bolt, nut and the rear suspension arm assy No.2 (outer side) from the rear axle carrier. NOTICE: When removing the bolt, keep the nut from rotating. C82993 G26316 3. (a) TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH Install the rear suspension arm assy No.2 (inner side) with the bolt, and temporarily tighten the bolt. HINT: Ensure that the paint mark on the rear suspension arm assy No.2 faces the rear side of the vehicle. C82992 Paint Mark F47191 (b) Connect the rear suspension arm assy No.2 (outer side) to the rear axle carrier with the bolt and nut, and temporarily tighten the bolt. NOTICE: When installing the bolt, fix the nut and temporarily tighten the bolt. C82993 G26316 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2971 27-24 REAR SUSPENSION 4. - REAR SUSPENSION ARM ASSY NO.2 LH (FF) STABILIZE SUSPENSION (SEE PAGE 27-13 ) 5. (a) FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH Fully tighten the bolt. Torque: 120 N⋅m (1,220 kgf⋅cm, 89 ft⋅lbf) C82992 (b) C82997 6. 7. Fully tighten the bolt. Torque: 112 N⋅m (1,140 kgf⋅cm, 83 ft⋅lbf) G26317 INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT REAR WHEEL ALIGNMENT (SEE PAGE 27-5 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2972 28-2 TIRE & WHEEL - WHEEL AND TIRE SYSTEM 2804E-01 HOW TO PROCEED WITH TROUBLESHOOTING 1. 2. VEHICLE PULLING DIAGNOSIS (SEE PAGE 26-2 ) DIAGNOSIS OF TIRE VIBRATION Check that the wheel nuts are fully tightened NG NG Repair Inspect bearing backlash OK Inspect axle hud deviation OK Check tire pressure OK Return the vehicle to customer OK Check wheel balance OK NG NG Inspect bearing backlash Adjustment Replace tire(s) Adjustment NG Inspect axle hud deviation Repair NG OK Check wheel balance 3. DIAGNOSIS OF PREMATURE OF IRREGULAR TIRE WEAR Check tire pressure OK Check wheel alignment NG NG Adjustment Adjustment OK Tire rotation or replace tire(s) NG Check wheel alignment OK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2981 28-1 TIRE & WHEEL - WHEEL AND TIRE SYSTEM WHEEL AND TIRE SYSTEM 28009-14 INSPECTION 1. (a) (b) INSPECT TIRE Check the tires for wear and proper inflation pressure. Cold tire inflation pressure: Tire size Front, Rear kPa (kgf/cm2, psi) P225/70R16 101S 210 (2.1, 30) Using a dial indicator, check the tire runout. Tire runout: 1.4 mm (0.055 in.) or less R03031 2. ROTATE TIRE HINT: See the illustration for where to rotate each tire when you include the spare tire in the rotation and when you do not. Front R14931 3. (a) (b) INSPECT WHEEL BALANCE Check and adjust the Off-the-car balance. If necessary, check and adjust the On-the-car balance. Imbalance after adjustment: 8.0 g (0.018 lb) or less C80976 4. 5. 6. 7. INSPECT INSPECT INSPECT INSPECT BEARING BACKLASH (See page 30-3 ) BEARING BACKLASH (See page 30-3 ) AXLE HUB DEVIATION (See page 30-3 ) AXLE HUB DEVIATION (See page 30-3 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2980 29-1 DIFFERENTIAL - DIFFERENTIAL SYSTEM (4WD) DIFFERENTIAL SYSTEM (4WD) 2900W-04 PRECAUTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Before disassembly, clean the outside of the rear differential assy and remove any sand or mud to prevent it from entering the inside of the assembly during disassembly and installation. When removing a connected part made of light alloy such as a rear differential carrier cover, tap it off with a plastic hammer. Do not attempt to pry it off with a screwdriver. Always arrange disassembled parts in order and protect them from dust. Before installation, thoroughly clean and dry each part and then apply hypoid gear oil LSD to it. Do not use alkaline cleaner for aluminum or rubber parts and ring gear set bolts. Also, do not clean rubber parts such as O-rings or oil seals with white gasoline. Coat any sliding surface and rotating part with hypoid gear oil LSD. When holding a part by vice, be sure to place an aluminum sheet under the part. Do not put it directly on the vice. Be careful not to damage the contact surfaces of the case. Such damage may cause oil leakage. Before applying sealant, remove deposited oil sealant and clean the part to be sealed using white gasoline. Do not fill oil immediately after installing sealed parts. Leave it for at least an hour. Damage on the surface being contact with an oil seal, O-ring or gasket may cause oil leakage. Special attention should be paid. When press-fitting an oil seal, be careful not to damage the oil seal lip and outside periphery. When replacing a bearing, replace the inner and outer races as a set. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2982 29-2 DIFFERENTIAL - DIFFERENTIAL SYSTEM (4WD) 2900X-04 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The causes of the problem are listed in order of probability in the ”Suspected Area” column. Check each part in order. If necessary, replace these parts. Symptom Suspected Area See page Oil leak from rear differential 1. 2. 3. 4. 5. Oil level (Too high or wrong grade) Rear differential front oil seal (Worn or damaged) Side gear shaft oil seal (Worn or damaged) Companion flange (Loose or damaged) Drive shaft (Damaged) 29-5 29-6 29-9 29-11 30-45 Oil leak from drive pinion shaft 1. Oil level (Too high or wrong grade) 2. Rear differential front oil seal (Worn or damaged) 3. Companion flange (Loose or damaged) 29-5 29-6 29-11 Noise in rear differential 1. 2. 3. 4. 5. 29-11 29-11 29-11 29-11 29-11 Oil level (Low or wrong grade) Excessive backlash between pinion and ring gear Ring, pinion or side gears (Worn or chipped) Drive pinion bearing Side bearing (Worn) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2983 29-5 DIFFERENTIAL - DIFFERENTIAL OIL (4WD) DIFFERENTIAL OIL (4WD) 2900Y-05 ADJUSTMENT 1. (a) (b) (c) 0 to 5 mm (0 to 0.20 in.) D25304 INSPECT DIFFERENTIAL OIL Stop the vehicle on the level place. Remove the differential filler plug and gasket. Check that the oil surface is within 5 mm (0.20 in.) from the lowest position of the inner surface of the differential filler plug opening. NOTICE:
Excessively large or small amount of oil may cause troubles.
After replacing oil, drive the vehicle and check the oil level. HINT: If nesesary, fill the rear differential carrier assy with hypoid gear oil. Oil grade: Hypoid gear oil API GL-5 Recommended oil viscosity: Above -18°C (0°F) SAE 90 Below -18°C (0°F) SAE 80W or 80W-90 Capacity: 0.9 ± 0.05 liters (0.95 ± 0.05 US qts, 0.79 ± 0.04 lmp. qts) (d) Check for oil leakage when the oil level is low. (e) Install the differential filler plug and a new gasket. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2986 29-3 DIFFERENTIAL - DIFFERENTIAL (4WD) DIFFERENTIAL (4WD) 29084-02 COMPONENTS 181 (1,850, 134)
Rear Differential Mount Cushion No.2 95 (970, 70) Rear Suspension Member Sub-assy
Rear Differential Mount Cushion No.1 115 (1,170, 85) Rear Drive Shaft Assy RH 181 (1,850, 134)
Rear Drive Shaft Snap Ring RH 294 (3,000, 217)
Rear Axle Shaft RH Nut 115 (1,170, 85) 74 (750, 54) Differential Carrier Sub-assy Rear Rear Drive Shaft Assy LH Propeller w/ Center Bearing Shaft Assy
Rear Drive Shaft Snap Ring LH Rear Differential Support No.1 294 (3,000, 217)
Rear Axle Shaft LH Nut 137 (1,400, 101) 103 (1,050, 76) N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part D30569 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2984 29-4 DIFFERENTIAL - DIFFERENTIAL (4WD) Rear Differential Pinion Shaft Straight Pin Rear Differential Side Gear Thrust No.1 Washer Rear Differential Pinion Shaft Differential Side Gear Differential Pinion Gear Rear Differential Case Bearing Rear Differential Pinion Thrust Washer Differential Ring Gear Rear Differential Side Shaft Plate Washer Rear Differential Case
Rear Differential Ring Gear Set Bolt Lock Plate Rear Differential Drive Pinion Plate Washer 97 (989, 71) Differential Drive Pinion Rear Drive Pinion Rear Tapered Roller Bearing

Rear Differential Side Gear Shaft Plate Washer

Rear Differential Side Gear Shaft Seal Oil Rear Differential Filler Plug Rear Differential Case Bearing Rear Differential Breather Plug Differential Carrier 21 (210, 15) Sub-assy Rear
Rear Differential Filler Plug Gasket X8 47 (475, 34) Bearing Cap 49 (500, 36) Rear Differential Drive Pinion Oil Slinger Rear Drive Pinion Front Tapered Roller Bearing
Rear Differential Dust Deflector Rear Differential Carrier Cover 79 (800, 58)
Rear Differential Side
Rear Differential Drive Gear Shaft Seal Oil Pinion Bearing Spacer
Rear Differential
Rear Differential Drain Carrier Oil Seal Plug Gasket 49 (500, 36) Rear Drive Pinion Companion Rear Differential Flange Sub-assy Rear See Page 29-11 Drain Plug
Rear Drive Pinion Nut N·m (kgf·cm, ft·lbf) : Specified torque MP grease Hypoid gear oil
Non-reusable part D30570 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2985 29-6 DIFFERENTIAL - REAR DIFFERENTIAL CARRIER OIL SEAL (4WD) REAR DIFFERENTIAL CARRIER OIL SEAL (4WD) 2909K-01 REPLACEMENT 1. 2. 3. 4. (a) 5. (a) REMOVE EXHAUST PIPE ASSY (2AZ-FE ENGINE TYPE) (SEE PAGE 15-2 ) REMOVE EXHAUST PIPE ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 15-5 ) REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY (SEE PAGE 30-12 ) REMOVE REAR DIFFERENTIAL FILLER PLUG Using a hexagon wrench (10 mm), remove the filler plug and gasket. REMOVE REAR DIFFERENTIAL DRAIN PLUG Using a hexagon wrench (10 mm), remove the drain plug and gasket, drain the oil. 6. (a) (b) REMOVE REAR DRIVE PINION NUT Using a chisel and a hammer, unstake the staked part of the nut. Using SST to hold the flange, remove the nut. SST 09330-00021 SST F40600 7. SST (a) REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR Using SST, remove the companion flange. SST 09950- 30012 (09951- 03010, 09953- 03010, 09954-03010, 09955-03030, 09956-03020) D30955 8. (a) SST REMOVE REAR DIFFERENTIAL DUST DEFLECTOR Using SST and a press, remove the dust deflector. SST 09950- 00020, 09950- 60010 (09951- 00360), 09950-70010 (09951-07150) F40564 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2987 29-7 DIFFERENTIAL 9. (a) SST 10. - REAR DIFFERENTIAL CARRIER OIL SEAL (4WD) REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL Using SST, remove the oil seal. SST 09308-10010 REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER D30956 11. SST (a) REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING Using SST, remove the front tapered roller bearing. SST 09556-22010 F40718 12. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER Rear Diff erent ia l Drive Pinion Oil Slinger Rear Drive Pinion Front Tapered Roller Bearing Rear Differential Drive Pinion Bearing Spacer G24180 13. (a) 14. (a) 15. (a) 16. (a) SST (b) G24181 INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER Install a new bearing spacer. INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING Install the tapered roller bearing. INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER Install the oil slinger. INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL Using SST and a hammer, install a new oil seal. Oil seal drive in depth: 2.0
0.3 mm (0.079
0.012 in.) Coat MP grease to the oil seal lip. SST 09554-22010 G25655 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2988 29-8 DIFFERENTIAL - REAR DIFFERENTIAL CARRIER OIL SEAL (4WD) 17. (a) INSTALL REAR DIFFERENTIAL DUST DEFLECTOR Using SST and a press, install a new dust deflector. SST 09223-00010 NOTICE: Be careful not to damage the dust deflector. SST F40464 18. INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR (a) Using SST, install the companion flange on the shaft. SST 09950- 30012 (09951- 03010, 09953- 03010, 09954-03010, 09955-03030, 09956-03020) NOTICE: Apply hypoid gear oil to the SST center bolt tip and threads before use. SST D30957 19. (a) (b) INSTALL REAR DRIVE PINION NUT Coat the threads of a new nut with hypoid gear oil LSD. Using SST to hold the flange, torque the nut. SST 09330-00021 Torque: 108 N·m (1,100 kgf·cm, 80 ft·lbf) SST F40601 20. 21. (a) 22. 23. (a) 24. (a) 25. 26. (a) 27. 28. INSPECT DIFFERENTIAL DRIVE PINION PRELOAD (SEE PAGE 29-1 1) INSTALL REAR DRIVE PINION NUT Using a chisel and a hammer, stake the drive pinion nut. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY (SEE PAGE 30-12 ) INSTALL REAR DIFFERENTIAL DRAIN PLUG Using a hexagon wrench (10 mm), install the drain plug and a new gasket. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) ADD DIFFERENTIAL OIL Fill the rear differential carrier assy with hypoid gear oil. Oil grade: Hypoid gear oil API GL-5 Recommended oil viscosity: Above -18°C (0°F) SAE 90 Below -18°C (0°F) SAE 80W or 80W-90 Capacity: 0.9 ± 0.05 liters (0.95 ± 0.05 US qts, 0.79 ± 0.04 lmp. qts) INSPECT DIFFERENTIAL OIL (SEE PAGE 29-5 ) INSTALL REAR DIFFERENTIAL FILLER PLUG Using a hexagon wrench (10 mm), install the filler plug and a new gasket. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) INSTALL EXHAUST PIPE ASSY (2AZ-FE ENGINE TYPE) (SEE PAGE 15-2 ) INSTALL EXHAUST PIPE ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 15-5 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 2989 DIFFERENTIAL - REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL (4WD) 29-9 REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL (4WD) 29085-02 REPLACEMENT HINT:


1. 2. Differential components (See page 29-3 ) Rear drive shaft components (See page 30-4 ) Replace the RH side following the same procedures as with the LH side. REMOVE REAR WHEEL REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY (2AZ-FE ENGINE TYPE) (SEE PAGE 30-12 ) SST 09325-20010 REMOVE EXHAUST PIPE ASSY (2AZ-FE ENGINE TYPE) (SEE PAGE 15-2 ) 3. HINT: Perform this procedure only when removing the RH side. 4. REMOVE EXHAUST PIPE ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 15-5 ) 5. REMOVE REAR DIFFERENTIAL FILLER PLUG (a) Using a hexagon wrench (10 mm), remove the filler plug and gasket. 6. REMOVE REAR DIFFERENTIAL DRAIN PLUG (a) Using a hexagon wrench (10 mm), remove the drain plug and gasket, and drain the oil. 7. SEPARATE SPEED SENSOR REAR LH (SEE PAGE 30-45 ) 8. REMOVE REAR AXLE SHAFT LH NUT (SEE PAGE 30-45 ) 9. SEPARATE REAR SUSPENSION ARM ASSY NO.1 LH (SEE PAGE 27-18 ) 10. SEPARATE STRUT ROD ASSY REAR (SEE PAGE 27-13 ) 11. SEPARATE REAR SUSPENSION ARM ASSY NO.2 LH (SEE PAGE 27-25 ) 12. REMOVE REAR DRIVE SHAFT ASSY LH (SEE PAGE 30-45 ) 13. SST (a) REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL Using SST, remove the oil seal. SST 09308-00010 G24185 14. (a) (b) SST INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL Using SST and a hammer, install a new oil seal until it is flush with the carrier end surface. Oil seal drive in depth: 0
0.5 mm (0
0.019 in.) Apply MP grease to the oil seal lip. SST 09550-00032, 09950-70010 (09951-07200) G24186 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2990 29-10 15. 16. 17. 18. 19. DIFFERENTIAL - REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL (4WD) INSTALL REAR DRIVE SHAFT ASSY LH (SEE PAGE 30-45 ) TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH (SEE PAGE 27-25 ) TEMPORARILY TIGHTEN STRUT ROD ASSY REAR (SEE PAGE 27-13 ) TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH (SEE PAGE 27-18 ) INSTALL REAR AXLE SHAFT LH NUT (SEE PAGE 30-45 ) SST 09930-00010 INSTALL SPEED SENSOR REAR LH (SEE PAGE 30-45 ) STABILIZE SUSPENSION (SEE PAGE 27-13 ) FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH (SEE PAGE 27-25 ) FULLY TIGHTEN STRUT ROD ASSY REAR (SEE PAGE 27-13 ) FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH (SEE PAGE 27-18 ) INSTALL EXHAUST PIPE ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 15-5 ) 20. 21. 22. 23. 24. 25. HINT: Perform this procedure only when removing the RH side. 26. INSTALL EXHAUST PIPE ASSY (2AZ-FE ENGINE TYPE) (SEE PAGE 15-2 ) HINT: Perform this procedure only when removing the RH side. 27. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY (2AZ-FE ENGINE TYPE) (SEE PAGE 30-12 ) HINT: Perform this procedure only when removing the RH side. 28. FULLY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSY (2AZ-FE ENGINE TYPE) (SEE PAGE 30-12 ) HINT: Perform this procedure only when removing the RH side. SST 09370-50010 29. INSTALL REAR DIFFERENTIAL DRAIN PLUG (a) Using a hexagon wrench (10 mm), install the drain plug and a new gasket. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) 30. ADD DIFFERENTIAL OIL (a) Fill the rear differential carrier assy with hypoid gear oil. Oil grade: Hypoid gear oil API GL-5 Recommended oil viscosity: Above -18°C (0°F) SAE 90 Below -18°C (0°F) SAE 80W or 80W-90 Capacity: 0.9 ± 0.05 liters (0.95 ± 0.05 US qts, 0.79 ± 0.04 lmp. qts) 31. INSPECT DIFFERENTIAL OIL (SEE PAGE 29-5 ) 32. INSTALL REAR DIFFERENTIAL FILLER PLUG (a) Using a hexagon wrench (10 mm), install the filler plug and a new gasket. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) 33. INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) 34. INSPECT AND ADJUST REAR WHEEL ALIGNMENT (SEE PAGE 27-5 ) 35. CHECK FOR EXHAUST GAS LEAKS HINT: Perform this procedure only when removing the RH side. 36. CHECK ABS SPEED SENSOR SIGNAL (SEE PAGE 05-765 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 2991 29-1 1 DIFFERENTIAL - DIFFERENTIAL CARRIER ASSY REAR (4WD) DIFFERENTIAL CARRIER ASSY REAR (4WD) 2909L-01 OVERHAUL HINT:

1. 2. Differential components (see page 29-3 ) Rear drive shaft components (see page 30-45 ) REMOVE REAR WHEEL REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY (SEE PAGE 30-12 ) SST 09325-20010 REMOVE EXHAUST PIPE ASSY (2AZ-FE ENGINE TYPE) (SEE PAGE 15-2 ) REMOVE EXHAUST PIPE ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 15-5 ) REMOVE REAR DIFFERENTIAL FILLER PLUG Using a hexagon wrench (10 mm), remove the filler plug and gasket. REMOVE REAR DIFFERENTIAL DRAIN PLUG Using a hexagon wrench (10 mm), remove the drain plug and gasket, and drain the oil. SEPARATE SPEED SENSOR REAR LH (SEE PAGE 30-45 ) SEPARATE SPEED SENSOR REAR RH 3. 4. 5. (a) 6. (a) 7. 8. HINT: Removal procedure of the RH side is the same as that of the LH side. 9. REMOVE REAR AXLE SHAFT LH NUT (SEE PAGE 30-45 ) SST 09930-00010 10. REMOVE REAR AXLE SHAFT RH NUT SST 09930-00010 HINT: Removal procedure of the RH side is the same as that of the LH side. 11. SEPARATE STRUT ROD ASSY REAR (SEE PAGE 27-13 ) 12. SEPARATE REAR SUSPENSION ARM ASSY NO.1 LH (SEE PAGE 27-18 ) 13. SEPARATE REAR SUSPENSION ARM ASSY NO.1 RH HINT: Removal procedure of the RH side is the same as that of the LH side. 14. SEPARATE REAR SUSPENSION ARM ASSY NO.2 LH (SEE PAGE 27-18 ) 15. SEPARATE REAR SUSPENSION ARM ASSY NO.2 RH HINT: Removal procedure of the RH side is the same as that of the LH side. 16. REMOVE REAR DRIVE SHAFT ASSY LH (SEE PAGE 30-45 ) 17. REMOVE REAR DRIVE SHAFT ASSY RH HINT: Removal procedure of the RH side is the same as that of the LH side. 18. REMOVE REAR SUSPENSION MEMBER SUB-ASSY (SEE PAGE 27-18 ) Author
: Date
: 2992 29-12 DIFFERENTIAL 19. (a) (b) - DIFFERENTIAL CARRIER ASSY REAR (4WD) REMOVE DIFFERENTIAL CARRIER ASSY REAR Support the differential carrier assy rear with a jack. Remove the 2 bolts and 2 lock nuts, and separate the rear differential support No.1 from the rear suspension member sub-assy. G24187 (c) Remove the 3 bolts and differential carrier sub-assy rear from the rear suspension member sub-assy. NOTICE: Be careful not to drop the differential carrier assy rear. G24188 20. REMOVE REAR DIFFERENTIAL MOUNT CUSHION NO.1 HINT: Perform this operation only when the rear differential mount cushion No.1 is damaged. (a) Using SST, remove the rear differential mount cushion No.1. SST 09570-24010, 09316-12010 NOTICE:
Do not bring SST into contact with the sub-frame.
Do not slant the bolts of SST.
Do not set the SST in the wrong direction.
Screw the 2 bolts of SST equally into the 2 holes of the rear differential mount. SST LH F53635 Author
: Date
: 2993 29-13 DIFFERENTIAL 21. - DIFFERENTIAL CARRIER ASSY REAR (4WD) REMOVE REAR DIFFERENTIAL MOUNT CUSHION NO.2 HINT: Perform this operation only when the rear differential mount cushion No.2 is damaged. (a) Using SST, remove the rear differential mount cushion No.2. SST 09570-24010, 09316-12010 NOTICE:
Do not bring SST into contact with the sub-frame.
Do not slant the bolt of SST.
Do not set the SST in the wrong direction. SST RH F53636 22. (a) REMOVE REAR DIFFERENTIAL SUPPORT NO.1 Remove the 2 bolts, 2 lock nuts and rear differential support No.1 from the differential carrier sub-assy rear. 23. (a) (b) REMOVE REAR DIFFERENTIAL CARRIER COVER Remove the 8 bolts from the carrier cover. Using a brass bar and a hammer, separate the carrier cover from differential carrier sub-assy. Remove the breather plug from the differential carrier cover. G24189 (c) G21126 24. FIX DIFFERENTIAL CARRIER ASSY REAR G21127 Author
: Date
: 2994 29-14 DIFFERENTIAL - DIFFERENTIAL CARRIER ASSY REAR (4WD) 25. (a) INSPECT RUNOUT OF DIFFERENTIAL RING GEAR Using a dial indicator, check the runout of the ring gear. Maximum runout: 0.07 mm (0.0028 in.) If the runout is greater than the maximum, replace the ring gear with a new one. G21128 26. (a) INSPECT DIFFERENTIAL RING GEAR BACKLASH Using a dial indicator, check the backlash of the ring gear. Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 in.) If the backlash is not within the specification, adjust the side bearing preload or repair as necessary. G21129 27. F01259 G22651 30 mm (1.18 in.) INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION (a) Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead primer. (b) Hold the companion flange firmly and rotate the ring gear in both directions. (c) Inspect the contact pattern. If tooth contact pattern is not correct, replace the adjusting washer installed on the front of the drive pinion rear bearing to adjust it. 28. INSPECT DIFFERENTIAL PINION AND SIDE GEAR BACKLASH (a) Using a dial indicator, check the backlash of the side gear while holding 1 pinion gear toward the differential case. Backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 in.) If the backlash is not within the specification, install the 2 side gear thrust washers of different thickness (See step 52). HINT: Measure the backlash of the side gear with the side gear shaft installed. 29. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR (a) Using a dial indicator, measure the runout of the companion flange vertically and horizontally. Maximum runout: 0.10 mm (0.0039 in.) If the runout is greater than the maximum, replace the rear drive pinion companion flange sub-assy rear. F01237 Author
: Date
: 2995 29-15 DIFFERENTIAL - DIFFERENTIAL CARRIER ASSY REAR (4WD) 30. (a) SA2352 INSPECT DIFFERENTIAL DRIVE PINION PRELOAD Using a torque wrench, measure the preload of the drive pinion. Preload (at starting): 0.6 to 0.9 N·m (6 to 9 kgf·cm, 5.2 to 7.8 in.·lbf) If the preload is not within the specification, adjust the rear differential drive pinion preload or repair as necessary. HINT: This preload is within the backlash between the drive pinion and ring gear. 31. INSPECT TOTAL PRELOAD (a) Using a torque wrench, measure the total preload. Total preload (at starting): Drive pinion preload plus 0.3 to 0.5 N·m (3 to 5 kgf·cm, 2.6 to 4.3 in.·lbf) If the total preload is not within the specification, adjust the total preload or repair as necessary. HINT: Disassemble and inspect the differential as necessary. SA2352 32. SST (a) REMOVE REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL Using SST, remove the 2 oil seals from the housing. SST 09308-00010 F01241 33. (a) REMOVE REAR DRIVE PINION NUT Using SST and a hammer, unstake the staked part of the nut. SST 09930-00010 (b) Using SST to hold the flange, remove the nut. SST 09330-00021 SST C60487 G24173 SST SA2349 Author
: Date
: 2996 29-16 DIFFERENTIAL 34. (a) - DIFFERENTIAL CARRIER ASSY REAR (4WD) REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR Using SST, remove the companion flange. SST 09950- 30012 (09951- 03010, 09953- 03010, 09954-03010, 09955-03030, 09956-03020) SST R11391 SST 35. (a) REMOVE REAR DIFFERENTIAL DUST DEFLECTOR Using SST and a press, remove the dust deflector. SST 09950- 60010 (09951- 00360), 09950- 70010 (09951-07150), 09950-00020 36. (a) REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL Using SST, remove the oil seal from the differential carrier. SST 09308-10010 F40564 SST SA2348 37. REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER 38. SST (a) REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING Using SST, remove the front bearing from the drive pinion. SST 09556-22010 Z00641 39. REMOVE REAR DIFFERENTIAL DRIVE PINION BEARING SPACER Author
: Date
: 2997 29-17 DIFFERENTIAL 40. (a) Matchmarks (b) - DIFFERENTIAL CARRIER ASSY REAR (4WD) REMOVE DIFFERENTIAL CASE ASSY Align matchmarks on the bearing cap and differential carrier. Remove the 4 bolts and 2 bearing caps. F03753 (c) SST Using SST and a hammer, remove the 2 plate washers. SST 09504-2201 1 HINT: Measure the thickness of the plate washers and note it down. C67710 (d) Remove the differential case assy and the 2 bearing outer races from the differential carrier. HINT: Tag the 2 bearing outer races to show the location for reassembly. C68107 41. REMOVE DIFFERENTIAL DRIVE PINION 42. SST (a) R10668 REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING Using SST and a press, remove the rear bearing from the drive pinion. SST 09950-00020 HINT: If either the drive pinion or ring gear is damaged, replace both as a set. (b) Remove the plate washer. Author
: Date
: 2998 29-18 DIFFERENTIAL 43. (a) - DIFFERENTIAL CARRIER ASSY REAR (4WD) REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING Using a brass bar and a hammer, remove the front bearing (outer race) from the carrier. C51361 44. (a) REMOVE REAR DRIVE PINION REAR TAPERED ROLLER BEARING Using a brass bar and a hammer, remove the rear bearing (outer race) from the carrier. C51362 45. (a) (b) (c) (d) Matchmarks REMOVE DIFFERENTIAL RING GEAR Align matchmarks on the ring gear and differential case. Using a screwdriver and a hammer, unstake the 4 lock plates. Remove the 8 ring gear set bolts and 4 lock plates. Using a plastic hammer, tap on the ring gear to separate it from the differential case. F03755 46. (a) (b) C68112 SST SST INSPECT RUNOUT OF DIFFERENTIAL CASE ASSY Install the differential case to the differential carrier. Install the right and left bearing caps with the 4 bolts. Torque: 79 N⋅m (800 kgf⋅cm, 58 ft⋅lbf) (c) Using a dial indicator, measure the differential case runout. Maximum case runout: 0.07 mm (0.0028 in.) If the runout is greater than the maximum, replace the differential case assy with a new one. (d) Remove the differential case. 47. REMOVE REAR DIFFERENTIAL CASE BEARING (a) Using SST, remove the case bearing (LH) from the differential case. SST 09950- 40011 (09951- 04020, 09952- 04010, 09953- 04030, 09954- 04010, 09955- 04061, 09957- 04010, 09958- 04011), 09950- 60010 (09951-00360) F40345 Author
: Date
: 2999 29-19 DIFFERENTIAL - DIFFERENTIAL CARRIER ASSY REAR (4WD) 48. (a) REMOVE REAR DIFFERENTIAL CASE BEARING Using SST, remove the case bearing (RH) from the differential case. SST 09950- 40011 (09951- 04020, 09952- 04010, 09953- 04030, 09954- 04010, 09955- 04061, 09957- 04010, 09958- 04011), 09950- 60010 (09951-00360) 49. (a) REMOVE REAR DIFFERENTIAL PINION SHAFT Using a pin punch (5 mm) and a hammer, remove the straight pin. (b) (c) (d) (e) (f) Remove Remove Remove Remove Remove SST SST F40346 C63262 [C] [D] [B] [E] [B] the the the the the differential pinion shaft. [A] 2 differential pinion gears. [B] 2 differential pinion thrust washers. [C] 2 side gears. [D] 2 side gear thrust washers. [E] [E] [A] [C] [D] ZK1879 50. INSPECT DIFFERENTIAL PINION AND SIDE GEAR (a) Check that there is no damage to the differential pinion gear and side gear. If the differential pinion gear and/or side gear is damaged, replace them with new ones. 51. INSPECT DIFFERENTIAL CASE (a) Check that there is no damage to the differential case. If the differential case is damaged, replace it. 52. (a) (b) INSTALL REAR DIFFERENTIAL PINION SHAFT Install the 2 thrust washers to the 2 side gears. Install the 2 side gears, 2 differential pinion gears, 2 differential pinion thrust washers and differential pinion shaft to the differential case. HINT:
Align the holes of the differential case and differential pinion shaft. FA1121 Author
: Date
: 3000 29-20 DIFFERENTIAL - DIFFERENTIAL CARRIER ASSY REAR (4WD) 53. (a) ZD7930 ADJUST DIFFERENTIAL PINION GEAR BACKLASH Measure the side gear backlash while holding 1 pinion gear toward the differential case. Backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 in.) If the backlash is not within the specification, install the 2 side gear thrust washers of different thicknesses. HINT: Refer to the following table to select 2 thrust washers. Thrust washer thickness: Thickness (b) (c) mm (in.) Thickness mm (in.) 0.93 to 0.97 (0.0366 to 0.0382) 1.18 to 1.22 (0.0465 to 0.0480) 0.98 to 1.02 (0.0386 to 0.0402) 1.23 to 1.27 (0.0484 to 0.0500) 1.03 to 1.07 (0.0406 to 0.0421) 1.28 to 1.32 (0.0504 to 0.0520) 1.08 to 1.12 (0.0425 to 0.0441) 1.33 to 1.37 (0.0524 to 0.0539) 1.13 to 1.17 (0.0445 to 0.0461) 1.38 to 1.42 (0.0543 to 0.0559) Using a pin punch (5 mm) and a hammer, install the straight pin through the differential case and hole of the pinion shaft. Using a chisel and a hammer, stake the outside of the differential case pin hole. FA1124 54. (a) Boiling Water (b) (c) (d) INSTALL DIFFERENTIAL RING GEAR Clean the contact surfaces of the differential case and ring gear. Heat the ring gear to approx. 100°C (212°F) in boiling water. Carefully take the ring gear out of the boiling water. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case. SA1143 (e) (f) (g) Matchmarks F03758 Align the matchmarks on the ring gear and differential case. Temporarily install 4 new lock plates and 8 bolts. After the ring gear cools down enough, torque the 8 bolts uniformly. Torque: 97 N·m (989 kgf·cm, 71 ft·lbf) HINT: Tighten the bolts, in diagonal order, a little at a time until they are all tightened. Author
: Date
: 3001 29-21 DIFFERENTIAL - DIFFERENTIAL CARRIER ASSY REAR (4WD) (h) Using a chisel and a hammer, stake the 4 lock plates. (1) Stake one claw so that it is flush against the flat surface of the bolt. (2) As for the other claw, stake it against the surface of the bolt head so as to act as a stopper if the bolt starts to loosen. 55. (a) INSTALL REAR DIFFERENTIAL CASE BEARING Using SST and a press, install the case bearing (RH) to the differential case. SST 09636-20010 56. (a) INSTALL REAR DIFFERENTIAL CASE BEARING Using SST and a press, install the case bearing (LH) to the differential case. SST 09636-20010 (2) (1) Z02483 SST F40347 SST F40463 57. (a) C68116 INSPECT RUNOUT OF DIFFERENTIAL RING GEAR Install the differential case to the carrier, and install the 2 plate washers so that there is no play in the bearing. (b) Install the 2 bearing caps with the 4 bolts. Torque: 79 N·m (800 kgf·cm, 58 ft·lbf) (c) Using a dial indicator, measure the runout of the ring gear. Maximum runout: 0.07 mm (0.0028 in.) If the runout is greater than the maximum, replace the drive pinion, ring gear and differential case. (d) Remove the 2 bearing caps, 2 plate washers and differential carrier. Author
: Date
: 3002 29-22 DIFFERENTIAL 58. SST (a) - DIFFERENTIAL CARRIER ASSY REAR (4WD) INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING Using SST and a press, install the front bearing (outer race) to the carrier. SST 09950- 60010 (09951- 00620), 09950- 70010 (09951-07150) F40461 59. SST (a) INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING Using SST and a press, install the rear bearing (outer race) to the carrier. SST 09950- 60020 (09951- 00710), 09950- 70010 (09951-07150) F40462 60. (a) (b) SST INSTALL REAR DRIVE PINION REAR TAPERED ROLLER BEARING Install the removed plate washer to the drive pinion. Using SST and a press, install the rear bearing to the drive pinion. SST 09506-30012 SA3102 61. ADJUST DIFFERENTIAL DRIVE PINION PRELOAD (a) Install the drive pinion and front bearing. HINT: Assemble the spacer and oil seal after adjusting the gear contact pattern. F01250 (b) Install the rear differential drive pinion oil slinger to the drive pinion. G21132 Author
: Date
: 3003 29-23 DIFFERENTIAL (c) (d) - DIFFERENTIAL CARRIER ASSY REAR (4WD) Using SST, install the companion flange. SST 09950- 30012 (09951- 03010, 09953- 03010, 09954-03010, 09955-03030, 09956-03020) Coat the threads of the nut with hypoid gear oil LSD. SST R11163 (e) Using SST to hold the flange, torque the nut. SST 09330-00021 Torque: 108 N·m (1,100 kgf·cm, 80 ft·lbf) NOTICE:
Torque the nut a little at a time, being careful not to overtighten it.
Apply hypoid gear oil LSD to the nut. SST SA2351 (f) Using a torque wrench, measure the preload. Drive pinion preload (at starting): New bearing: 1.1 to 1.7 N·m (11 to 17 kgf·cm, 9.6 to 14.8 in.·lbf) Reused bearing: 0.6 to 0.9 N·m (6 to 9 kgf·cm, 5.2 to 7.8 in.·lbf) If the preload is not within the specification, adjust the differential drive pinion preload or repair as necessary. SA2352 62. (a) INSTALL DIFFERENTIAL CASE ASSY Place the 2 bearing outer races on their respective bearings. Make sure the right and left races are not interchanged. Author
: Date
: 3004 29-24 DIFFERENTIAL 63. (a) - DIFFERENTIAL CARRIER ASSY REAR (4WD) ADJUST DIFFERENTIAL RING GEAR BACKLASH Install the right and left bearing caps with the 4 bolts. Torque: 79 N·m (800 kgf·cm, 58 ft·lbf) HINT:
F01239 When using a new side bearing select a thrust shim which is thinner than the removed one.
If the side bearing is reused, select a thrust shim of the same thickness as the removed one. (b) Make snug the differential case bearing and thrust shim by tapping on the ring gear with a plastic hammer. (c) Set the dial indicator perpendicular to the end of the ring gear face. (d) While holding the rear drive pinion companion flange rear, rotate the ring gear and measure the backlash. Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 in.) NOTICE: Measure it at 3 points or more on the ring gear periphery. If the measured value is out of the specified value, select a proper thrust shim so that the backlash of the differential ring gear is within the value, and install it to the ring gear back side. Washer thickness: Thickness mm (in.) Thickness mm (in.) Thickness mm (in.) 2.21 to 2.23 (0.0870 to 0.0878) 2.57 to 2.59 (0.1012 to 0.1020) 2.93 to 2.95 (0.1154 to 0.1161) 2.24 to 2.26 (0.0882 to 0.0890) 2.60 to 2.62 (0.1024 to 0.1031) 2.96 to 2.98 (0.1165 to 0.1173) 2.27 to 2.29 (0.0894 to 0.0902) 2.63 to 2.65 (0.1035 to 0.1043) 2.99 to 3.01 (0.1177 to 0.1185) 2.30 to 2.32 (0.0906 to 0.0913) 2.66 to 2.68 (0.1047 to 0.1055) 3.02 to 3.04 (0.1189 to 0.1197) 2.33 to 2.35 (0.0917 to 0.0925) 2.69 to 2.71 (0.1059 to 0.1067) 3.05 to 3.07 (0.1201 to 0.1209) 2.36 to 2.38 (0.0929 to 0.0937) 2.72 to 2.74 (0.1071 to 0.1079) 3.08 to 3.10 (0.1213 to 0.1220) 2.39 to 2.41 (0.0941 to 0.0949) 2.75 to 2.77 (0.1083 to 0.1091) 3.11 to 3.13 (0.1224 to 0.1232) 2.42 to 2.44 (0.0953 to 0.0961) 2.78 to 2.80 (0.1094 to 0.1102) 3.14 to 3.16 (0.1236 to 0.1244) 2.45 to 2.47 (0.0965 to 0.0972) 2.81 to 2.83 (0.1106 to 0.1114) 3.17 to 3.19 (0.1248 to 0.1256) 2.48 to 2.50 (0.0976 to 0.0984) 2.84 to 2.86 (0.1118 to 0.1126) 3.20 to 3.22 (0.1260 to 0.1268) 2.51 to 2.53 (0.0988 to 0.0996) 2.87 to 2.89 (0.1130 to 0.1138) - 2.54 to 2.56 (0.1000 to 0.1008) 2.90 to 2.92 (0.1142 to 0.1150) - 64. (a) (b) (c) ADJUST TOTAL PRELOAD After adjusting the backlash of the differential ring gear, remove the teeth side thrust shim. Using a micrometer, measure the thickness of the removed thrust shim. Select a new thrust shim 0.06 to 0.09 mm (0.0024 to 0.0035 in.) which is thicker than the removed one. HINT: Select a thrust shim which can be pressed in 2/3 rds of the way by finger. Author
: Date
: 3005 29-25 DIFFERENTIAL (d) SST - DIFFERENTIAL CARRIER ASSY REAR (4WD) Using SST and a plastic hammer, drive in the thrust shim. SST 09504-2201 1 F40494 (e) Align matchmarks on the bearing cap and differential carrier, and install the 2 bearing caps. NOTICE: Make sure the right and left bearing caps are not interchanged. (f) Tighten both bearing caps with the 4 bolts. Torque: 79 N·m (800 kgf·cm, 58 ft·lbf) F03753 (g) C68124 Set the dial indicator to the end of the differential ring gear face. (h) While holding the rear drive pinion companion flange rear, rotate the differential ring gear and measure the backlash. Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 in.) (i) If the measured value is out of the specified value, adjust it by increasing or decreasing the thickness of both right and left thrust shims equally. SST 09504-2201 1 (j) Using a torque wrench, measure the preload. Total preload (at starting): Drive pinion preload plus 0.3 to 0.5 N·m (3 to 5 kgf·cm, 2.6 to 4.3 in.·lbf) If the preload is not within the specification, adjust the total preload or repair as necessary. SA2352 65. (a) (b) INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead primer. Hold the companion flange firmly and rotate the ring gear in both directions. F01259 Author
: Date
: 3006 29-26 DIFFERENTIAL (c) - DIFFERENTIAL CARRIER ASSY REAR (4WD) Inspect the tooth contact pattern. Heel Contact Face Contact Proper Contact Select an adjusting washer that brings the drive pinion closer to the ring gear. Toe Contact Flank Contact Select an adjusting washer that shifts the drive pinion away from the ring gear. SA1653 If the teeth are not contacting properly, use the following table to select a proper washer for correction. Plate Washer SA1586 Washer thickness: Thickness 66. 67. 68. 69. mm (in.) Thickness mm (in.) Thickness mm (in.) 2.26 to 2.28 (0.0890 to 0.0898) 2.41 to 2.43 (0.0949 to 0.0957) 2.56 to 2.58 (0.1008 to 0.1016) 2.29 to 2.31 (0.0902 to 0.0909) 2.44 to 2.46 (0.0961 to 0.0969) 2.59 to 2.61 (0.1020 to 0.1028) 2.32 to 2.34 (0.0913 to 0.0921) 2.47 to 2.49 (0.0972 to 0.0980) 2.62 to 2.64 (0.1031 to 0.1039) 2.35 to 2.37 (0.0925 to 0.0933) 2.50 to 2.52 (0.0984 to 0.0992) 2.65 to 2.67 (0.1043 to 0.1051) 2.38 to 2.40 (0.0937 to 0.0945) 2.53 to 2.55 (0.0996 to 0.1004) 2.68 to 2.70 (0.1055 to 0.1063) REMOVE REAR DRIVE PINION NUT (SEE STEP 33) SST 09330-00021 REMOVE REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR (SEE STEP 34) SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) REMOVE REAR DIFFERENTIAL DRIVE PINION OIL SLINGER REMOVE REAR DRIVE PINION FRONT TAPERED ROLLER BEARING (SEE STEP 38) SST 09556-22010 Author
: Date
: 3007 29-27 DIFFERENTIAL 70. (a) - DIFFERENTIAL CARRIER ASSY REAR (4WD) INSTALL REAR DIFFERENTIAL DRIVE PINION BEARING SPACER Install a new bearing spacer. 71. (a) INSTALL REAR DRIVE PINION FRONT TAPERED ROLLER BEARING Install the rear drive pinion front tapered roller bearing to the drive pinion. F01250 72. (a) INSTALL REAR DIFFERENTIAL DRIVE PINION OIL SLINGER Install the rear differential drive pinion oil slinger to the drive pinion. G21132 73. (a) (b) INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL Using SST and a hammer, install a new oil seal. SST 09554-22010 Oil seal drive in depth: 2.0
0.3 mm (0.079
0.012 in.) Apply MP grease to the oil seal lip. SST F01261 74. (a) INSTALL REAR DIFFERENTIAL DUST DEFLECTOR Using SST and a press, install a new dust deflector. SST 09223-00010 NOTICE: Be careful not to damage the dust deflector. SST F40464 Author
: Date
: 3008 29-28 DIFFERENTIAL 75. (a) (b) - DIFFERENTIAL CARRIER ASSY REAR (4WD) INSTALL REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR Using SST, install the companion flange to the drive pinion. SST 09950- 30012 (09951- 03010, 09953- 03010, 09954-03010, 09955-03030, 09956-03020) Coat the threads of a new nut with hypoid gear oil LSD. SST R11163 (c) SST Using SST to hold the flange, torque the nut. SST 09330-00021 Torque: 108 N⋅m (1,100 kgf⋅cm, 80 ft⋅lbf) SA2351 76. (a) SA2352 INSPECT DIFFERENTIAL DRIVE PINION PRELOAD Using a torque wrench, measure the preload of the drive pinion. Preload (at starting): New bearing: 1.1 to 1.7 N·m (11 to 17 kgf·cm, 9.6 to 14.8 in.·lbf) Reused bearing: 0.6 to 0.9 N·m (6 to 9 kgf·cm, 5.2 to 7.8 in.·lbf)
If the preload is greater than the specification, replace the bearing spacer.
If the preload is less than the specification, retorque the nut with 13 N·m (130 kgf·cm, 9 ft·lbf) of torque at a time until the specified preload is reached. Torque: 108 to 235 N·m (1,100 to 2,400 kgf·cm, 80 to 174 ft⋅lbf)
If the torque exceeds the maximum while retightening the nut, replace the bearing spacer and repeat the preload adjusting procedure. NOTICE: Do not loosen the pinion nut to reduce the preload. HINT: This preload is within the backlash between the drive pinion and ring gear. Author
: Date
: 3009 29-29 DIFFERENTIAL - DIFFERENTIAL CARRIER ASSY REAR (4WD) 77. (a) INSPECT TOTAL PRELOAD Using a torque wrench, measure the preload. Total preload (at starting): Drive pinion preload plus 0.3 to 0.5 N·m (3 to 5 kgf·cm, 2.6 to 4.3 in.·lbf) If the total preload is not within the specification, adjust the total preload or repair as necessary. SA2352 78. (a) INSPECT DIFFERENTIAL RING GEAR BACKLASH Using a dial indicator, check the backlash of the ring gear. Backlash: 0.13 to 0.18 mm (0.0051 to 0.0071 in.) If the backlash is not within the specification, adjust the side bearing preload or repair as necessary. G21129 79. INSPECT RUNOUT OF REAR DRIVE PINION COMPANION FLANGE SUB-ASSY REAR (a) Using a dial indicator, measure the runout of the companion flange vertically and horizontally. Maximum runout: 0.10 mm (0.0039 in.) If the runout is greater than the maximum, replace the rear drive pinion companion flange sub-assy rear. 30 mm (1.18 in.) 80. (a) F01237 INSTALL REAR DRIVE PINION NUT Using a chisel and hammer, stake the drive pinion nut. 81. (a) SST F01262 (b) 82. (a) (b) INSTALL REAR DIFFERENTIAL SIDE GEAR SHAFT SEAL OIL Using SST and a hammer, install 2 new oil seals. SST 09550-00032, 09950-70010 (09951-07200) Oil seal drive in depth: 0
0.5 mm (0
0.019 in.) Apply MP grease to the oil seal lip. INSTALL REAR DIFFERENTIAL CARRIER COVER Install the breather plug to the carrier cover. Torque: 21 N⋅m (210 kgf⋅cm, 15 ft⋅lbf) Clean contacting surfaces of any residual FIPG material using gasoline or alcohol. Author
: Date
: 3010 29-30 DIFFERENTIAL (c) 2 to 3 mm (0.08 to 0.12 in.) DIFFERENTIAL CARRIER ASSY REAR (4WD) Apply FIPG to the carrier. FIPG: 08826-00090, THREE BOND 1281 or equivalent HINT:

F03983 -

(d) FIPG should be applied 2 to 3 mm (0.08 to 0.12 in.) in diameter with no break. Allow for an overlap of 10 mm (0.39 in.) or more between the start and end of FIPG application. Install the carrier cover within 3 minutes after applying FIPG. Do not add oil immediately after installing the cover, and leave differential carrier as is for at least an hour. Also, for 12 hours or more, avoid rapid acceleration/deceleration. Install the carrier cover with the 8 bolts. Torque: 47 N⋅m (475 kgf⋅cm, 34 ft⋅lbf) G21126 83. INSTALL REAR DIFFERENTIAL MOUNT CUSHION NO.1 (a) Using SST, install a new rear differential mount cushion No.1. SST 09570-24010 NOTICE: Do not set the SST in the wrong direction. HINT: Perform this operation only when the rear differential mount cushion No.1 replaced. SST LH F53634 Author
: Date
: 3011 29-31 DIFFERENTIAL - DIFFERENTIAL CARRIER ASSY REAR (4WD) 84. INSTALL REAR DIFFERENTIAL MOUNT CUSHION NO.2 (a) Using SST, install a new rear differential mount cushion No.2. SST 09570-24010 NOTICE: Do not set the SST in the wrong direction. HINT: Perform this operation only when the rear differential mount cushion No.2 replaced. SST RH F53633 85. (a) INSTALL REAR DIFFERENTIAL SUPPORT NO.1 Install the rear differential support No.1 to the differential carrier assy rear with the 2 bolts and 2 lock nuts. Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) 86. (a) INSTALL DIFFERENTIAL CARRIER ASSY REAR Jack up the differential carrier assy rear and rear suspension member with a jack. Connect the rear differential support No.1 to the rear suspension member with 2 bolts and 2 lock nuts. Torque: 137 N⋅m (1,400 kgf⋅cm, 101 ft⋅lbf) G24189 (b) G24187 (c) Install the differential carrier assy rear to the rear suspension member sub-assy with the 3 bolts. Torque: 95 N⋅m (970 kgf⋅cm, 70 ft⋅lbf) G24188 Author
: Date
: 3012 29-32 DIFFERENTIAL - DIFFERENTIAL CARRIER ASSY REAR (4WD) 87. INSTALL REAR SUSPENSION MEMBER SUB-ASSY (SEE PAGE 27-18 ) 88. INSTALL REAR DRIVE SHAFT ASSY LH (SEE PAGE 30-45 ) 89. INSTALL REAR DRIVE SHAFT ASSY RH HINT: Installation procedure of the RH side is the same as that of the LH side. 90. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH (SEE PAGE 27-18 ) 91. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 RH HINT: Installation procedure of the RH side is the same as that of the LH side. 92. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH (SEE PAGE 27-18 ) 93. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 RH HINT: Installation procedure of the RH side is the same as that of the LH side. 94. TEMPORARILY TIGHTEN STRUT ROD ASSY REAR (SEE PAGE 27-13 ) 95. INSTALL REAR AXLE SHAFT LH NUT (SEE PAGE 30-45 ) SST 09930-00010 96. INSTALL REAR AXLE SHAFT RH NUT SST 09930-00010 HINT: Installation procedure of the RH side is the same as that of the LH side. 97. INSTALL SPEED SENSOR REAR LH (SEE PAGE 30-45 ) 98. INSTALL SPEED SENSOR REAR RH HINT: Installation procedure of the RH side is the same as that of the LH side. 99. STABILIZE SUSPENSION (SEE PAGE 27-13 ) 100. FULLY TIGHTEN STRUT ROD ASSY REAR (SEE PAGE 27-13 ) 101. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH (SEE PAGE 27-18 ) 102. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 RH HINT: Installation procedure of the RH side is the same as that of the LH side. 103. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH (SEE PAGE 27-18 ) 104. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 RH HINT: Installation procedure of the RH side is the same as that of the LH side. 105. INSTALL EXHAUST PIPE ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 15-5 ) 106. INSTALL EXHAUST PIPE ASSY (2AZ-FE ENGINE TYPE) (SEE PAGE 15-2 ) 107. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY (SEE PAGE 30-12 ) 108. FULLY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSY (SEE PAGE 30-12 ) SST 09370-50010 109. INSTALL REAR DIFFERENTIAL DRAIN PLUG (a) Using a hexagon wrench (10 mm), install the drain plug with a new gasket. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) 110. ADD DIFFERENTIAL OIL (a) Fill the rear differential carrier assy with hypoid gear oil. Oil grade: Hypoid gear oil API GL-5 Recommended oil viscosity: Above -18°C (0°F) SAE 90 Below -18°C (0°F) SAE 80W or 80W-90 Capacity: 0.9 ± 0.05 liters (0.95 ± 0.05 US qts, 0.79 ± 0.04 lmp. qts) 111. INSPECT DIFFERENTIAL OIL (SEE PAGE 29-5 ) Author
: Date
: 3013 29-33 DIFFERENTIAL - DIFFERENTIAL CARRIER ASSY REAR (4WD) 112. INSTALL REAR DIFFERENTIAL FILLER PLUG (a) Using a hexagon wrench (10 mm), install the filler plug with a new gasket. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) 113. INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) 114. INSPECT AND ADJUST REAR WHEEL ALIGNMENT (SEE PAGE 27-5 ) 115. CHECK FOR EXHAUST GAS LEAKS 116. CHECK ABS SPEED SENSOR SIGNAL (SEE PAGE 05-763 ) Author
: Date
: 3014 30-3 DRIVE SHAFT / PROPELLER SHAFT - DRIVE SHAFT, PROPELLER SHAFT, AXLE 3001V-09 ON-VEHICLE INSPECTION 1. (a) INSPECT FRONT AXLE HUB BEARING LOOSENESS Using a dial indicator, check for looseness near the center of the axle hub. Maximum: 0 mm (0 in.) If looseness exceeds the maximum, replace the bearing. NOTICE: Ensure that the dial indicator is set at right angles to the measurement surface. D26919 2. (a) INSPECT FRONT AXLE HUB BEARING RUNOUT Using a dial indicator, check for runout in the surface of the axle hub outside the hub bolt. Maximum: 0.05 mm (0.0020 in.) If runout exceeds the maximum, replace the axle hub. NOTICE: Ensure that the dial indicator is set at right angles to the measurement surface. D26920 3. (a) INSPECT REAR AXLE HUB BEARING LOOSENESS Using a dial indicator, check for looseness near the center of the axle hub. Maximum: 0 mm (0 in.) If looseness exceeds the maximum, replace the axle hub assy. NOTICE: Ensure that the dial indicator is set at right angles to the measurement surface. C98686 4. (a) INSPECT REAR AXLE HUB BEARING RUNOUT Using a dial indicator, check for runout in the surface of the axle hub outside the hub bolt. Maximum: 0.08 mm (0.0031 in.) If runout exceeds the maximum, replace the axle hub assy. NOTICE: Ensure that the dial indicator is set at right angles to the measurement surface. C98687 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3017 30-1 DRIVE SHAFT / PROPELLER SHAFT - DRIVE SHAFT, PROPELLER SHAFT, AXLE DRIVE SHAFT, PROPELLER SHAFT, AXLE 300K2-04 PRECAUTION 1. (a) NOTICE OF REMOVING AND INSTALLING FRONT DRIVE SHAFT ASSY RH When removing and installing the front drive shaft assy RH in a 4WD vehicle, be sure to first drain all the transaxle oil and transfer oil. If removal and installation is carried out without draining these oils, the transfer oil will flow into the transaxle side. Extensive cleaning will be required if the two oils mix. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3015 30-2 DRIVE SHAFT / PROPELLER SHAFT - DRIVE SHAFT, PROPELLER SHAFT, AXLE 3001U-15 PROBLEM SYMPTOMS TABLE Use the table below to help determine the cause of the problem. The causes of problem are listed in order of probability in the ”Suspected Area” column. Check each part in order. If necessary, replace these parts. Symptom Suspected Area See page Wander 6. Wheel alignment (Front) 7. Wheel alignment (Rear) 8. Steering linkage (Loosen or worn) 9. Hub bearing (Worn) 10.Stabilizer bar (Front [2WD]) 11.Stabilizer bar (Front [4WD]) 12.Stabilizer bar (Rear [2WD]) 13.Stabilizer bar (Rear [4WD]) 26-7 27-5 30-3 26-22 26-25 27-27 27-29 Front wheel shimmy 1. 2. 3. 4. 5. 28-1 26-12 27-7 26-20 30-3 Noise (Front drive shaft) 1. Inboard or outboard joint (Worn) (2WD) 2. Inboard or outboard joint (Worn) (4WD) 30-21 30-21 Noise (Rear drive shaft) 1. Inboard or outboard joint (Worn) 30-45 Noise (Propeller shaft) 1. Sleeve yoke spline (Worn) 2. Center support bearing (Worn) 3. Spider bearing (Worn or stuck) 30-12 30-12 30-12 Vibration (Propeller shaft) 1. 2. 3. 4. 5. 6. 30-12 30-12 30-12 30-12 30-12 30-12 Wheel balance Shock absorber (Front) Shock absorber (Rear) Ball joint (Worn) Hub bearing (Worn) Propeller and intermediate shafts (Runout) Propeller shafts (Imbalance) Front flange (Runout) Rear flange (Runout) Universal joint (Stuck or damaged) Sleeve yoke spline (Stuck) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3016 30-45 DRIVE SHAFT / PROPELLER SHAFT - REAR DRIVE SHAFT (4WD) REAR DRIVE SHAFT (4WD) 300OK-01 OVERHAUL HINT: COMPONENTS: SEE PAGE 30-4 Overhaul the RH side using the same procedures as for the LH side. 1. REMOVE REAR WHEEL 2. SEPARATE SPEED SENSOR REAR LH (a) Remove the bolt and the speed sensor from the axle carrier. NOTICE:
Be careful not to damage the speed sensor.
Prevent foreign matter from adhering to the speed sensor. 3. (a) SST C89299 F45049 REMOVE REAR AXLE SHAFT LH NUT Using SST and a hammer, unstake the staked part of the axle shaft LH nut. SST 09930-00010 NOTICE: Loosen the staked part of the nut completely, otherwise the screw of the drive shaft may be damaged. (b) While applying the brakes, remove the lock axle shaft LH nut. 4. 5. 6. 7. (a) SEPARATE REAR SUSPENSION ARM ASSY NO.1 LH (SEE PAGE 30-60 ) SEPARATE STRUT ROD ASSY REAR (SEE PAGE 30-60 ) SEPARATE REAR SUSPENSION ARM ASSY NO.2 LH (SEE PAGE 30-60 ) SEPARATE REAR AXLE CARRIER SUB-ASSY LH Push the rear axle carrier sub-assy LH toward the outside of the vehicle, using a plastic hammer, separate the rear drive shaft assy LH from the rear axle carrier sub-assy LH. NOTICE:
Be careful not to damage the joint boot and speed sensor rotor.
Do not push out the rear axle carrier sub-assy LH excessively. 8. REMOVE REAR DRIVE SHAFT ASSY LH (a) Remove the rear drive shaft, as shown in the illustration. NOTICE: Move the drive shaft assy while keeping it level. G24056 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3059 30-46 DRIVE SHAFT / PROPELLER SHAFT 9. (a) (b) (c) (d) - REAR DRIVE SHAFT (4WD) INSPECT REAR DRIVE SHAFT ASSY LH Check that there is no remarkable play in the radial direction of the outboard joint. Check that the inboard joint slides smoothly in the thrust direction. Check that there is no remarkable play in the radial direction of the inboard joint. Check the boots for damage. 10. REMOVE REAR DRIVE SHAFT INBOARD JOINT BOOT LH CLAMP (a) Using pliers, remove the inboard joint boot LH clamp, as shown in the illustration. G20980 11. (a) REMOVE REAR DRIVE SHAFT INBOARD JOINT BOOT RH NO.2 CLAMP Using pliers, remove the inboard joint boot LH No.2 clamp, as shown in the illustration. G20981 12. (a) SEPARATE INBOARD JOINT BOOT Separate the inboard joint boot from the inboard joint assy. 13. REMOVE REAR DRIVE SHAFT INBOARD JOINT ASSY LH (a) Put matchmarks on the inboard joint assy and outboard joint shaft. NOTICE: Do not punch the marks. (b) Remove the inboard joint assy from the outboard joint shaft. Matchmarks F40222 (c) Using a snap ring expander, remove the snap ring. G24058 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3060 30-47 DRIVE SHAFT / PROPELLER SHAFT - REAR DRIVE SHAFT (4WD) (d) Matchmarks N00194 Put matchmarks on the outboard joint shaft and tripod joint. NOTICE: Do not punch the marks. (e) Using a brass bar and a hammer, remove the tripod joint from the outboard joint shaft. NOTICE: Do not tap the roller. (f) Remove the inboard joint boot, inboard joint boot LH clamp and inboard joint boot LH No.2 clamp. 14. REMOVE REAR DRIVE SHAFT OUTBOARD JOINT BOOT LH CLAMP (a) Using pliers, remove the outboard joint boot LH clamp, as shown in the illustration. G20982 15. (a) REMOVE REAR DRIVE SHAFT OUTBOARD JOINT BOOT LH NO.2 CLAMP Using pliers, remove the outboard joint boot LH No.2 clamp, as shown in the illustration. G21590 16. REMOVE OUTBOARD JOINT BOOT (a) Remove the outboard joint boot from the outboard joint shaft. (b) Remove the old grease from the outboard joint. NOTICE: Do not disassemble the outboard joint. 17. REMOVE REAR DRIVE SHAFT INBOARD JOINT LH SHAFT SNAP RING (a) Using a screwdriver, remove the shaft snap ring. 18. (a) REMOVE REAR DRIVE SHAFT DUST COVER LH Using SST and a press, remove the drive shaft dust cover LH. SST 09950-00020 NOTICE: Be careful not to drop the inboard joint assy. Do not overtighten the SST. SST C68353 F45514 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3061 30-48 DRIVE SHAFT / PROPELLER SHAFT REAR DRIVE SHAFT (4WD) 19. (a) INSTALL REAR DRIVE SHAFT DUST COVER LH Using SST and a steel plate, install a new drive shaft dust cover LH SST 09527-2101 1 NOTICE:
Dust cover should be completely installed.
Be careful not to damage the dust cover. Steel Plate SST C68354 20. (a) - F45515 INSTALL REAR DRIVE SHAFT INBOARD JOINT LH SHAFT SNAP RING Install a new hole snap ring. 21. INSTALL OUTBOARD JOINT BOOT HINT: Before installing the boot, wrap the spline of the outboard joint shaft with vinyl tape to prevent the boot from being damaged. (a) Install a new outboard joint boot, 2 outboard joint boot clamps, 2 inboard joint boot clamps and inboard joint boot. (b) Make sure that the 2 boots are on the shaft groove. Vinyl Tape RA1310 22. Hold SST Turn R10425 INSTALL REAR DRIVE SHAFT OUTBOARD JOINT BOOT LH CLAMP Hold the drive shaft lightly in a soft vise. Install the 2 outboard joint boot clamps to the boot. (a) (b) HINT: Before installing the clamps, pack the outboard joint and boot with grease in the boot kit. Grease capacity: 95 to 105 g (3.4 to 3.7 oz.) (c) Place SST onto the outboard joint boot LH clamp. SST 09521-24010 (d) Tighten the SST so that the outboard joint boot LH clamp is pinched. NOTICE: Do not overtighten the SST. (e) Using SST, measure the clearance of the outboard joint boot LH clamp. SST 09240-00020 Clearance: 1.3 mm (0.051 in.) or less NOTICE: When the measured value is greater than the specified value, retighten the clamp. SST R10426 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3062 30-49 DRIVE SHAFT / PROPELLER SHAFT - REAR DRIVE SHAFT (4WD) 23. INSTALL REAR DRIVE SHAFT OUTBOARD JOINT BOOT LH NO.2 CLAMP (a) Place SST onto the outboard joint boot LH No.2 clamp. SST 09521-24010 (b) Tighten the SST so that the outboard joint boot LH No.2 clamp is pinched. NOTICE: Do not overtighten the SST. Turn Hold SST G21594 (c) Using SST, measure the clearance of the outboard joint boot LH No.2 clamp. SST 09240-00020 Clearance: 1.3 mm (0.051 in.) or less NOTICE: When the measured value is greater than the specified value, retighten the clamp. SST G21598 24. (a) (b) INSTALL REAR DRIVE SHAFT INBOARD JOINT ASSY LH Place the beveled side of the tripod joint axial spline toward the outboard joint shaft. Align the matchmarks. Matchmarks C58023 F40930 (c) Using a brass bar and a hammer, tap in the tripod joint to the outboard joint shaft. NOTICE:
Do not tap the roller.
Be sure to install the tripod joint assy in the correct direction. F40931 (d) (e) Using a snap ring expander, install a new shaft snap ring. Pack the outboard joint shaft and boot with grease. Grease capacity : 125.5 to 135.5 g (4.4 to 4.7 oz.) G24058 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3063 30-50 DRIVE SHAFT / PROPELLER SHAFT (f) Matchmarks - REAR DRIVE SHAFT (4WD) Align the matchmarks, install the inboard joint assy to the outboard joint shaft assy. F40222 25. (a) INSTALL INBOARD JOINT BOOT Install the inboard joint boot to the outboard joint shaft. SST 26. Hold Turn G21591 INSTALL REAR DRIVE SHAFT INBOARD JOINT BOOT LH CLAMP (a) Install the inboard joint boot LH clamp. (1) Hold the drive shaft lightly in a soft vise. (2) Install the 2 inboard joint boot clamps to the boot. (3) Place SST onto the inboard joint boot LH clamp. SST 09521-24010 (4) Tighten the SST so that the inboard joint boot LH clamp is pinched. NOTICE: Do not overtighten the SST. (5) Using SST, measure the clearance of the inboard joint boot LH clamp. SST 09240-00020 Clearance: 1.1 mm (0.043 in.) or less NOTICE: When the measured value is greater than the specified value, retighten the clamp. SST G21595 27. Hold SST Turn G21592 INSTALL REAR DRIVE SHAFT INBOARD JOINT BOOT LH NO.2 CLAMP (a) Install the inboard joint boot LH No.2 clamp. (b) Place SST onto the inboard joint boot LH No.2 clamp. SST 09521-24010 (c) Tighten the SST so that the inboard joint boot LH No.2 clamp is pinched. NOTICE: Do not overtighten the SST. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3064 30-51 DRIVE SHAFT / PROPELLER SHAFT - REAR DRIVE SHAFT (4WD) (1) Using SST, measure the clearance of the inboard joint boot LH No.2 clamp. SST 09240-00020 Clearance: 1.1 mm (0.043 in.) or less NOTICE: When the measured value is greater than the specified value, retighten the clamp. SST G21596 28. (a) (b) (c) (d) INSPECT REAR DRIVE SHAFT ASSY LH Check that there is no remarkable play in the radial direction of the outboard joint. Check that the inboard joint slides smoothly in the thrust direction. Check that there is no remarkable play in the radial direction of the inboard joint. Check the boots for damage. 29. INSTALL REAR DRIVE SHAFT ASSY LH (a) Align the shaft splines and install the drive shaft assy with a brass bar and a hammer. NOTICE:
Set the snap ring with the opening side facing downward.
Be careful not to damage the oil seal boot and dust cover.
Move the drive shaft assy while keeping it level. F45240 30. (a) INSTALL REAR AXLE CARRIER SUB-ASSY LH Push the rear axle carrier sub-assy LH toward the inside of the vehicle fitting it to the splined part of the rear drive shaft assy LH and insert. NOTICE:
Be careful not to damage the joint boot and speed sensor rotor. 31. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH (SEE PAGE 30-60 ) 32. TEMPORARILY TIGHTEN STRUT ROD ASSY REAR (SEE PAGE 30-60 ) 33. TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH (SEE PAGE 30-60 ) 34. (a) (b) INSTALL REAR AXLE SHAFT LH NUT Install a new axle shaft LH nut. Torque: 294 N⋅m, (3,000 kgf⋅cm, 217 ft⋅lbf) Using a chisel and a hammer, stake the axle shaft LH nut. C89301 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3065 30-52 DRIVE SHAFT / PROPELLER SHAFT - REAR DRIVE SHAFT (4WD) 35. (a) INSTALL SPEED SENSOR REAR LH Install the speed sensor with the bolt. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) NOTICE:
Be careful not to damage the speed sensor.
Prevent foreign matter from adhering to the speed sensor.
Do not twist the sensor wire when installing the sensor. 36. INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) 37. STABILIZE SUSPENSION (SEE PAGE 27-29 ) 38. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH (SEE PAGE 27-25 ) 39. FULLY TIGHTEN STRUT ROD ASSY REAR (SEE PAGE 27-13 ) 40. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH (SEE PAGE 27-18 ) 41. INSPECT AND ADJUST REAR WHEEL ALIGNMENT (SEE PAGE 27-5 ) 42. CHECK ABS SPEED SENSOR SIGNAL (SEE PAGE 05-765 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3066 30-12 DRIVE SHAFT / PROPELLER SHAFT - PROPELLER W/CENTER BEARING SHAFT ASSY (4WD) PROPELLER W/CENTER BEARING SHAFT ASSY (4WD) 300OG-01 OVERHAUL HINT: COMPONENTS:SEE PAGE 30-4 1. REMOVE EXHAUST PIPE ASSY 2. (a) (b) F40503 C23342 REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY Depress the brake pedal and hold it. Using a hexagon wrench (6 mm), loosen the cross groove joint set bolts 1/2 turn. HINT: Put a piece of shop rag or equivalent into the inside of the universal joint cover so that the boot does not touch the inside of the universal joint cover. (c) (d) Place matchmarks on both the flanges. Remove the 4 nuts, bolts and washers. (e) Remove the 4 bolts, 2 adjusting shims and propeller shaft w/ center bearing shaft assy. (f) Insert SST in the transfer to prevent oil leakage. SST 09325-20010 Matchmarks F40504 C83005 SST F40505 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3026 DRIVE SHAFT / PROPELLER SHAFT 3. (a) (b) - PROPELLER W/CENTER BEARING SHAFT ASSY (4WD) 30-13 REMOVE PROPELLER SHAFT ASSY Place matchmarks on both the flanges. Remove the 4 nuts, bolts and washers. Matchmarks F40506 4. REMOVE INTERMEDIATE SHAFT (a) Place matchmarks on the joint and flange. NOTICE: Do not make matchmarks with a punch. (b) Using a hexagon wrench (6 mm), remove the 6 bolts and 2 washers and separate the intermediate shaft from the rear propeller shaft. Matchmarks F40507 5. (a) INSPECT SPIDER BEARING Check the spider bearing axial play by turning the flange while holding the shaft tightly. HINT: If necessary, replace the shaft. Q07980 6. (a) INSPECT INTERMEDIATE SHAFT Using a dial indicator, inspect the runout of the shaft. Maximum runout: 0.8 mm (0.031 in.) HINT: If the shaft runout exceeds the maximum, replace the shaft. C53258 (b) Using a dial indicator, inspect the front side of the intermediate shaft flange runout. Maximum runout: 0.1 mm (0.004 in.) HINT: If the shaft runout exceeds the maximum, replace the shaft. C53240 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3027 30-14 DRIVE SHAFT / PROPELLER SHAFT (c) - PROPELLER W/CENTER BEARING SHAFT ASSY (4WD) Using a dial indicator, inspect the rear side of the intermediate shaft flange runout in the horizontal direction. Maximum runout: 0.1 mm (0.004 in.) HINT: If the intermediate shaft flange runout exceeds the maximum, replace the intermediate shaft. C53241 (d) Using a dial indicator, inspect the rear side of the intermediate shaft flange runout in the vertical direction. Maximum runout: 0.1 mm (0.004 in.) HINT: If the intermediate shaft flange runout exceeds the maximum, replace the intermediate shaft. C53244 7. (a) INSPECT PROPELLER SHAFT ASSY Using a dial indicator, inspect the runout of the propeller shaft. Maximum runout: 0.8 mm (0.031 in.) HINT: If the shaft runout exceeds the maximum, replace the propeller shaft. C36277 8. (a) SST (b) REMOVE CENTER SUPPORT BEARING ASSY NO.2 Using a chisel and a hammer, loosen the staked part of the nut. Using SST to hold the front flange, remove the nut and plate washer. SST 09330-00021 F40508 (c) Matchmarks Place matchmarks on the rear flange and shaft. F40509 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3028 DRIVE SHAFT / PROPELLER SHAFT (d) (e) - PROPELLER W/CENTER BEARING SHAFT ASSY (4WD) 30-15 Using SST, remove the rear flange. SST 09950- 40011 (09951- 04020, 09952- 04010, 09953- 04030, 09954- 04010, 09955- 04061, 09957-04010, 09958-04011) Remove the center support bearing assy No.2 and plate washer. SST F40510 SST 9. (a) (b) REMOVE CENTER SUPPORT BEARING ASSY NO.1 Using a chisel and a hammer, loosen the staked part of the nut. Using SST to hold the front flange, remove the nut and plate washer. SST 09330-00021 F40511 Matchmarks (c) Place matchmarks on the front flange and shaft. (d) Using SST, remove the front flange. SST 09950- 40011 (09951- 04020, 09952- 04010, 09953- 04030, 09954- 04010, 09955- 04061, 09957-04010, 09958-04011) Remove the center support bearing assy No.1 and plate washer. F40512 SST (e) C23354 F40513 10. (a) C22188 INSPECT CENTER SUPPORT BEARING ASSY NO.2 Turn the bearing by hand with applying force in the rotation direction. Check the bearing turns smoothly. Check that the seals are not cracked or damaged. (b) HINT: If the bearing is damaged, worn, or does not turn freely, replace it. 11. INSPECT CENTER SUPPORT BEARING ASSY NO.1 (a) Inspect the center support bearing assy No.1 by the same procedures with center support bearing assy No.2. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3029 30-16 DRIVE SHAFT / PROPELLER SHAFT 12. (a) - PROPELLER W/CENTER BEARING SHAFT ASSY (4WD) INSPECT PROPELLER SHAFT Using a dial indicator, inspect the runout of the rear propeller shaft. Maximum runout: 0.8 mm (0.031 in.) HINT: If the shaft runout exceeds the maximum, replace the rear propeller shaft. C53259 13. (a) (b) INSTALL CENTER SUPPORT BEARING ASSY NO.1 Set the center support bearing assy No.1 on the intermediate shaft, as shown in the illustration. Install the plate washer to the intermediate shaft. Front F40522 Matchmarks (c) Align the matchmarks on the front flange and shaft and place the flange on the shaft. (d) Using SST to hold the front flange, press the center support bearing assy No.1 into position by tightening down a new nut and plate washer. SST 09330-00021 Torque: 182 N·m (1,850 kgf·cm, 134 ft·lbf) Loosen the nut. Torque the nut again. Torque: 69 N·m (700 kgf·cm, 51 ft·lbf) Using a chisel and a hammer, stake the nut. F40512 (e) (f) SST F40523 (g) 14. (a) Rear (b) INSTALL CENTER SUPPORT BEARING ASSY NO.2 Set the center support bearing assy No.2 on the shaft as shown in the illustration. Install the plate washer to the shaft. F40524 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3030 DRIVE SHAFT / PROPELLER SHAFT Matchmarks PROPELLER W/CENTER BEARING SHAFT ASSY (4WD) 30-17 (c) Align the matchmarks on the rear flange and shaft and place the flange on the shaft. (d) Using SST to hold the front flange, press the center support bearing assy No.2 into position by tightening down a new nut and plate washer. SST 09330-00021 Torque: 182 N·m (1,850 kgf·cm, 134 ft·lbf) Loosen the nut. Torque the nut again. Torque: 69 N·m (700 kgf·cm, 51 ft·lbf) Using a chisel and a hammer, stake the nut. F40509 SST (e) (f) F40525 (g) 15. (a) (b) Matchmarks - INSTALL INTERMEDIATE SHAFT Align the matchmarks on the intermediate shaft and rear propeller shaft, then install the 2 washers and 6 bolts. Using a hexagon wrench (6 mm), tighten the 6 bolts temporarily. F40507 16. (a) (b) INSTALL PROPELLER SHAFT ASSY Align the matchmarks on the propeller shaft flange and differential companion flange, and connect the shaft with the 4 bolts, washers and nuts. Torque: 74 N·m (750 kgf·cm, 54 ft·lbf) Check that the each joint of the propeller shaft is facing to the direction, as shown in the illustration. Matchmarks F40506 C83556 F45568 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3031 30-18 DRIVE SHAFT / PROPELLER SHAFT 17. Matchmarks - PROPELLER W/CENTER BEARING SHAFT ASSY (4WD) (a) INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY Align the matchmarks on the propeller shaft flange and differential companion flange, and connect the shaft with the 4 bolts, washers and nuts. (b) (c) Remove SST from the transaxle. Insert the yoke into the transaxle. (d) Install the 2 adjusting shims and propeller shaft w/ center bearing, and temporarily tighten the 4 bolts. (e) Tighten the 4 nuts. Torque: 74 N·m (750 kgf·cm, 54 ft·lbf) 18. FULLY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSY Remove the shop rag to the joint. Using a hexagon wrench (6 mm), tighten the 6 bolts. Torque: 29 N·m (296 kgf·cm, 21 ft·lbf) F40504 SST F40505 C83005 F40504 (a) (b) C23342 F40503 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3032 DRIVE SHAFT / PROPELLER SHAFT 58.0
0.5 mm (2.283
0.020 in.) PROPELLER W/CENTER BEARING SHAFT ASSY (4WD) 30-19 (c) With the vehicle unloaded, adjust the dimension between the rear side of the cover and shaft, as shown in the illustration. (d) Under the same condition as (a), adjust the front and rear dimensions between edge surface of the center support bearing and the edge surface of the cushion to 12.5
1.0 mm (0.492
0.039 in.) respectively as shown, then torque the bolts. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) Check that the center line of the bracket is at the right angle in the shaft axial direction. F40527 Front Center Support Bearing 12.5
1.0 mm (0.492
0.039 in.) Rear Center Support Bearing - (e) (a) 12.5
1.0 mm (0.492
0.039 in.) (a) F40528 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3033 30-20 DRIVE SHAFT / PROPELLER SHAFT (f) - PROPELLER W/CENTER BEARING SHAFT ASSY (4WD) If any vibration or noise occurs, perform joint angle check as follows and replace the adjusting shim with proper one. (1) Turn the propeller shaft several times by hand to stabilize the center support bearings. (2) Using a jack, raise and lower the differential to stabilize the differential mounting cushion. (3) Remove the transfer dynamic damper. (4) Using SST, measure the installation angle of the transfer (A) and front propeller shaft (B). SST 09370-50010 No.1 joint angle: A - B = -1.6
to -3.6
(5) Using SST, measure the installation angle of the rear propeller shaft (C) and rear differential (D). SST 09370-50010 No.2 joint angle: C - D = 2.1
to 4.1
No.1 Joint Angle A - B = -1.6
to -3.6
No.2 Joint Angle C - D = 2.1
to 4.1
B A D C SST SST F40924 HINT: If the measured angle is not within the specification, adjust it with the center support bearing adjusting shim. Center support bearing adjusting shim thickness: Thickness mm (in.) (g) 19. 20. 21. Thickness mm (in.) 3.2 (0.126) 11.0 (0.433) 4.5 (0.177) 13.5 (0.531) 6.5 (0.256) 15.5 (0.610) 9.0 (0.354) 17.5 (0.689) Install the transfer dynamic damper. Torque: 26 N·m (260 kgf·cm, 19 ft·lbf) INSTALL EXHAUST PIPE ASSY CHECK FOR EXHAUST GAS LEAKS INSPECT AND ADJUST TRANSFER OIL 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3034 30-38 DRIVE SHAFT / PROPELLER SHAFT - FRONT AXLE HUB SUB-ASSY LH FRONT AXLE HUB SUB-ASSY LH 300OI-02 REPLACEMENT HINT: COMPONENTS: SEE PAGE 30-4 Replace the RH side by the same procedures with LH side. 1. REMOVE FRONT WHEEL 2. (a) SST (b) REMOVE FRONT AXLE HUB LH NUT Using SST and a hammer, unstake the staked part of the lock nut. SST 09930-00010 While applying the brakes, remove the lock nut. F40146 3. (a) SEPARATE SPEED SENSOR FRONT LH Remove the bolt, separate the sensor wire and flexible hose from the shock absorber. (b) Remove the bolt and separate the speed sensor from the steering knuckle. 4. (a) SEPARATE FRONT DISC BRAKE CALIPER ASSY LH Remove the 2 bolts, separate the brake caliper. F40138 F40147 F40167 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3052 30-39 DRIVE SHAFT / PROPELLER SHAFT 5. - FRONT AXLE HUB SUB-ASSY LH REMOVE FRONT DISC 6. (a) (b) SEPARATE TIE ROD END SUB-ASSY LH Remove the cotter pin and nut. Using SST, separate the tie rod end from the steering knuckle. SST 09628-6201 1 7. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH Remove the bolt and 2 nuts, and separate the lower suspension arm from the lower ball joint. SST F40145 (a) F40142 Matchmarks 8. (a) (b) REMOVE FRONT AXLE ASSY LH Put matchmarks on the drive shaft and the axle hub. Using a plastic hammer, separate the drive shaft from the axle hub. NOTICE: Be careful not to damage the boot and speed sensor rotor. D32030 (c) 9. (a) Remove the 2 bolts, nuts and steering knuckle with the axle hub. REMOVE LOWER BALL JOINT ASSY FRONT LH Remove the cotter pin and nut. C83023 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3053 30-40 DRIVE SHAFT / PROPELLER SHAFT - FRONT AXLE HUB SUB-ASSY LH (b) Using SST, remove the ball joint. SST 09628-6201 1 10. (a) REMOVE FRONT WHEEL BEARING DEFLECTOR NO.1 LH Using a screwdriver, remove the dust deflector. 11. (a) REMOVE FRONT AXLE HUB LH HOLE SNAP RING Using a snap ring plier, remove the snap ring. 12. (a) REMOVE FRONT AXLE HUB SUB-ASSY LH Using SST, remove the axle hub. (b) Using SST and a press, remove the inner race (outside) from the axle hub. SST 09520- 00031, 09950- 00020, 09950- 60010 (09951-00430), 09950-70010 (09951-07100) REMOVE DISC BRAKE DUST COVER FRONT LH Using a torx wrench (T30), remove the 4 bolts and dust cover. SST F40153 DUST F40154 F40155 SST F40156 SST 13. (a) F02261 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3054 30-41 DRIVE SHAFT / PROPELLER SHAFT 14. (a) (b) SST - FRONT AXLE HUB SUB-ASSY LH REMOVE FRONT AXLE HUB LH BEARING Place the inner race (outside) on the bearing. Using SST and a press, press the bearing until it contacts with the SST. SST F40230 (c) Using a spanner to make the steering knuckle horizontal, fix it to the V block as shown in the illustration. NOTICE: Be sure the steering knuckle is horizontally positioned. (d) Using SST and a press, remove the bearing. SST 09527- 17011, 09950- 60020 (09951- 00750), 09950-70010 (09951-07100) SST F11547 15. (a) SST 16. (a) INSTALL FRONT AXLE HUB LH BEARING Using SST and a press, install a new bearing to the steering knuckle. SST 09608- 32010, 09950- 60020 (09951- 00810), 09950-70010 (09951-07100) INSTALL DISC BRAKE DUST COVER FRONT LH Place the dust cover and using a torx wrench (T30), torque the 4 bolts. F40231 SST 17. (a) INSTALL FRONT AXLE HUB SUB-ASSY LH Using SST and a press, install the axle hub. SST 09608- 32010, 09950- 60020 (09951- 00810), 09950-70010 (09951-07100) 18. (a) INSTALL FRONT AXLE HUB LH HOLE SNAP RING Using snap ring pliers, install a new snap ring. F40157 F40155 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3055 30-42 DRIVE SHAFT / PROPELLER SHAFT 19. (a) SST - FRONT AXLE HUB SUB-ASSY LH INSTALL FRONT WHEEL BEARING DUST DEFLECTOR NO.1 LH Using SST and a hammer, install a new dust deflector. SST 09316- 60011 (09316- 00011, 09316- 00031), 09608-32010 HINT: Align the holes for the ABS speed sensor in the dust deflector with steering knuckle. F02216 20. (a) INSTALL LOWER BALL JOINT ASSY FRONT LH Install the lower ball joint and tighten the nut. Torque: 123 N⋅m (1,250 kgf⋅cm, 90 ft⋅lbf) (b) Install a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60. 21. INSTALL FRONT AXLE ASSY LH (a) Align the matchmarks and install the drive shaft assy LH Matchmarks to the front axle assy LH. D32030 F47689 (b) 22. (a) 23. (a) (b) 24. Install the 2 bolts, nuts and axle assembly to the shock absorber. Torque: 230 N⋅m (2,345 kgf⋅cm, 170 ft⋅lbf) HINT: Insert the bolt from the front side of the vehicle and tighten the nut. (c) Push the front axle assy toward the outside of the vehicle, fit the spline part of the drive shaft assy to that of the front axle assy and insert the drive shaft assy into the front axle C83023 assy. NOTICE:
Do not push out the front axle assy excessively.
Be careful not to damage the drive shaft outboard joint boot.
Be careful not to damage the speed sensor rotor. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH Connect the lower arm and ball joint with the 2 nuts and bolt. INSTALL TIE ROD END SUB-ASSY LH Connect the tie rod end to the steering knuckle. Install the nut and a new cotter pin. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) INSTALL FRONT DISC 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3056 30-43 DRIVE SHAFT / PROPELLER SHAFT 25. (a) 26. - FRONT AXLE HUB SUB-ASSY LH INSTALL FRONT DISC BRAKE CALIPER ASSY LH Install the brake caliper assembly with the 2 bolts to the steering knuckle. Torque: 107 N⋅m (1,090 kgf⋅cm, 79 ft⋅lbf) INSTALL FRONT AXLE HUB LH NUT F40167 27. 28. SEPARATE FRONT DISC BRAKE CALIPER ASSY LH REMOVE FRONT DISC 29. (a) INSPECT BEARING BACKLASH Using a dial indicator, check the backlash near the center of the axle hub. Maximum: 0 mm (0 in.) If the backlash exceeds the maximum, replace the bearing. F40163 30. (a) INSPECT AXLE HUB DEVIATION Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt. Maximum: 0.07 mm (0.0027 in.) If the backlash exceeds the maximum, replace the axle hub. 31. INSTALL FRONT DISC F40164 32. (a) 33. INSTALL FRONT DISC BRAKE CALIPER ASSY LH Install the brake caliper assy with the 2 bolts to the steering knuckle. Torque: 107 N⋅m (1,090 kgf⋅cm, 79 ft⋅lbf) INSTALL SPEED SENSOR FRONT LH F40167 34. 35. 36. INSTALL FRONT WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (SEE PAGE 26-7 ) CHECK ABS SPEED SENSOR SIGNAL (SEE PAGE 05-765 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3057 30-44 DRIVE SHAFT / PROPELLER SHAFT - FRONT AXLE LH HUB BOLT FRONT AXLE LH HUB BOLT 300OJ-01 REPLACEMENT HINT: COMPONENTS:SEE PAGE 30-4 Replace the RH side by the same procedures with LH side. 1. REMOVE FRONT WHEEL 2. SEPARATE FRONT DISC BRAKE CALIPER ASSY LH(SEE PAGE 30-38 ) 3. REMOVE FRONT DISC 4. (a) REMOVE FRONT AXLE LH HUB BOLT Using SST and a screwdriver or an equivalent to hold, remove the hub bolt. SST 09628-1001 1 5. (a) INSTALL FRONT AXLE LH HUB BOLT Install a washer and nut to a new hub bolt as shown in the illustration. Using a screwdriver to hold, install the hub bolt by torquing the nut. INSTALL FRONT DISC INSTALL FRONT DISC BRAKE CALIPER ASSY LH (SEE PAGE 30-38 ) INSTALL FRONT WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) SST F40170 (b) 6. 7. F40171 8. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3058 30-58 DRIVE SHAFT / PROPELLER SHAFT - REAR AXLE CARRIER SUB-ASSY LH (FF) REAR AXLE CARRIER SUB-ASSY LH (FF) 300OM-02 REPLACEMENT HINT: COMPONENTS: SEE PAGE 30-4 Replace the RH side by the same procedures with the LH side. 1. REMOVE REAR WHEEL 2. SEPARATE REAR DISC BRAKE CALIPER ASSY LH 3. REMOVE REAR DISC (SEE PAGE 32-29 ) 4. DISCONNECT SKID CONTROL SENSOR (a) Disconnect the connector. 5. REMOVE REAR AXLE HUB & BEARING ASSY LH 6. SEPARATE STRUT ROD ASSY REAR 7. (a) SEPARATE REAR SUSPENSION ARM ASSY NO.2 LH Remove the bolt, nut and rear suspension arm No. 2 from the rear axle carrier. HINT: While fixing the nut, turn and remove the bolt. C83017 8. (a) SEPARATE REAR SUSPENSION ARM ASSY NO.1 LH Remove the bolt, nut and rear suspension arm No. 1 from the rear axle carrier. HINT: While fixing the nut, turn and remove the bolt. C83018 9. (a) REMOVE REAR AXLE CARRIER SUB-ASSY LH Remove the 2 bolts, nuts and rear axle carrier from the shock absorber. C83019 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3072 30-59 DRIVE SHAFT / PROPELLER SHAFT 10. (a) - REAR AXLE CARRIER SUB-ASSY LH (FF) INSTALL REAR AXLE CARRIER SUB-ASSY LH Install the rear axle carrier with the 2 bolts and nuts. Torque: 180 N⋅m (1,840 kgf⋅cm, 133 ft⋅lbf) HINT: Insert the bolt from the rear side of the vehicle and install the nut. C83019 11. (a) TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH Install the rear suspension arm No. 1 to the rear axle carrier with the bolt and nut, temporarily tighten the bolt. HINT: Insert the bolt from the front side of the vehicle and while fixing the nut, turn and install the bolt. C83018 12. (a) TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH Install the rear suspension arm No. 2 to the rear axle carrier with the bolt and nut, temporarily tighten the bolt. HINT: Insert the bolt from the rear side of the vehicle and while fixing the nut, turn and install the bolt. C83017 13. TEMPORARILY TIGHTEN STRUT ROD ASSY REAR (SEE PAGE 27-13 ) 14. INSTALL REAR AXLE HUB & BEARING ASSY LH (SEE PAGE 30-53 ) 15. INSPECT BEARING BACKLASH (SEE PAGE 30-3 ) 16. INSPECT AXLE HUB DEVIATION (SEE PAGE 30-3 ) 17. CONNECT SKID CONTROL SENSOR (a) Connect the connector. NOTICE: Do not twist the sensor wire when connecting it. 18. INSTALL REAR DISC (SEE PAGE 32-29 ) 19. INSTALL REAR DISC BRAKE CALIPER ASSY LH (SEE PAGE 30-53 ) 20. INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) 21. STABILIZE SUSPENSION (SEE PAGE 27-27 ) 22. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH (SEE PAGE 27-16 ) 23. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH (SEE PAGE 27-23 ) 24. FULLY TIGHTEN STRUT ROD ASSY REAR (SEE PAGE 27-13 ) 25. INSPECT AND ADJUST REAR WHEEL ALIGNMENT (SEE PAGE 27-5 ) 26. CHECK ABS SPEED SENSOR SIGNAL (SEE PAGE 05-765 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3073 30-64 DRIVE SHAFT / PROPELLER SHAFT - REAR AXLE LH HUB BOLT REAR AXLE LH HUB BOLT 300OP-02 REPLACEMENT HINT: COMPONENTS:SEE PAGE 30-4 Replace the RH side by the same procedures with the LH side. 1. REMOVE REAR WHEEL 2. SEPARATE REAR DISC BRAKE CALIPER ASSY LH (2WD DRIVE TYPE) (a) Remove the 2 bolts and brake caliper. (b) Support the brake caliper securely. 3. SEPARATE REAR DISC BRAKE CALIPER ASSY LH (4WD DRIVE TYPE) 4. REMOVE REAR DISC (SEE PAGE 32-29 ) SST 5. (a) REMOVE REAR AXLE LH HUB BOLT Using SST and a screwdriver or an equivalent to hold, remove the hub bolt. SST 09628-1001 1 6. (a) INSTALL REAR AXLE LH HUB BOLT Install a washer and nut to a new hub bolt as shown in the illustration. Using a screwdriver to hold, install the hub bolt by torquing the nut. INSTALL REAR DISC (SEE PAGE 32-29 ) INSTALL REAR DISC BRAKE CALIPER ASSY LH (2WD DRIVE TYPE) Install the brake caliper with the 2 bolts. Torque: 2WD: 61.8 N⋅m (630 kgf⋅cm, 46 ft⋅lbf) INSTALL REAR DISC BRAKE CALIPER ASSY LH (4WD DRIVE TYPE) Install the brake caliper with the 2 bolts. Torque: 4WD: 58 N⋅m (592 kgf⋅cm, 43 ft⋅lbf) INSTALL REAR WHEEL C83020 (b) 7. 8. C83021 (a) 9. (a) 10. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3078 30-21 DRIVE SHAFT / PROPELLER SHAFT - FRONT DRIVE SHAFT FRONT DRIVE SHAFT 300OH-02 OVERHAUL HINT: COMPONENTS: SEE PAGE 30-4 Overhaul the RH side following the same procedures as for the LH side. 1. DRAIN AUTOMATIC TRANSAXLE FLUID (SEE PAGE 40-2 ) 2. DRAIN TRANSFER OIL (4WD DRIVE TYPE) (SEE PAGE 31-9 ) HINT: Perform the procedure only when removing the RH side. 3. REMOVE FRONT WHEEL 4. (a) SST F40146 Hold REMOVE FRONT AXLE HUB LH NUT Using SST and a hammer, unstake the staked part of the axle hub LH nut. SST 09930-00010 NOTICE: Loosen the staked part of the nut completely, otherwise the screw of the drive shaft may be damaged. (b) While applying the brakes, remove the lock axle hub LH nut. 5. SEPARATE FRONT STABILIZER LINK ASSY LH (a) Remove the nut, and separate the stabilizer link assy LH. HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud. Turn F40136 6. (a) SEPARATE SPEED SENSOR FRONT LH Remove the bolt and clip, and separate the sensor wire and hose from the shock absorber. NOTICE: Be careful not to damage the speed sensor. C83022 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3035 30-22 DRIVE SHAFT / PROPELLER SHAFT - FRONT DRIVE SHAFT (b) Remove the bolt, and separate the speed sensor front LH from the steering knuckle. NOTICE: Prevent foreign matter from adhering to the speed sensor. F40147 Hold 7. (a) (b) SEPARATE TIE ROD END SUB-ASSY LH Remove the cotter pin and nut. Using SST, separate the tie rod end from the steering knuckle. SST 09628-6201 1 8. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH Remove the bolt and 2 nuts, and separate the front suspension arm sub-assy lower No.1 LH from the lower ball joint. Turn D27487 SST F45060 (a) F40142 Matchmarks 9. (a) (b) SEPARATE FRONT AXLE ASSY LH Put matchmarks on the drive shaft and the axle hub. Using a plastic hammer, separate the drive shaft from the axle hub. NOTICE: Be careful not to damage the boot and speed sensor rotor. D32030 10. (a) REMOVE FRONT DRIVE SHAFT ASSY LH Using SST, remove the front drive shaft assy LH. SST 09520-01010, 09520-24010 (09520-32040) NOTICE:
Be careful not to damage the transaxle case oil seal, inboard joint boot and drive shaft dust cover.
Be careful not to drop the drive shaft assy. SST F40148 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3036 30-23 DRIVE SHAFT / PROPELLER SHAFT 11. (a) (b) - FRONT DRIVE SHAFT REMOVE FRONT DRIVE SHAFT ASSY RH (3MZ-FE for 2WD DRIVE TYPE) Using a screwdriver, remove the bearing bracket hole snap ring. Remove the bolt and front drive shaft assy RH from the drive shaft bearing bracket. C80304 12. (a) (b) REMOVE FRONT DRIVE SHAFT ASSY RH (2AZ-FE for 2WD DRIVE TYPE) Remove the 2 bolts and pull out the drive shaft together with the center bearing bracket. Remove the drive shaft assy RH. F44774 13. REMOVE FRONT DRIVE SHAFT ASSY RH (RH for 4WD DRIVE TYPE) SST 09520-01010, 09520-24010 (09520-32040) HINT: Overhaul the RH side following the same procedures as for the LH side. NOTICE:
When removing and installing the front drive shaft assy RH in a 4WD vehicle, be sure to first drain all the transaxle oil and transfer oil. If removal and installation is carried out without draining these oils, the transfer oil will flow into the transaxle side. Extensive cleaning will be required if the two oils mix.
Do not damage the oil seal and dust cover.
Move the drive shaft assy while keeping it level. 14. FIX FRONT AXLE ASSY LH SST 09608-16042 (09608-02021, 09608-02041) NOTICE: The hub bearing could be damaged if it is subjected to the vehicle’s full weight, such as when moving the vehicle with the drive shaft removed. Therefore, if it is absolutely necessary to place the vehicle weight on the hub bearing, first support it with SST. SST C54583 F45045 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3037 30-24 DRIVE SHAFT / PROPELLER SHAFT 15. (a) (b) (c) (d) - FRONT DRIVE SHAFT INSPECT FRONT DRIVE SHAFT ASSY LH Check that there is no remarkable play in the radial direction of the outboard joint. Check that the inboard joint slides smoothly in the thrust direction. Check that there is no remarkable play in the radial direction of the inboard joint. Check the boots for damage. C91598 16. Omega Type: (a) (b) REMOVE FRONT AXLE INBOARD JOINT BOOT LH NO.2 CLAMP Omega Type: Using pliers, remove the inboard joint boot LH No.2 clamp, as shown in the illustration. Claw Engagement Type: Using pliers, remove the inboard joint boot LH No.2 clamp, as shown in the illustration. Claw Engagement Type: C86265 F07391 F45953 (c) One Touch Type: 17. (a) One Touch Type: Using a screwdriver, remove the inboard joint boot LH No.2 clamp, as shown in the illustration. REMOVE FRONT AXLE INBOARD JOINT BOOT LH CLAMP Remove the inboard joint boot LH clamp using the same procedures as for the inboard joint boot LH No.2 clamp. C67412 18. (a) SEPARATE FR AXLE INBOARD JOINT BOOT Separate the inboard joint boot from the inboard joint assy. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3038 30-25 DRIVE SHAFT / PROPELLER SHAFT FRONT DRIVE SHAFT 19. (a) REMOVE FRONT DRIVE INBOARD JOINT ASSY LH Put matchmarks on the inboard joint assy and outboard joint shaft. NOTICE: Do not use a punch for the marks. (b) Remove the inboard joint assy from the outboard joint shaft. Matchmarks C67413 - F45461 (c) Using a snap ring expander, remove the shaft snap ring. F45046 C67414 (d) Put matchmarks on the outboard joint shaft and tripod joint. NOTICE: Do not use a punch for the marks. (e) Using a brass bar and hammer, remove the tripod joint from the outboard joint shaft. NOTICE: Do not tap the roller. Matchmarks N00194 20. REMOVE FRONT DRIVE SHAFT DAMPER LH HINT: This procedure is unnecessary for a 3MZ-FE 4WD drive type vehicle (Front drive shaft RH) because it dose not have a drive shaft damper. (a) Omega Type: Using pliers, remove the drive shaft damper clamp, as shown in the illustration. Omega Type: F46963 (b) Claw Engagement Type: Claw Engagement: Using needle-nose pliers, remove the drive shaft damper clamp, as shown in the illustration. F46964 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3039 30-26 DRIVE SHAFT / PROPELLER SHAFT (c) One Touch Type: (d) - FRONT DRIVE SHAFT One Touch Type: Using a screwdriver, remove the drive shaft damper clamp, as shown in the illustration. Remove the drive shaft damper. D31926 21. Omega Type: (a) REMOVE FRONT AXLE OUTBOARD JOINT BOOT LH NO.2 CLAMP Omega Type: Using pliers, remove the outboard joint boot LH No.2 clamp, as shown in the illustration. C81167 (b) One Touch Type: 22. (a) One Touch Type: Using a screwdriver, remove the outboard joint boot LH No.2 clamp, as shown in the illustration. REMOVE FRONT AXLE OUTBOARD JOINT BOOT LH CLAMP Remove the outboard joint boot LH clamp using the same procedures as for the outboard joint boot LH No.2 clamp. C97385 23. (a) (b) REMOVE OUTBOARD JOINT BOOT Remove the outboard joint boot from the outboard joint shaft. Remove the old grease from the outboard joint. 24. (a) REMOVE FRONT DRIVE INNER SHAFT INNER LH SHAFT SNAP RING Using a screwdriver, remove the hole snap ring. C57543 25. (a) REMOVE FRONT DRIVE INNER SHAFT INNER RH SHAFT SNAP RING (RH for 4WD DRIVE TYPE) Using a screwdriver, remove the hole snap ring. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3040 30-27 DRIVE SHAFT / PROPELLER SHAFT - FRONT DRIVE SHAFT 26. (a) REMOVE FRONT DRIVE SHAFT DUST COVER LH Using SST and a press, remove the drive shaft dust cover LH. SST 09950-00020 NOTICE: Be careful not to drop the inboard joint assy. SST F40647 27. (a) REMOVE FRONT DRIVE SHAFT DUST COVER RH (RH for 2WD DRIVE TYPE) Using a press, remove the drive shaft dust cover RH. C67101 28. SST (a) REMOVE FRONT DRIVE SHAFT DUST COVER RH (RH for 4WD DRIVE TYPE) Using SST and a press, remove the drive shaft dust cover RH. SST 09950-00020 F40648 29. (a) REMOVE FRONT DRIVE SHAFT DUST COVER (RH for 2WD DRIVE TYPE) Using SST and a press, remove the drive shaft dust cover. SST 09950-00020 SST C68342 F40208 30. (a) REMOVE CASE SUB ASSY, DRIVE SHAFT BEARING SNAP RING (2AZ-FE for 2WD DRIVE TYPE) Using a screwdriver, remove the bearing case snap ring. C68337 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3041 30-28 DRIVE SHAFT / PROPELLER SHAFT - FRONT DRIVE SHAFT 31. REMOVE DRIVE SHAFT BEARING CASE SUB ASSY (2AZ-FE for 2WD DRIVE TYPE) (a) Using a press, remove the bearing case snap ring. NOTICE: Be careful not to drop the inboard joint assy. C68338 32. (a) C53236 REMOVE FRONT DRIVE SHAFT BEARING (RH for 2WD DRIVE TYPE) Using a snap ring expander, remove the drive shaft hole snap ring. F40209 (b) Using SST and a press, remove the bearing. SST 09527-1001 1 (c) Remove the bearing bracket hole snap ring. NOTICE: Be careful not to drop the inboard joint assy. C68339 SST F40210 33. Steel Plate SST D27495 INSTALL FRONT DRIVE SHAFT BEARING (3MZ-FE for 2WD DRIVE TYPE) (a) Install a new bearing bracket hole snap ring to the front driver shaft assy RH. (b) Using SST and a steel plate, install a new front drive shaft bearing. SST 09710-30021 (09710-03141) NOTICE: Bearing should be completely installed. (c) Using a snap ring expander, install a new drive shaft hole snap ring. D27493 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3042 30-29 DRIVE SHAFT / PROPELLER SHAFT - FRONT DRIVE SHAFT 34. SST C91253 27.1
0.3 mm (1.067
0.012 in.) INSTALL FRONT DRIVE SHAFT DUST COVER (3MZ-FE for 2WD DRIVE TYPE) (a) Using SST and a press, install a new drive shaft dust cover. SST 09726-40010, 09527-10011 NOTICE:
Dust cover should be completely installed.
Be careful not to damage the dust cover. F45047 35. SST C68340 (a) INSTALL FRONT DRIVE SHAFT BEARING (2AZ-FE for 2WD DRIVE TYPE) Using SST and a press, install a new drive shaft bearing. SST 09950- 60020 (09951- 00710), 09950- 70010 (09951-07100) F40211 36. (a) INSTALL CASE SUB ASSY, DRIVE SHAFT BEARING SNAP RING (2AZ-FE for 2WD DRIVE TYPE) Using a screwdriver, install a new bearing case snap ring. C68341 37. INSTALL DRIVE SHAFT BEARING CASE SUB ASSY (2AZ-FE for 2WD DRIVE TYPE) (a) Using SST and a press, install the drive shaft bearing case to the inboard joint assy RH. SST 09527-1001 1, 09710-04081 NOTICE: Bearing should be installed completely. SST C52593 F40212 (b) C68582 Using a snap ring expander, install a new drive shaft hole snap ring. F40213 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3043 30-30 DRIVE SHAFT / PROPELLER SHAFT - FRONT DRIVE SHAFT 38. INSTALL FRONT DRIVE SHAFT DUST COVER (2AZ-FE for 2WD DRIVE TYPE) (a) Using SST and a press, install a new driver shaft dust cover. SST 09726-40010, 09527-10011 Distance (A): 0.5
0.5 mm (0.020
0.020 in.) NOTICE: Be careful not to damage the dust cover. (A) SST F40214 39. SST (a) (A) INSTALL FRONT DRIVE SHAFT DUST COVER RH (RH for 2WD DRIVE TYPE) Using SST and a press, install a new drive shaft dust cover RH until the distance from the tip of the center drive shaft to the drive shaft dust cover RH meets the specification, as shown in the illustration. SST 09527-1001 1 Type F02277 Distance (A) 2AZ-FE 91.5 mm (3.602 in.) 3MZ-FE 110.5 mm (4.350 in.) NOTICE:
Dust cover should be completely installed.
Be careful not to damage the dust cover. 40. INSTALL FRONT DRIVE SHAFT DUST COVER RH (RH for 4WD DRIVE TYPE) (a) Using SST and a press, install a new drive shaft dust cover RH. SST 09527-1001 1 NOTICE:
Dust cover should be completely installed.
Be careful not to damage the dust cover. SST C68948 F40215 41. (a) INSTALL FRONT DRIVE SHAFT DUST COVER LH Using SST and a press, install a new drive shaft dust cover LH. SST 09527-1001 1 NOTICE:
Dust cover should be completely installed.
Be careful not to damage the dust cover. SST F41033 42. (a) 43. (a) INSTALL FRONT DRIVE INNER SHAFT INNER LH SHAFT SNAP RING Install a new hole snap ring. INSTALL FRONT DRIVE INNER SHAFT INNER RH SHAFT SNAP RING (RH for 4WD DRIVE TYPE) Install a new hole snap ring. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3044 30-31 DRIVE SHAFT / PROPELLER SHAFT W01994 Type Grease capacity g (oz.) 3MZ-FE (FF) 205 to 225 g (7.3 to 8.0 oz.) EXCEPT 3MZ-FE (FF) 190 to 200 g (6.7 to 7.0 oz.) 45. Hold SST Turn FRONT DRIVE SHAFT 44. INSTALL OUTBOARD JOINT BOOT HINT: Before installing the boots, wrap the spline of the drive shaft with vinyl tape to prevent the boots from being damaged. (a) Hold the drive shaft lightly in a soft vise. (b) Temporarily install a new outboard joint boot with 2 clamps to the drive shaft. (c) Pack the outboard joint shaft and boot with grease. Vinyl Tape Omega Type: - R10425 SST R10426 INSTALL FRONT AXLE OUTBOARD JOINT BOOT LH NO.2 CLAMP (a) Omega Type: Secure the 2 outboard joint boot clamps onto the boot. (b) Place SST onto the outboard joint boot LH No.2 clamp. SST 09521-24010 (c) Tighten the SST so that the outboard joint boot LH No.2 clamp is pinched. NOTICE: Do not overtighten the SST. (d) Using SST, measure the clearance of the outboard joint boot LH No.2 clamp. SST 09240-00020 Clearance: 0.8 mm (0.031 in.) or less NOTICE: When the measured value is greater than the specified value, retighten the clamp. 46. INSTALL FRONT AXLE OUTBOARD JOINT BOOT LH CLAMP (a) The procedure for the outboard joint boot LH clamp is the same as above. SST 09521-24010, 09240-00020 47. (a) (b) (c) (A) INSTALL FRONT DRIVE SHAFT DAMPER LH Install the drive shaft damper LH to the drive shaft. Make sure that the damper is on the shaft groove. Set the distance, as described below. Type Distance (A) 3MZ-FE (FF) 227.5
2.0 mm (8.957
0.079 in.) EXCEPT 3MZ-FE (FF) 225.4
2.0 mm (8.874
0.079 in.) G31217 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3045 30-32 DRIVE SHAFT / PROPELLER SHAFT Omega Type: FRONT DRIVE SHAFT 48. (a) Hold SST Turn - D31927 INSTALL FRONT DRIVE SHAFT DAMPER RH CLAMP Omega Type: Hold the front drive shaft lightly in a soft vise. (b) Install the drive shaft damper clamp to the damper. NOTICE: Be sure to install the clamp in the correct position. (c) Place SST onto the drive shaft damper clamp. SST 09521-24010 (d) Tighten the SST so that the clamp is pinched. NOTICE: Do not overtighten the SST. (e) SST D31928 One Touch Type: Using SST, measure the clearance of the drive shaft damper clamp. SST 09240-00020 Clearance: 0.8 mm (0.031 in.) or less NOTICE: When the measured value is greater than the specified value, retighten the clamp. HINT: This procedure is unnecessary for a 3MZ-FE 4WD drive type vehicle (Front drive shaft RH) because it dose not have a drive shaft damper. (f) One Touch Type: Set a new damper clamp to the drive shaft damper RH and install the damper clamp with a screwdriver. (g) Claw Engagement Type: Set a new damper clamp to the drive shaft damper RH and install the damper clamp with needle-nose pliers. F47132 Claw Engagement Type: F47133 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3046 30-33 DRIVE SHAFT / PROPELLER SHAFT - FRONT DRIVE SHAFT 49. (a) Matchmarks C67417 INSTALL FRONT DRIVE INBOARD JOINT ASSY LH Temporarily install a new inboard joint boot with 2 clamps to the drive shaft. (b) Place the beveled side of the tripod joint axial spline toward the outboard joint shaft. (c) Align the matchmarks. (d) Using a brass bar and hammer, tap in the tripod joint to the outboard joint shaft. NOTICE:
Do not tap the roller.
Be sure to install the tripod joint assy in the correct direction. (e) (f) C67414 Using a snap ring expander, install a new shaft snap ring. Pack the outboard joint shaft and boot with grease. Type Grease capacity g (oz.) 3MZ-FE (FF) 155 to 175 g (5.6 to 6.2 oz.) EXCEPT 3MZ-FE (FF) 175 to 185 g (6.2 to 6.5 oz.) F45046 (g) Matchmarks Align the matchmarks, install the inboard joint assy to the outboard joint shaft assy. F40222 50. (a) INSTALL FR AXLE INBOARD JOINT BOOT Install the inboard joint boot to the inboard joint assy. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3047 30-34 DRIVE SHAFT / PROPELLER SHAFT - FRONT DRIVE SHAFT 51. Omega Type: SST C86269 INSTALL FRONT AXLE INBOARD JOINT BOOT LH CLAMP (a) Omega Type: Install new inboard joint boot clamps. (1) Hold the drive shaft lightly in a soft vise. (2) Install 2 new inboard joint boot clamps to the boot. (3) Place SST onto the inboard joint boot LH No.2 clamp. SST 09521-24010 (4) Tighten the SST so that the inboard joint boot LH No.2 clamp is pinched. NOTICE: Do not overtighten the SST. (5) Using SST, measure the clearance of the inboard joint boot LH No.2 clamp. SST 09240-00020 Clearance: 0.8 mm (0.031 in.) or less NOTICE: When the measured value is greater than the specified value, retighten the clamp. SST C86270 Claw Engagement Type: (b) Claw Engagement Type: Using pliers, install the inboard joint boot LH No.2 clamp, as shown in the illustration. (c) One Touch Type: Using a screwdriver, install the inboard joint boot LH No.2 clamp, as shown in the illustration. INSTALL FRONT AXLE INBOARD JOINT BOOT LH CLAMP Install the inboard joint boot LH clamp using the same procedures as for the inboard joint boot LH No.2 clamp. SST 09521-24010, 09240-00020 F07391 52. One Touch Type: (a) C81794 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3048 30-35 DRIVE SHAFT / PROPELLER SHAFT 53. (a) (b) (c) (d) - FRONT DRIVE SHAFT INSPECT FRONT DRIVE SHAFT Check that there is no remarkable play in the radial direction of the outboard joint. Check that the inboard joint slides smoothly in the thrust direction. Check that there is no remarkable play in the radial direction of the inboard joint. Check the boots for damage. C91598 HINT: For dimension (A), refer to the following table. (A) C81796 DRIVE TYPE LH mm (in.) RH mm (in.) 2WD 2AZ-FE: 591.2 (23.27)
2.0 (0.08) 3MZ-FE: 579.4 (22.81)
2.0 (0.08) 2AZ-FE: 890.0 (35.03)
2.0 (0.08) 3MZ-FE: 898.0 (35.35)
2.0 (0.08) 4WD 556.5 (21.90)
2.0 (0.08) 932.5 (36.71)
2.0 (0.08) F45048 54. (a) (b) C83851 INSTALL FRONT DRIVE SHAFT ASSY LH Coat the spline of the inboard joint shaft assy with ATF. Align the shaft splines and install the drive shaft assy with a brass bar and a hammer. NOTICE:
Set the snap ring with the opening side facing downward.
Be careful not to damage the oil seal boot and dust cover.
Move the drive shaft assy while keeping it level. 55. INSTALL FRONT DRIVE SHAFT ASSY RH (3MZ-FE for 2WD DRIVE TYPE) (a) Using a screwdriver, install a new bearing bracket hole snap ring. NOTICE: Do not damage the oil seal and boot. (b) Install the bolt. Torque: 32 N⋅m (330 kgf⋅cm, 24 ft⋅lbf) C80304 56. INSTALL FRONT DRIVE SHAFT ASSY RH (2AZ-FE for 2WD DRIVE TYPE) (a) Coat the spline of the inboard joint shaft assy RH with gear oil. (b) Align the shaft splines and install the drive shaft assy RH with the 2 bolts. NOTICE: Do not damage the oil seal, boot and dust cover. F44774 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3049 30-36 DRIVE SHAFT / PROPELLER SHAFT - FRONT DRIVE SHAFT 57. INSTALL FRONT DRIVE SHAFT ASSY RH (RH for 4WD DRIVE TYPE) HINT: Install the RH side using the same procedures as for the LH side. NOTICE:
Set the snap ring with the opening side facing downward.
Be careful not to damage the transaxle case oil seal, inboard joint boot and drive shaft dust cover. 58. (a) Matchmarks D32030 INSTALL FRONT AXLE ASSY LH Align the matchmarks and install the drive shaft assy LH to the front axle assy LH. NOTICE: Be careful not to damage the outboard joint boot. Be careful not to damage the speed sensor rotor. F47689 59. (a) INSTALL FRONT SUSPENSION ARM SUB- ASSY LOWER NO.1 LH Install the lower ball joint to the front suspension arm subassy lower with the bolt and nuts. Torque: 127 N⋅m (1,300 kgf⋅cm, 94 ft⋅lbf) F40142 60. (a) INSTALL TIE ROD END SUB-ASSY LH Install the tie rod end to the steering knuckle with the nut. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) (b) Install a new cotter pin. NOTICE: If the holes for the cotter pin are not aligned, tighten the nut up to 60 further. 61. (a) INSTALL SPEED SENSOR FRONT LH Install the speed sensor to the steering knuckle with the bolt. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) NOTICE: Prevent foreign matter from adhering to the speed sensor. F40147 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3050 30-37 DRIVE SHAFT / PROPELLER SHAFT - FRONT DRIVE SHAFT (b) C83022 Hold Turn Install the flexible hose and the speed sensor to the shock absorber with the bolt and set the clip of the sensor on the knuckle. Torque: 19 N⋅m (192 kgf⋅cm, 14 ft⋅lbf) NOTICE:
Be careful not to damage the speed sensor.
Prevent foreign matter from adhering to the speed sensor.
Do not twist the sensor wire when installing the speed sensor. 62. INSTALL FRONT STABILIZER LINK ASSY LH (a) Install the stabilizer link assy LH with the nut. Torque: 74 N⋅m (755 kgf⋅cm, 55 ft⋅lbf) HINT: If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud. F40136 63. (a) (b) INSTALL FRONT AXLE HUB LH NUT Using a socket wrench (30 mm), install a new axle hub LH nut. Torque: 294 N⋅m (3,000 kgf⋅cm, 217 ft⋅lbf) Using a chisel and a hammer, stake the axle hub LH nut. C68609 64. INSTALL FRONT WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) ADD AUTOMATIC TRANSAXLE FLUID INSPECT AUTOMATIC TRANSAXLE FLUID (SEE PAGE 40-2 ) ADD TRANSFER OIL (4WD DRIVE TYPE) 65. 66. 67. HINT: Perform the procedure only when installing the RH side. 68. INSPECT TRANSFER OIL (4WD DRIVE TYPE) (SEE PAGE 31-4 ) HINT: Perform the procedure only when installing the RH side. 69. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (SEE PAGE 26-7 ) 70. CHECK ABS SPEED SENSOR SIGNAL (SEE PAGE 05-765 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3051 30-60 DRIVE SHAFT / PROPELLER SHAFT - REAR AXLE CARRIER SUB-ASSY LH (4WD) REAR AXLE CARRIER SUB-ASSY LH (4WD) 300OO-02 REPLACEMENT HINT: COMPONENTS: SEE PAGE 30-4 Replace the RH side using the same procedures as for the LH side. 1. REMOVE REAR WHEEL 2. SEPARATE SPEED SENSOR REAR LH (a) Remove the bolt and separate the speed sensor from the axle carrier. NOTICE:
Be careful not to damage the speed sensor.
Prevent foreign matter from adhering to the speed sensor. 3. (a) SST C89299 F45516 REMOVE REAR AXLE SHAFT LH NUT Using SST and a hammer, unstake the staked part of the axle hub LH nut. SST 09930-00010 NOTICE: Loosen the staked part of the nut completely, otherwise the screw of the drive shaft may be damaged. (b) While applying the brakes, remove the lock axle hub LH nut. 4. (a) SEPARATE REAR DISC BRAKE CALIPER ASSY LH Remove the bolt, and separate the flexible hose from the shock absorber. (b) Remove the 2 bolts and separate rear disc brake caliper assy. NOTICE: Use a string or other device to keep the brake caliper from hanging down. G24026 5. REMOVE REAR DISC (SEE PAGE 32-29 ) 6. (a) REMOVE REAR AXLE HUB & BEARING ASSY LH Remove the 4 bolts and the rear axle hub & bearing assy LH. G32185 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3074 30-61 DRIVE SHAFT / PROPELLER SHAFT - REAR AXLE CARRIER SUB-ASSY LH (4WD) 7. (a) SEPARATE REAR SUSPENSION ARM ASSY NO.1 LH Using a jack, raise the rear axle carrier sub-assy LH, as shown in the illustration. (b) Remove the bolt and nut, and separate the rear suspension arm assy No.1 LH (rear axle carrier side) from the rear axle carrier. G31901 HINT: When removing the bolt, keep the nut from rotating. G31902 8. (a) SEPARATE STRUT ROD ASSY REAR Remove the bolt and nut, and separate the strut rod assy rear (rear axle carrier side) from the rear axle carrier. HINT: When removing the bolt, keep the nut from rotating. G31903 9. (a) SEPARATE REAR SUSPENSION ARM ASSY NO.2 LH Remove the bolt and nut, and separate the rear suspension arm assy No.2 LH (rear axle carrier side) from the rear axle carrier. HINT: When removing the bolt, keep the nut from rotating. G31904 10. (a) REMOVE REAR AXLE CARRIER SUB-ASSY LH Remove the 2 bolts and 2 nuts, and the rear axle carrier sub-assy LH from the shock absorber. G24032 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3075 30-62 DRIVE SHAFT / PROPELLER SHAFT 11. (a) - REAR AXLE CARRIER SUB-ASSY LH (4WD) INSTALL REAR AXLE CARRIER SUB-ASSY LH Install the rear axle carrier sub-assy LH with the 2 bolts and nuts. Torque: 180 N⋅m (1,840 kgf⋅cm, 133 ft⋅lbf) HINT: Insert the bolt from the rear side of the vehicle and temporarily install the nut to the shock absorber. G24032 12. (a) TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH Temporarily tighten the rear suspension arm assy No.2 LH with the bolt and nut. HINT: Insert the bolt from the rear side of the vehicle and lightly tighten the bolt. G31904 13. (a) TEMPORARILY TIGHTEN STRUT ROD ASSY REAR Temporarily tighten the strut rod assy rear with the bolt and nut. HINT: Insert the bolt from the inside of the vehicle and lightly tighten the bolt. G31903 14. (a) TEMPORARILY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH Temporarily tighten the rear suspension arm assy No.1 LH with the bolt and nut. HINT: Insert the bolt from the front side of the vehicle and lightly tighten the bolt. G31902 15. (a) INSTALL REAR AXLE HUB & BEARING ASSY LH Install the rear axle hub & bearing assy LH with the 4 bolts. Torque: 75 N⋅m (765 kgf⋅cm, 55 ft⋅lbf) G32185 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3076 30-63 DRIVE SHAFT / PROPELLER SHAFT 16. 17. 18. - REAR AXLE CARRIER SUB-ASSY LH (4WD) INSPECT BEARING BACKLASH (SEE PAGE 30-3 ) INSPECT AXLE HUB DEVIATION (SEE PAGE 30-3 ) INSTALL REAR DISC (SEE PAGE 32-29 ) 19. (a) (b) INSTALL REAR DISC BRAKE CALIPER ASSY LH Install the rear disc brake caliper assy LH with the 2 bolts. Torque: 78 N⋅m (800 kgf⋅cm, 58 ft⋅lbf) Install the flexible hose with the bolt to the shock absorber. Torque: 19 N⋅m (192 kgf⋅cm, 14 ft⋅lbf) G24026 20. (a) (b) INSTALL REAR AXLE SHAFT LH NUT Install a new axle shaft LH nut. Torque: 294 N⋅m, (3,000 kgf⋅cm, 217 ft⋅lbf) Using a chisel and a hammer, stake the axle shaft LH nut. C89301 21. (a) INSTALL SPEED SENSOR REAR LH Install the speed sensor with the bolt. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) NOTICE:
Be careful not to damage the speed sensor.
Prevent foreign matter from adhering to the speed sensor.
Do not twist the sensor wire when installing the sensor. 22. INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) 23. STABILIZE SUSPENSION (SEE PAGE 27-29 ) 24. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH (SEE PAGE 27-25 ) 25. FULLY TIGHTEN STRUT ROD ASSY REAR (SEE PAGE 27-13 ) 26. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 LH (SEE PAGE 27-18 ) 27. INSPECT AND ADJUST REAR WHEEL ALIGNMENT (SEE PAGE 27-5 ) 28. CHECK ABS SPEED SENSOR SIGNAL (SEE PAGE 05-765 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3077 30-4 DRIVE SHAFT / PROPELLER SHAFT - DRIVE SHAFT / PROPELLER SHAFT / AXLE DRIVE SHAFT / PROPELLER SHAFT / AXLE 300OF-01 COMPONENTS Propeller Shaft Assy Adjusting Shim Center Support Bearing Assy No.1
1st: 182 (1,850, 134) 2nd: 69 (700, 51) Adjusting Shim 74 (750, 54) Intermediate Shaft Plate Washer Rear Flange Front Flange
Washer Center Support Bearing Assy No.1 37 (375, 27) Plate Washer 37 (375, 27) 74 (750, 54)
1st: 182 (1,850, 134) 2nd: 69 (700, 51)
Washer 74 (750, 54) 29 (296, 21) Propeller Shaft Assy Rear 74 (750, 54) Washer N⋅m (kgf⋅cm, ft⋅lbf) 29 (296, 21) : Specified torque
Non-reusable part G25996 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3018 30-5 DRIVE SHAFT / PROPELLER SHAFT Front Drive Shaft Assy RH (3MZ-FE: 4WD) - DRIVE SHAFT / PROPELLER SHAFT / AXLE Front Drive Shaft Assy RH (2AZ-FE: 4WD)
Front Drive Shaft RH Hole Snap Ring Front Drive Shaft Assy RH (2AZ-FE: 2WD) Front Drive Shaft Assy RH (3MZ-FE: 2WD) 74 (755, 55) 74 (755, 55)
Bearing Bracket Hole Snap Ring
Front Drive Shaft LH Hole Snap Ring 32 (330, 24) Front Drive Shaft Assy LH Front Stabilizer Link Assy LH Tie Rod End Sub-assy LH 74 (755, 55) 19 (192, 14) Speed Sensor Front LH 8.0 (82, 71 in.⋅lbf) Front Suspension Arm Sub-assy Lower No.1 LH
294 (3,000, 217) Front Axle Hub LH Nut 49 (500, 36)
Non-reusable parts N⋅m (kgf⋅cm, ft⋅lbf) : Specified Torque
Cotter Pin 127 (1,300, 94) F46819 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3019 30-6 DRIVE SHAFT / PROPELLER SHAFT LH: - DRIVE SHAFT / PROPELLER SHAFT / AXLE
Front Drive Shaft Dust Cover LH Front Drive Inboard Joint Assy LH
Front Drive Inner Shaft Inner LH Shaft Snap Ring
Front Axle Inboard Joint Boot LH No.2 Clamp Tripod Joint Assy One Touch Type
Front Axle Inboard Joint Boot LH Clamp 3MZ-FE(FF) Omega Type Claw Engagement Type
Inboard Joint Boot One Touch Type Drive Shaft Damper
Front Axle Inboard Joint Boot LH Clamp One Touch Type 3MZ-FE(FF) Omega Type Claw Engagement Type 3MZ-FE(FF) Omega Type
Drive Shaft Damper Clamp
Front Axle Outboard Joint Boot LH Clamp One Touch Type
Outboard Joint Boot
Front Axle Outboard Joint Boot LH No.2 Clamp One Touch Type Supply parts: Front Drive Outboard Joint Shaft Assy LH Supply parts: 3MZ-FE(FF) Omega Type
Non-reusable parts F46820 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3020 30-7 DRIVE SHAFT / PROPELLER SHAFT - DRIVE SHAFT / PROPELLER SHAFT / AXLE RH:
Front Axle Outboard Joint Boot RH No.2 Clamp OmegType One Touch Type Supply parts 3MZ-FE(FF): Claw Engagement Type
Outboard Joint Boot
Front Axle Outboard Joint Boot RH Clamp
Front Axle Inboard Joint Boot RH No.2 Clamp 3MZ-FE(FF): w/o: 3MZ-FE (4WD)
Drive Shaft Damper Clamp 3MZ-FE(FF):
Drive Shaft Damper
Front Axle Inboard Joint Boot RH Clamp Supply parts
Inboard Joint Boot 3MZ-FE(FF): Front Drive Outboard Joint Shaft Assy RH 3MZ-FE(FF): Front Drive Inboard Joint Assy RH 2MZ-FE(FF): Front Drive Inboard Joint Assy RH
Front Axle Inboard Joint Boot RH No.2 Clamp Tripod Joint Assy
Front Drive Shaft Bearing Case Snap Ring
Front Drive Inner Shaft Inner RH Shaft Snap Ring
Front Drive Shaft Bearing
Straight Pin
Front Drive Shaft Hole Snap Ring (4WD): Front Drive Inboard Joint Assy RH
Front Drive Shaft Bearing
Front Drive Shaft Dust Cover RH
Front Drive Shaft Hole Snap Ring
Front Drive Shaft Dust Cover Front Drive Shaft Bearing Case
Front Drive Shaft Dust Cover RH
Front Drive Shaft Dust Cover
Front Drive Shaft Dust Cover RH
Non-reusable parts F46821 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3021 30-8 DRIVE SHAFT / PROPELLER SHAFT - DRIVE SHAFT / PROPELLER SHAFT / AXLE Front Shock Absorber LH 230 (2,345, 170) 19 (192, 14) Speed Sensor Front LH Tie Rod End Sub-assy LH Front Drive Shaft LH 8.0 (82, 71 in.·lbf) Steering Knuckle with Axle Hub Front Disc Brake Caliper Assy LH 107 (1,090, 79) Front Disc Front Suspension Arm Sub-assy Lower No.1 LH
Front Wheel Bearing Dust Deflector No.1 LH 49 (500, 36) Front Axle Hub Bolt 294 (3,000, 217) 127 (1,300, 94)
Front Axle Hub LH Hole Snap Ring
Cotter Pin
Front Axle Hub LH Nut Steering Knuckle LH
Front Axle Hub LH Bearing Disc Brake Dust Cover Front LH
Cotter Pin 123 (1,250, 90) 8.3 (85, 74 in.·lbf) Front Axle Hub Sub-assy LH Lower Ball Joint Assy Front LH N·m (kgf·cm, ft·lbf) : Specified torque
Non-reusable part F45572 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3022 30-9 DRIVE SHAFT / PROPELLER SHAFT - DRIVE SHAFT / PROPELLER SHAFT / AXLE
Rear Drive Shaft Inboard Joint LH Shaft Snap Ring Rear Drive Shaft Assy LH Rear Axle Carrier Sub-assy LH Rear Suspension Arm Assy No.2 LH 180 (1,840, 133) 112 (1,140, 83) Rear Suspension Arm Assy No.1 LH 112 (1,140, 83) 8.0 (82, 71 in.⋅lbf) Speed Sensor Rear LH
294 (3,000, 217) Rear Axle Shaft LH Nut 80 (816, 59) Strut Rod Assy Rear N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part G25993 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3023 30-10 DRIVE SHAFT / PROPELLER SHAFT - DRIVE SHAFT / PROPELLER SHAFT / AXLE FF: Rear Axle Carrier Sub-assy LH 180 (1,840, 133) Rear Suspension Arm Assy No.2 LH 112 (1,140, 83) Skid Control Sensor 19 (192, 14) 78 (800, 58) 112 (1,140, 83) 78 (800, 58) Rear Suspension Arm Assy No.1 LH 80 (816, 59) Rear Disc Brake Caliper Assy LH 75 (765, 55) Strut Rod Assy Rear Rear Axle Hub & Bearing Assy LH Rear Disc 75 (765, 55)
Rear Axle LH Hub Bolt
Non-reusable part N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque G25994 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3024 30-1 1 DRIVE SHAFT / PROPELLER SHAFT - DRIVE SHAFT / PROPELLER SHAFT / AXLE 4WD: Rear Drive Shaft Assy LH 180 (1,840, 133) Rear Axle Carrier Sub-assy LH Rear Suspension Arm Assy No.2 LH 112 (1,140, 83) Rear Suspension Arm Assy No.1 LH 19 (192, 14) 78 (800, 58) Speed Sensor Rear LH 112 (1,140, 83) 78 (800, 58) 8.0 (82, 71 in.⋅lbf) Rear Disc Brake Caliper Assy LH 80 (816, 59) 75 (765, 55) Strut Rod Assy Rear Rear Axle Hub & Bearing Assy LH Rear Disc 75 (765, 55)
Rear Axle LH Hub Bolt
294 (3,000, 217) Rear Axle Shaft LH Nut N⋅m (kgf⋅cm, ft⋅lbf) : Specified Torque
Non-reusable parts F45252 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3025 30-53 DRIVE SHAFT / PROPELLER SHAFT - REAR AXLE HUB & BEARING ASSY LH (FF) REAR AXLE HUB & BEARING ASSY LH (FF) 300OL-02 REPLACEMENT HINT: COMPONENTS: SEE PAGE 30-4 Replace the RH side by the same procedures with LH side. 1. REMOVE REAR WHEEL 2. (a) SEPARATE RR DISC BRAKE CALIPER ASSY RH Remove the bolt and separate the flexible hose. (b) (c) Remove the 2 bolts and brake caliper. Support the brake caliper securely. C83014 C83008 3. 4. (a) REMOVE REAR DISC (SEE PAGE 32-29 ) SEPARATE SKID CONTROL SENSOR WIRE Disconnect the connector. 5. (a) REMOVE REAR AXLE HUB & BEARING ASSY LH Remove the 4 bolts and axle hub. G32184 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3067 30-54 DRIVE SHAFT / PROPELLER SHAFT 6. (a) - REAR AXLE HUB & BEARING ASSY LH (FF) INSTALL REAR AXLE HUB & BEARING ASSY LH Install the axle hub with the 4 bolts. Torque: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf) G32184 7. (a) INSTALL SKID CONTROL SENSOR WIRE Connect the connector. 8. (a) INSPECT BEARING BACKLASH Set a dial indicator near the center of the axle hub and check the backlash in the bearing shaft direction. Maximum: 0 mm (0 in.) If the backlash exceeds the maximum, replace the axle hub assembly. C83015 9. (a) INSPECT AXLE HUB DEVIATION Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt. Maximum: 0.08 mm (0.0031 in.) If the backlash exceeds the maximum, replace the axle hub assembly. C83016 10. INSTALL REAR DISC (SEE PAGE 32-29 ) 11. (a) INSTALL RR DISC BRAKE CALIPER ASSY RH Install the brake caliper with the 2 bolts. Torque: 78 N⋅m (800 kgf⋅cm, 58 ft⋅lbf) C83008 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3068 30-55 DRIVE SHAFT / PROPELLER SHAFT (b) - REAR AXLE HUB & BEARING ASSY LH (FF) Install the flexible hose with the bolt. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) C83014 12. 13. 14. INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT REAR WHEEL ALIGNMENT (SEE PAGE 27-5 ) CHECK ABS SPEED SENSOR SIGNAL (SEE PAGE 05-765 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3069 30-56 DRIVE SHAFT / PROPELLER SHAFT - REAR AXLE HUB & BEARING ASSY LH (4WD) REAR AXLE HUB & BEARING ASSY LH (4WD) 300ON-02 REPLACEMENT HINT: COMPONENTS: SEE PAGE 30-4 1. REMOVE REAR WHEEL 2. SEPARATE SPEED SENSOR REAR LH 3. (a) SST C89299 F45516 REMOVE REAR AXLE SHAFT LH NUT Using SST and a hammer, unstake the staked part of the axle hub LH nut. SST 09930-00010 NOTICE: Loosen the staked part of the nut completely, otherwise the screw of the drive shaft may be damaged. (b) While applying the brakes, remove the lock axle hub LH nut. 4. (a) SEPARATE REAR DISC BRAKE CALIPER ASSY LH Remove the bolt, and separate the flexible hose from the shock absorber. (b) Remove the 2 bolts and separate rear disc brake caliper assy. NOTICE: Use a string or other device to keep the brake caliper from hanging down. G24026 5. REMOVE REAR DISC (SEE PAGE 32-29 ) 6. (a) REMOVE REAR AXLE HUB & BEARING ASSY LH Remove the 4 bolts and the rear axle hub & bearing assy LH. G32185 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3070 30-57 DRIVE SHAFT / PROPELLER SHAFT 7. (a) - REAR AXLE HUB & BEARING ASSY LH (4WD) INSTALL REAR AXLE HUB & BEARING ASSY LH Install the rear axle hub & bearing assy LH with the 4 bolts. Torque: 75 N⋅m (765 kgf⋅cm, 55 ft⋅lbf) G32185 8. INSTALL REAR DISC (SEE PAGE 32-29 ) 9. (a) (b) INSTALL REAR DISC BRAKE CALIPER ASSY LH Install the rear disc brake caliper assy LH with the 2 bolts. Torque: 78 N⋅m (800 kgf⋅cm, 58 ft⋅lbf) Install the flexible hose with the bolt to the shock absorber. Torque: 19 N⋅m (192 kgf⋅cm, 14 ft⋅lbf) G24026 10. (a) 11. 12. 13. 14. 15. 16. INSTALL REAR AXLE SHAFT LH NUT Install a new axle shaft LH nut. Torque: 294 N⋅m, (3,000 kgf⋅cm, 217 ft⋅lbf) REMOVE REAR DISC BRAKE CALIPER ASSY LH REMOVE REAR DISC INSPECT BEARING BACKLASH (SEE PAGE 30-3 ) INSPECT AXLE HUB DEVIATION (SEE PAGE 30-3 ) INSTALL REAR DISC (SEE PAGE 32-29 ) INSTALL REAR DISC BRAKE CALIPER ASSY LH 17. (a) (b) INSTALL REAR AXLE SHAFT LH NUT Install a new axle shaft LH nut. Torque: 294 N⋅m, (3,000 kgf⋅cm, 217 ft⋅lbf) Using a chisel and a hammer, stake the axle shaft LH nut. C89301 18. 19. 20. INSTALL SPEED SENSOR REAR LH INSTALL REAR WHEEL CHECK ABS SPEED SENSOR SIGNAL (SEE PAGE 05-765 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3071 31-4 TRANSFER - TRANSFER OIL (4WD) TRANSFER OIL (4WD) 3100S-04 ADJUSTMENT 1. 2. REMOVE EXHAUST PIPE ASSY FRONT (3MZ-FE ENGINE TYPE) (SEE PAGE 15-5 ) REMOVE EXHAUST PIPE ASSY FRONT (2AZ-FE ENGINE TYPE) (SEE PAGE 15-2 ) 0 to 5 mm (0 to 0.1968 in.) C70667 C83746 3. (a) (b) INSPECT TRANSFER OIL Remove the No.1 plug and gasket. Check the oil level is within 0 to 5 mm (0 to 0.1968 in.) down from the lowest end of the hole for No.1 plug. NOTICE:
When changing oil, recheck the oil level after driving.
Excessively large or small quantity of oil may cause some trouble. (c) When the oil level is too low, check for oil leakage. (d) Tighten the No.1 plug with a new gasket. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) 4. ADD TRANSFER OIL (a) Remove the No.1 plug and gasket and supply oil. NOTICE:
When supplying oil, pour it slowly.
Repeat supplying oil several times at several minutes interval. HINT: Within 0 to 5 mm (0 to 0.1968 in.) down from the lowest end of the hole for the No.1 plug. (b) After leaving it alone for 5 min., check the oil level again. (c) Tighten the No. 1 plug with a new gasket. 5. INSTALL EXHAUST PIPE ASSY FRONT (3MZ-FE ENGINE TYPE) (SEE PAGE 15-5 ) 6. INSTALL EXHAUST PIPE ASSY FRONT (2AZ-FE ENGINE TYPE) (SEE PAGE 15-2 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3082 31-1 TRANSFER - TRANSFER SYSTEM (4WD) TRANSFER SYSTEM (4WD) 3100Q-05 PRECAUTION












Before disassembly, clean the transfer assy and remove any deposited sand or mud to prevent it from entering the inside of the transfer during disassembly and assembly. When removing any light alloy part such as a transfer cover, do not pry it off with a tool like a screwdriver but tap it out with a plastic hammer. Always organize the removed parts properly and protect them away from dust. After cleaning and drying completely before installation, apply hypoid gear oil to each part. Do not use alkaline chemicals when cleansing aluminum or rubber parts and ring gear set bolts. Also, do not use any cleansing oil (ex. white gasoline) to clean the rubber parts such as O rings and oil seals. Sufficiently apply hypoid gear oil to any sliding surface or rotating part. Do not directly hold a part by vise. Make sure to put an aluminum sheet between them. Replace any damaged or deformed snap ring with new one. If mating surface of the case is scratched, it may cause oil leakage. Therefore, carefully avoid such damage when handling. Before applying a sealant, completely remove old sealant stuck on the sealed parts and clean them with white gasoline. Do not supply oil immediately after installing sealed parts. Allow 1 hour or more. Scratches on a contact surface with an oil seal, O ring or gasket may result in oil leakage. Carefully avoid such damage when handling. When press-fitting an oil seal, take care to prevent the oil seal lip and its periphery from being damaged. When replacing a bearing, replace both outer and inner races as one set. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3079 31-2 TRANSFER - TRANSFER SYSTEM (4WD) 3100P-04 PROBLEM SYMPTOMS TABLE Symptom Suspect Area See page Noise 1. Oil (Level low) 2. Backlash adjustment 3. Preload adjustment 4. Tooth contact adjustment 5. Transfer driven pinion bearing (Worn) 6. Ring gear mounting case bearing (Worn) 31-4 31-9 31-9 31-9 31-9 31-9 Oil leakage 1. Oil (Level high) 2. Oil seal (Worn or damage) 3. Oil seal (Worn or damage) 4. Oil seal (Worn or damage) 5. Gasket (Damaged) 6. Seal (Damaged) 31-4 31-5 31-7 31-8 31-9 31-9 Right bearing retainer Transfer case Extension housing 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3080 31-5 TRANSFER - TRANSFER RH BEARING RETAINER OIL SEAL (4WD) TRANSFER RH BEARING RETAINER OIL SEAL (4WD) 3100T-07 REPLACEMENT 1. 2. 3. (a) (b) 4. 5. (a) 6. 7. REMOVE EXHAUST PIPE ASSY FRONT (3MZ-FE ENGINE TYPE) (SEE PAGE 15-5 ) REMOVE EXHAUST PIPE ASSY FRONT (2AZ-FE ENGINE TYPE) (SEE PAGE 15-2 ) DRAIN AUTOMATIC TRANSAXLE FLUID Remove the drain plug, gasket and drain ATF. Install a new gasket and drain plug. REMOVE TRANSFER CASE NO.1 PLUG REMOVE TRANSFER DRAIN PLUG Remove the transfer drain plug, drain gasket and bleed the drain transfer oil. REMOVE FRONT WHEEL REMOVE FRONT DRIVE SHAFT ASSY RH (SEE PAGE 30-21 ) SST 09520-01010, 09520-24010 (09520-32040) 8. REMOVE TRANSFER RH BEARING RETAINER OIL SEAL (a) Using SST, remove the right bearing retainer oil seal. SST 09308-00010 NOTICE: Do not damage the oil-seal-fitted surface of the case. SST C68563 C83628 9. C68564 0.7 - 1.3 mm (0.0275 - 0.0511 in.) INSTALL TRANSFER RH BEARING RETAINER OIL SEAL (a) Using SST, drive a new oil seal into the case to the position shown in the illustration. SST 09223-4601 1 NOTICE: Do not install the oil seal obliquely. (b) Apply small amount of MP grease to the oil seal lip. C83629 10. 11. 12. 13. 14. (a) 15. (a) INSTALL FRONT DRIVE SHAFT ASSY RH (SEE PAGE 30-21 ) INSTALL FRONT WHEEL ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE) INSPECT AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE) (SEE PAGE 40-2 ) INSTALL TRANSFER DRAIN PLUG Install the drain plug with a new gasket. INSTALL TRANSFER CASE NO.1 PLUG Supply oil up to the level 0 to 5 mm (0 to 0.1968 in.) down from the lowest end of the plug hole. Oil quantity: 0.9 L (0.95 US qts, 0.71 lmp.qts) NOTICE: When supplying oil, be careful to do it slowly. (b) Install the plug No. 1 with a new gasket. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) 16. INSTALL EXHAUST PIPE ASSY FRONT (3MZ-FE ENGINE TYPE) (SEE PAGE 15-5 ) 17. INSTALL EXHAUST PIPE ASSY FRONT (2AZ-FE ENGINE TYPE) (SEE PAGE 15-2 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3083 31-6 TRANSFER 18. 19. 20. - TRANSFER RH BEARING RETAINER OIL SEAL (4WD) CHECK FOR EXHAUST GAS LEAKS INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (SEE PAGE 26-7 ) CHECK ABS SPEED SENSOR SIGNAL (SEE PAGE 05-765 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3084 31-7 TRANSFER - TRANSFER CASE OIL SEAL (4WD) TRANSFER CASE OIL SEAL (4WD) 3100U-07 REPLACEMENT 1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 ) REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (2AZ-FE ENGINE TYPE) (SEE PAGE 14-24 ) REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (2AZ-FE ENGINE TYPE) (SEE PAGE 31-9 ) REMOVE TRANSFER STIFFENER PLATE RH (2AZ-FE ENGINE TYPE) (SEE PAGE 31-9 ) REMOVE AUTOMATIC TRANSMISSION W/TRANSFER (3MZ-FE ENGINE TYPE) (SEE PAGE 40-20 ) REMOVE TRANSFER ASSY (SEE PAGE 31-9 ) REMOVE CTR DIFFERENTIAL LOCK SLEEVE (SEE PAGE 31-9 ) SST 09308-00010 2. 3. 4. 5. 6. 7. 8. (a) REMOVE TRANSFER CASE OIL SEAL Using SST, remove the oil seal from the case. SST 09308-00010 NOTICE: Do not damage the oil-seal-fitted surface of the case. SST C50328 C83630 9. (a) SST C50353 10. 11. 12. 13. 14. 15. 16. 8.7 to 9.3 mm (0.3425 to 0.3661 in.) INSTALL TRANSFER CASE OIL SEAL Using SST, drive a new oil seal into the case to the position shown in the illustration. SST 09387-00010, 09950-70010 (09951-07150) NOTICE: Do not install it obliquely. (b) Apply small amount of MP grease to the oil seal lip. C83631 INSTALL CTR DIFFERENTIAL LOCK SLEEVE (SEE PAGE 31-9 ) SST 09950-60010 (09951-00610), 09950-70010 (09951-07150) INSTALL TRANSFER ASSY (SEE PAGE 31-9 ) INSTALL TRANSFER STIFFENER PLATE RH (2AZ-FE ENGINE TYPE) (SEE PAGE 31-9 ) INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (2AZ-FE ENGINE TYPE) (SEE PAGE 31-9 ) INSTALL AUTOMATIC TRANSMISSION W/TRANSFER (3MZ-FE ENGINE TYPE) (SEE PAGE 40-20 ) INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 ) INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (2AZ-FE ENGINE TYPE) (SEE PAGE 14-24 ) Author
: Date
: 3085 31-8 TRANSFER - TRANSFER EXTENSION HOUSING TYPE T OIL SEAL (4WD) TRANSFER EXTENSION HOUSING TYPE T OIL SEAL (4WD) 3100V-07 REPLACEMENT 1. 2. 3. 4. 5. REMOVE REMOVE REMOVE REMOVE REMOVE EXHAUST PIPE ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 15-5 ) EXHAUST PIPE ASSY (2AZ-FE ENGINE TYPE) (SEE PAGE 15-2 ) TRANSFER CASE NO.1 PLUG TRANSFER DRAIN PLUG PROPELLER W/CENTER BEARING SHAFT ASSY (SEE PAGE 30-12 ) 6. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL (a) Using SST, remove the oil seal from the extension housing. SST 09308-00010 NOTICE: Be careful not to damage the oil-seal-fitted surface and the inside surface of the bush. SST C52790 C83632 7. SST 1.1 to 1.9 mm (0.0433 to 0.0748 in.) C52791 C83633 INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL (a) Using SST, drive a new oil seal into the extension housing to the position shown in the illustration. SST 09550- 60010 (09951- 00380, 09951- 00580, 09952-06010), 09950-70010 (09951-07150) NOTICE: Do not install the oil seal obliquely. (b) Apply small amount of MP grease to the oil seal lip. 8. TEMPORARILY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSY (SEE PAGE 30-12 ) 9. FULLY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSY (SEE PAGE 30-12 ) 10. INSTALL TRANSFER DRAIN PLUG (a) Install the drain plug with a new gasket. 11. INSTALL TRANSFER CASE NO.1 PLUG (a) Supply oil up to the level 0 to 5 mm (0 to 0.1968 in.) down from the lowest end of the plug hole. Oil quantity: 0.9 L (0.95 US qts, 0.71 lmp.qts) NOTICE: When supplying oil, be careful to do it slowly. (b) Install the No. 1 plug with a new gasket. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) 12. INSTALL EXHAUST PIPE ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 15-5 ) 13. INSTALL EXHAUST PIPE ASSY (2AZ-FE ENGINE TYPE) (SEE PAGE 15-2 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3086 31-9 TRANSFER - TRANSFER ASSY (4WD) TRANSFER ASSY (4WD) 31050-02 OVERHAUL HINT: COMPONENT: 3MZ-FE ENGINE: See page 14-134 2AZ-FE ENGINE: See page 14-15 AUTOMATIC TRANSMISSION (U151E/U151F): See page 40-18 TRANSFER: See page 31-3 1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 ) 2. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (2AZ-FE ENGINE TYPE) (SEE PAGE 14-24 ) 3. (a) (b) No.2 Plug REMOVE TRANSFER CASE NO.1 PLUG Remove the transfer case No.1 plug. Remove the gasket No.1 from the transfer case No.1 plug. No.1 Plug Drain Plug C82977 4. (a) (b) 5. (a) (b) REMOVE TRANSFER CASE NO.2 PLUG Remove the transfer case No.2 plug. Remove the gasket No.2 from the transfer case No.2 plug. REMOVE TRANSFER DRAIN PLUG Remove the transfer drain plug and bleed the transfer oil. Remove the drain gasket from the transfer drain plug. 6. (a) REMOVE TRANSFER STIFFENER PLATE RH (2AZ-FE ENGINE TYPE) Remove the 5 bolts and the stiffener plate RH. F45388 7. (a) 8. REMOVE ENGINE MOUNTING BRACKET RR (2AZ-FE ENGINE TYPE) Remove the 3 bolts and the engine mounting bracket RR. REMOVE AUTOMATIC TRANSMISSION W/TRANSFER (3MZ-FE ENGINE TYPE) (SEE PAGE 40-20 ) Author
: Date
: 3087 31-10 TRANSFER - TRANSFER ASSY (4WD) 9. (a) (b) C82785 REMOVE TRANSFER ASSY Remove the 2 bolts and 6 nuts. Using a plastic hammer, remove the transfer assy from the transaxle assy. NOTICE:
Remove the transfer assy from the transaxle assy without tilting it.
When removing the transfer assy, do not hold onto the oil seal parts on both sides of the assy. 10. (a) REMOVE TRANSFER COVER GASKET Remove the transfer cover gasket from the transfer assy. C82798 11. (a) REMOVE TRANSFER CASE BREATHER PLUG Using a screwdriver and a hammer, remove the transfer case breather plug from the transfer case cover No.1. NOTICE: Be careful not to damage the contact surface of the case cover No.1. C94714 12. (a) REMOVE TRANSFER CASE COVER NO.1 Remove the 8 bolts. C83507 (b) Using a brass bar and a hammer, remove the transfer case cover No.1 from the transfer. NOTICE: Be careful not to damage the contact surfaces of the case and cover. C50303 Author
: Date
: 3088 31-1 1 TRANSFER - TRANSFER ASSY (4WD) 13. (a) REMOVE BREATHER OIL DEFLECTOR Remove the bolt and breather oil deflector from the transfer case cover No.1. 14. (a) REMOVE TRANSFER DYNAMIC DAMPER Remove the 3 bolts and the transfer dynamic damper from the transfer extension housing sub-assy. C67665 C82802 15. (a) 16. (a) 17. (a) REMOVE TRANSFER CASE STRAIGHT PIN Remove the 4 transfer case straight pins from the transfer case. REMOVE TRANSFER & TRANSAXLE SETTING STUD BOLT Remove the 4 transfer & transaxle setting stud bolts. FIX TRANSFER ASSY Fix the transfer assy to the overhaul attachment. 18. (a) REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR Using a plastic hammer, remove the transfer extension housing dust deflector from the transfer extension housing sub-assy. C82788 19. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL (a) Using SST, remove the transfer extension housing type T oil seal from the transfer extension housing. SST 09308-00010 NOTICE: Be careful not to damage the oil-seal-fitted surface of the housing and the inside surface of the bush. SST C82978 Author
: Date
: 3089 31-12 TRANSFER 20. (a) - TRANSFER ASSY (4WD) REMOVE TRANSFER EXTENSION HOUSING SUB-ASSY Remove the 4 bolts. C82790 (b) Using a plastic hammer, remove the transfer extension housing sub-assy from the transfer case. 21. (a) INSPECT PRELOAD Using SST and a torque wrench, check the initial torque within the backlash range. SST 09326-2001 1 Torque (preload): 0.9 to 1.4 N⋅m (9 to 14 kgf⋅cm, 8.0 to 12.4 in.⋅lbf) C82791 SST HINT:
C82792 C83635
(b) Use a torque wrench with a fulcrum length of 160 mm (6.30 in.) If the value is out of standard range, replace the driven pinion bearing. Using SST and a torque wrench, check the initial torque while the driven pinion is in contact with the ring gear face. SST 09326-2001 1 Torque: Preload + 0.15 to 0.30 N⋅m (+1.6 to 3.1 kgf⋅cm, +1.3 to 2.7 in.⋅lbf) HINT:
C50309 Use a torque wrench with a fulcrum length of 160 mm (6.30 in.)
If the value is out of standard range, overhaul the transfer. 22. INSPECT BACKLASH (a) Set the dial indicator perpendicular to the tooth face of the ring gear, fix the driven pinion and inspect the backlash while moving the gear. Backlash: 0.10 to 0.15 mm (0.0039 to 0.0059 in.) NOTICE: Inspect it at 3 points or more on the gear’s periphery. HINT: Write down the result. Author
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: 3090 31-13 TRANSFER - TRANSFER ASSY (4WD) 23. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION (a) Apply red lead primer thinly and uniformly to both faces of the ring gear and rotate several times. NOTICE: Inspect the tooth contact on the ring gear at 4 places or more. (b) Proper washer location is shown in the illustration. C50346 Heel Contact Face Contact Select an adjusting washer that will bring the driven pinion closer to the ring gear. Toe Contact Flank Contact Proper Contact Select an adjusting washer that will shift the drive pinion away from the ring gear. C30886 K3673 C50310 C83636 24. (a) REMOVE CTR DIFFERENTIAL LOCK SLEEVE Using snap ring pliers, remove the shaft snap ring. (b) Using SST, remove the CTR differential lock sleeve. SST 09308-00010 C83637 SST C51144 C83638 Author
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: 3091 31-14 TRANSFER - TRANSFER ASSY (4WD) 25. (a) REMOVE O-RING Using a screwdriver with the tip protected by vinyl tape, remove the O-ring from the CTR differential lock sleeve. NOTICE: Be careful not to damage the lock sleeve’s groove for the O-ring. C50311 26. (a) REMOVE TRANSFER CASE OIL SEAL Using SST, remove the transfer case oil seal from the case. SST 09308-00010 NOTICE: Be careful not to damage the oil-seal-fitted surface of the case. C50328 SST C83630 27. REMOVE TRANSFER RH BEARING RETAINER OIL SEAL (a) Using SST, remove the transfer RH bearing retainer oil seal from the transfer RH bearing retainer sub-assy. SST 09308-00010 NOTICE: Be careful not to damage the oil-seal-fitted surface of the retainer. SST C82980 28. (a) REMOVE TRANSFER RH BEARING RETAINER SUB-ASSY Remove the 7 bolts from the transfer RH bearing retainer sub-assy . C83509 (b) Using a screwdriver and a hammer, create a clearance between the transfer RH bearing retainer sub-assy and the transfer case. NOTICE: Be careful not to damage the transfer RH bearing retainer sub-assy and the transfer case. C82797 Author
: Date
: 3092 31-15 TRANSFER (c) SST - TRANSFER ASSY (4WD) Using SST, remove the transfer RH bearing retainer subassy from the transfer case. SST 09520-10021 C82981 29. (a) REMOVE O-RING Using a screwdriver with the tip protected by vinyl tape, remove the 2 O-rings from the transfer RH bearing retainer sub-assy. NOTICE: Be careful not to damage the retainer’s grooves for the Orings. C50313 30. SST C50315 C83639 REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING (a) Fix the transfer RH bearing retainer sub-assy in a vise. (b) Using SST, remove the center differential case tapered roller bearing RH outer race, transfer ring gear mounting case washer No.2 and right bearing retainer oil seal No.2 from the transfer RH bearing retainer sub-assy. SST 09308-00010 NOTICE: Be careful not to damage the oil-seal-fitted surface of the transfer RH bearing retainer sub-assy. 31. (a) (b) C50316 REMOVE SIDE GEAR SHAFT HOLDER BEARING Using snap ring pliers, remove the side gear shaft holder hole snap ring. Remove the side gear shaft holder bearing from the transfer RH bearing retainer sub-assy. C83640 Author
: Date
: 3093 31-16 TRANSFER 32. (a) - TRANSFER ASSY (4WD) REMOVE TRANSFER RING GEAR MOUNTING CASE Remove the transfer ring gear mounting case from the transfer case. C67673 33. SST C67674 C83641 SST C67685 C83642 SST C68270 C83643 REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING (a) LH side: Using SST, remove the inner race of the center differential case tapered roller bearing from the transfer ring gear mounting case. SST 09950- 40011 (09951- 04010, 09952- 04010, 09953- 04020, 09954- 04010, 09955- 04061, 09957- 04010, 09958- 04011), 09950- 60010 (09951-00420) NOTICE: Apply grease to the screw thread and tip of the SST before use. HINT: When the roller comes off due to deformation of the gauge, completely remove the roller and remaining inner races of the center differential case tapered roller bearing from the transfer ring gear mounting case. SST 09950- 00020, 09950- 00030, 09950- 60010 (09951-00430) NOTICE: Apply grease to the screw thread and tip of the SST before use. (b) RH side: Using SST, remove the inner race of the center differential case tapered roller bearing from the transfer ring gear mounting case. SST 09950- 40011 (09951- 04010, 09952- 04010, 09953- 04020, 09954- 04010, 09955- 04061, 09957- 04010, 09958- 04011), 09950- 60010 (09951-00360) NOTICE: Apply grease to the screw thread and tip of the SST before use. Author
: Date
: 3094 31-17 TRANSFER SST C50320 C83644 - TRANSFER ASSY (4WD) HINT: When the roller comes off due to deformation of the gauge, completely remove the roller and remaining inner races of the center differential case tapered roller bearing from the transfer ring gear mounting case. SST 09950- 00020, 09950- 00030, 09950- 60010 (09951-00360) NOTICE: Apply grease to the screw thread and tip of the SST before use. 34. REMOVE RING GEAR (a) Put matchmarks on the transfer ring gear mounting case and the ring gear. (b) Remove the 12 bolts. Matchmarks C67676 C83645 (c) Using a plastic hammer, remove the ring gear by tapping around its periphery. NOTICE: Do not damage the teeth of the ring gear. HINT: If the runout is too large, replace the transfer ring rear mounting case. C67677 35. (a) INSPECT RUNOUT OF TRANSFER RING GEAR MOUNTING CASE Using a dial indicator, check the transfer ring gear mounting case runout. Maximum runout: 0.03 mm (0.0012 in.) HINT: If the runout is too large, replace the center differential control coupling assy or transfer ring gear mounting case. C99000 36. (a) SST REMOVE DRIVEN PINION Using SST and a hammer, unstake the transfer gear nut. SST 09930-00010 C82795 Author
: Date
: 3095 31-18 TRANSFER (b) SST - TRANSFER ASSY (4WD) Using SST, remove the transfer gear nut. SST 09326-2001 1, 09556-16030 SST C82984 (c) Using a press, remove the driven pinion, transfer driven pinion rear bearing inner race and transfer pinion bearing spacer. NOTICE:
Put a shop rag around to help prevent the driven pinion from being dropped.
Place something like wooden blocks under the case to keep it level. C82796 37. SST C50327 (a) REMOVE TRANSFER DRIVEN PINION FRONT BEARING Using SST and a press, remove the transfer driven pinion front bearing inner race from the driven pinion. SST 09950-00020 C83646 38. (a) REMOVE TRANSFER DRIVEN PINION FRONT BEARING Using a brass bar and a hammer, lightly strike the center differential case tapered roller bearing LH outer race at 2 points to remove it from the transfer case. C50329 39. (a) REMOVE TRANSFER OUTPUT WASHER Remove the ring gear mounting case plate washer from the transfer case. Author
: Date
: 3096 31-19 TRANSFER 40. (a) - TRANSFER ASSY (4WD) REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING Using a brass bar and a hammer, lightly strike the transfer driven pinion front bearing outer race at 2 points to remove it from the transfer case. C82781 41. (a) REMOVE RING GEAR MOUNTING CASE PLATE WASHER Remove the transfer output washer from the transfer case. 42. (a) REMOVE TRANSFER DRIVEN PINION REAR BEARING Using a brass bar and a hammer, lightly strike the transfer driven pinion rear bearing outer race at 2 points to remove it from the transfer case. C50331 43. SST C82982 INSTALL TRANSFER DRIVEN PINION REAR BEARING (a) Using SST and a press, install the transfer driven pinion rear bearing outer race to the transfer case. SST 09950- 60010 (09951- 00620), 09950- 70010 (09951-07150) NOTICE: Place something like wooden blocks under the case to keep its level. 44. INSTALL TRANSFER OUTPUT WASHER (a) Install the transfer output washer to the transfer case. HINT: Reuse the washer. 45. SST (a) C50335 INSTALL TRANSFER DRIVEN PINION FRONT BEARING Install the transfer driven pinion front bearing outer race to the transfer case with SST, bolt and nut. SST 09950- 60020 (09951- 00750, 09951- 00770, 09951-00810), 09316-60011 (09316-00061) C83647 Author
: Date
: 3097 31-20 TRANSFER - TRANSFER ASSY (4WD) 46. INSTALL RING GEAR MOUNTING CASE PLATE WASHER (a) Install the ring gear mounting case plate washer to the transfer case. HINT: Reuse the washer. 47. (a) SST C50336 C83648 48. SST C50337 INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING Using SST and a press, install the center differential case tapered roller bearing LH outer race to the transfer case. SST 09950- 70010 (09951- 07200), 09316- 60011 (09316-00021) (a) INSTALL TRANSFER DRIVEN PINION FRONT BEARING Using SST and a press, install the transfer driven pinion front bearing inner race to the driven pinion. SST 09316-6001 1 (09316-00041) 49. (a) INSTALL DRIVEN PINION Install the driven pinion to the transfer case. (b) Install a new transfer pinion bearing spacer and a new transfer driven pinion rear bearing inner race to the driven pinion. C83649 C50338 C50339 Author
: Date
: 3098 31-21 TRANSFER - TRANSFER ASSY (4WD) (c) SST C82983 Using SST, tighten a new transfer gear nut (at a standard torque.) SST 09326-2001 1, 09556-16030 Torque: 277 to 378 N⋅m (2,820 to 3,855 kgf⋅cm, 204 to 279 ft⋅lbf) NOTICE: Do not stake the transfer gear nut. HINT: Use a torque wrench with a fulcrum length of 750 mm (29.53 in.) 50. (a) SST C82792 C83635 HINT: Use a torque wrench with a fulcrum length of 160 mm (6.30 in.) NOTICE: Measure preload after rotating the bearing both clockwise and counterclockwise to make it fit. (b) If the preload is too large, replace the transfer pinion bearing spacer with a new one. (c) If the preload is too small, repeatedly adjust the preload by tightening the transfer gear nut 5 to 10 degrees at a time until the standard value is obtained. (d) If the preload is insufficient, even though the tightening torque of the transfer gear nut exceeds the maximum of the standard value, loosen the transfer gear nut and apply gear oil SAE 90 (GL-5) to the transfer gear nut and the screw thread and the base of the driven pinion. And then repeat the preceding operation. If the tightening torque is smaller than the standard, replace the transfer pinion bearing spacer with a new one and adjust it. SST 09326-2001 1, 09556-16030 Torque: 378 N⋅m (3,855 kgf⋅cm, 279 ft⋅lbf) 51. (a) Boiling Water INSPECT AND ADJUST DRIVEN PINION PRELOAD Using SST and a torque wrench, measure the initial torque of the driven pinion. Preload (at starting): New bearing: 1.1 to 1.6 N⋅m (11 to 16 kgf⋅cm, 9.7 to 14.2 in.⋅lbf) Used bearing: 0.9 to 1.4 N⋅m (9 to 14 kgf⋅cm, 8.0 to 12.4 in.⋅lbf) (b) (c) INSTALL RING GEAR Completely remove grease and moisture on the contact surfaces of the ring gear and the transfer ring gear mounting case. Heat the ring gear in boiling water from 90 to 100C (194 to 212F). Carefully take the ring gear out of the boiling water. SA1143 Author
: Date
: 3099 31-22 TRANSFER - TRANSFER ASSY (4WD) (d) Matchmarks C50361 C83652 Align the matchmarks on the ring gear and transfer ring gear mounting case and quickly assemble them. (e) Tighten the12 bolts. Torque: 78 N⋅m (790 kgf⋅cm, 57 ft⋅lbf) NOTICE:
Tighten the bolts in diagonal order in splitting several times.
After the ring gear has well cooled down, fully tighten the bolts.
Make the bolt heads in order to check if they are retightened or not. 52. SST C50342 C83653 SST INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING (a) RH side: Using SST and a press, install the inner race of the center differential case tapered roller bearing to the transfer ring gear mounting case. SST 09506-35010, 09950-60010 (09951-00430) NOTICE: When replacing the inner race, replace it together with the outer race. (b) LH side: Using SST and a press, install the inner race of the center differential case tapered roller bearing to the transfer ring gear mounting case. SST 09223-00010 NOTICE: When replacing the inner race, replace it together with the outer race. C67688 53. (a) INSTALL TRANSFER RING GEAR MOUNTING CASE Install the transfer ring gear mounting case to the transfer case. NOTICE: Damage to the spline, the bearing’s rotating surface and gear face may cause a decrease in their strength. Care should be taken when installing them. C67673 54. INSTALL TRANSFER RING GEAR MOUNTING CASE WASHER NO.2 (a) Install the transfer ring gear mounting case washer No.2 to the transfer RH bearing retainer sub-assy. HINT: Reuse the washer. Author
: Date
: 3100 31-23 TRANSFER 55. SST (a) C50344 - TRANSFER ASSY (4WD) INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING Using SST and a press, install the center differential case tapered roller bearing RH outer race to the transfer RH bearing retainer sub-assy. SST 09950- 60010 (09951- 00620), 09950- 70010 (09951-07150) C83654 56. (a) (b) INSTALL TRANSFER RH BEARING RETAINER SUB-ASSY Place the transfer with the face where the transfer RH bearing retainer sub-assy is to be installed facing up. Center-align the transfer ring gear mounting case and the transfer case. C57486 (c) Insert the SST into the transfer RH bearing retainer subassy. SST 09387-00090 NOTICE: Insert SST straight in order not to damage the oil seal lip. SST C57487 (d) Insert the transfer RH bearing retainer sub-assy together with the SST into the transfer case. NOTICE: Interference between the case and retainer, and between the transfer ring gear mounting case and SST should be carefully avoided. HINT: If the retainer cannot be inserted, tap it in with a plastic hammer. C57488 (e) After inserting the transfer RH bearing retainer sub-assy into the transfer case, remove the SST. C57489 Author
: Date
: 3101 31-24 TRANSFER (f) - TRANSFER ASSY (4WD) Tighten the 7 bolts. Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) C83509 57. (a) C50309 Mark Washer Thickness AA 2.07 (0.0814) mm (in.) INSPECT BACKLASH Set the dial indicator perpendicular to the ring gear face, fix the driven pinion, and check backlash by moving the ring gear. Backlash: 0.10 to 0.15 mm (0.0039 to 0.0059 in.) NOTICE: Measure it at 3 points or more on the ring gear periphery. (b) If the measured value is out of standard, select a proper washer for the center differential case tapered roller bearing on the LH side from the table below and install it to obtain the standard value. Mark Washer Thickness mm (in.) AB 2.10 (0.0826) Mark Washer Thickness AC 2.13 (0.0838) BA 2.16 (0.0850) BB 2.19 (0.0862) BC 2.22 (0.0874) CA 2.25 (0.0885) CB 2.28 (0.0897) CC 2.31 (0.0909) DA 2.34 (0.0921) DB 2.37 (0.0933) DC 2.40 (0.0944) EA 2.43 (0.0956) EB 2.46 (0.0968) EC 2.49 (0.0980) FA 2.52 (0.0992) FB 2.55 (0.1003) FC 2.58 (0.1015) GA 2.61 (0.1027) GB 2.64 (0.1039) GC 2.67 (0.1051) HA 2.70 (0.1062) HB 2.73 (0.1074) HC 2.76 (0.1086) JA 2.79 (0.1098) JB 2.82 (0.1110) JC 2.85 (0.1122) KA 2.88 (0.1133) KB 2.91 (0.1145) KC 2.94 (0.1157) LA 2.97 (0.1169) LB 3.00 (0.1181) mm (in.) HINT: When the backlash is larger or smaller than the standard, select a thinner or thicker washer respectively. (c) Ring Gear Mounting Case Plate Washer C50345 Ring gear mounting case plate washer location is shown in the illustration. C83655 Author
: Date
: 3102 31-25 TRANSFER - TRANSFER ASSY (4WD) 58. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION (a) Apply red lead primer thinly and uniformly to both faces of the ring gear and rotate it several times. NOTICE: Check the tooth contact on the ring gear at 4 places or more. (b) Observe the pattern shown by red lead primer. C50346 Face Contact Heel Contact Select an adjusting washer that will bring the driven pinion closer to the ring gear. Flank Contact Toe Contact Proper Contact Select an adjusting washer that will shift the drive pinion away from the ring gear. C30886 K3673 C83636 (c) In case of poor tooth contact, select a washer for the driven pinion bearing front side from the following table and replace it. NOTICE: If the washer thickness is changed, the backlash will be also changed. Mark Washer Thickness mm (in.) Mark Washer Thickness mm (in.) Mark Washer Thickness AA 1.20 (0.0472) AC 1.22 (0.0480) BB 1.24 (0.0488) CA 1.26 (0.0496) CC 1.28 (0.0503) DB 1.30 (0.0511) EA 1.32 (0.0519) EC 1.34 (0.0527) FB 1.36 (0.0535) GA 1.38 (0.0543) GC 1.40 (0.0551) HB 1.42 (0.0559) JA 1.44 (0.0566) JC 1.46 (0.0574) KB 1.48 (0.0582) LA 1.50 (0.0590) LC 1.52 (0.0598) MB 1.54 (0.0606) NA 1.56 (0.0614) NC 1.58 (0.0622) PB 1.60 (0.0629) QA 1.62 (0.0637) QC 1.64 (0.0645) Author
: Date
: mm (in.) 3103 31-26 TRANSFER (d) - TRANSFER ASSY (4WD) The location of the transfer output washer for tooth contact adjustment is shown in the illustration. Transfer Output Washer C50363 C83656 59. (a) SST C82792 Mark C83635 Washer Thickness AA 1.47 (0.0578) mm (in.) Mark ADJUST TOTAL PRELOAD Using SST and a torque wrench, measure the initial torque with the driven pinion being contact with the ring gear face. SST 09326-2001 1 Torque: New bearing: Driven pinion preload +0.2 to 0.4 N⋅m (+2.3 to 3.9 kgf⋅cm, 1.8 to 3.5 in.⋅lbf) Used bearing: Driven pinion preload +0.15 to 0.30 N⋅m (+1.6 to 3.1 kgf⋅cm, 1.3 to 2.7 in.⋅lbf) NOTICE: Before measurement, rotate the bearing in both directions several times to make it fit. HINT: Use a torque wrench with a fulcrum length of 160 mm (6.30 in.). (b) If the value is out of standard range, select the washer for the center differential case tapered roller bearing RH side from the following table and replace it. Washer Thickness mm (in.) AB 1.50 (0.0590) Mark Washer Thickness AC 1.53 (0.0602) BA 1.56 (0.0614) BB 1.59 (0.0625) BC 1.62 (0.0637) CA 1.65 (0.0649) CB 1.68 (0.0661) CC 1.71 (0.0673) DA 1.74 (0.0685) DB 1.77 (0.0696) DC 1.80 (0.0708) EA 1.83 (0.0720) EB 1.86 (0.0732) EC 1.89 (0.0744) FA 1.92 (0.0755) FB 1.95 (0.0767) FC 1.98 (0.0779) GA 2.01 (0.0790) GB 2.04 (0.0803) GC 2.07 (0.0814) HA 2.10 (0.0826) HB 2.13 (0.0838) HC 2.16 (0.0850) JA 2.19 (0.0862) JB 2.22 (0.0874) JC 2.25 (0.0885) KA 2.28 (0.0897) KB 2.31 (0.0909) KC 2.34 (0.0921) LA 2.37 (0.0933) LB 2.40 (0.0944) LC 2.43 (0.0956) MA 2.46 (0.0968) MB 2.49 (0.0980) MC 2.52 (0.0992) NA 2.55 (0.1003) NB 2.58 (0.1015) Author
: Date
: mm (in.) 3104 31-27 TRANSFER TRANSFER ASSY (4WD) (c) The location of the transfer ring gear mounting case washer No.2 for preload adjustment is shown in the illustration. (d) Using a chisel, stake the transfer gear nut. 60. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSY Remove the 7 bolts from the transfer RH bearing retainer sub-assy . Transfer Ring Gear Mounting Case Washer No.2 C50349 - C83657 C70532 (a) C83509 (b) Using a screwdriver and a hammer, make a opening between the transfer RH bearing retainer sub-assy and the transfer case. NOTICE: Be careful not to damage the transfer RH bearing retainer sub-assy and the transfer case. C82797 (c) SST Using SST, remove the transfer RH bearing retainer subassy from the transfer case. SST 09520-10021 C82981 Author
: Date
: 3105 31-28 TRANSFER 61. SST C50341 (a) (b) - TRANSFER ASSY (4WD) REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING Fix the transfer RH bearing retainer sub-assy in a vise. Using SST, remove the center differential case tapered roller bearing RH outer race and transfer ring gear mounting case washer No.2 from the transfer RH bearing retainer sub-assy. SST 09308-00010 C83688 62. (a) (b) INSTALL SIDE GEAR SHAFT HOLDER BEARING Install the side gear shaft holder bearing to the transfer RH bearing retainer sub-assy. Using snap ring pliers, install the side gear shaft holder hole snap ring. HINT: Check that the side gear shaft holder hole snap ring fits in the groove of the transfer RH bearing retainer sub-assy. C50364 C83699 63. INSTALL TRANSFER RH BEARING RETAINER OIL SEAL SST 1.5 to 2.5 mm (a) Using SST and a press, install the transfer RH bearing re(0.059 to 0.098 in.) tainer oil seal No.2 to the transfer RH bearing retainer sub-assy . SST 09950- 60010 (09951- 00350, 09951- 00560, 09952-06010), 09950-70010 (09951-07150) NOTICE: Carefully press-fit so that the oil seal will not be tilted. C83689 C50350 (b) Apply small amount of MP grease No.2 to the oil seal lip. 64. INSTALL TRANSFER RING GEAR MOUNTING CASE WASHER NO.2 (a) Install the selected transfer ring gear mounting washer No.2 to the transfer RH bearing retainer subassy. 65. SST (a) C51147 INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING Using SST and a press, install the center differential case tapered roller bearing RH outer race to the transfer RH bearing retainer sub-assy. SST 09950- 60010 (09951- 00620), 09950- 70010 (09951-07150) C83690 Author
: Date
: 3106 31-29 TRANSFER - TRANSFER ASSY (4WD) 66. (a) (b) INSTALL O-RING Coat 2 new O-rings with hypoid gear oil. Install the 2 O-rings to the transfer RH bearing retainer sub-assy . NOTICE: Be careful not to twist the O-ring but to fit it properly in the retainer’s groove. C50352 67. (a) (b) INSTALL TRANSFER RH BEARING RETAINER SUB-ASSY Place the transfer with the surface where the transfer RH bearing retainer sub-assy is facing up. Align the centers of the transfer ring gear mounting case and the transfer case. C57486 (c) Insert SST into the transfer RH bearing retainer subassy. SST 09387-00090 NOTICE: Insert SST straight in order not to damage the oil seal. SST C57487 (d) C57488 Insert the transfer RH bearing retainer sub-assy together with SST into the transfer case. NOTICE:
Avoid interference between the case and the retainer, and between the SST and the transfer ring gear mounting case.
Carefully check the retainer’s O-ring for damage and incorrect fitting. HINT: If the retainer cannot be inserted into the case, tap it in with a plastic hammer. Author
: Date
: 3107 31-30 TRANSFER - TRANSFER ASSY (4WD) (e) After inserting the transfer RH bearing retainer sub-assy into the transfer case, remove the SST. (f) Tighten the 7 bolts. Torque: 28 N⋅m (286 kgf⋅cm, 21 ft⋅lbf) 68. (a) INSPECT TOTAL PRELOAD Using SST and a torque wrench, measure the initial torque with the driven pinion being in contact with the ring gear face. SST 09326-2001 1 Torque: New bearing: Driven pinion preload +0.2 to 0.4 N⋅m (+2.3 to 3.9 kgf⋅cm, 1.8 to 3.5 in.⋅lbf) Used bearing: Driven pinion preload +0.15 to 0.30 N⋅m (+1.6 to 3.1 kgf⋅cm, +1.3 to 2.7 in.⋅lbf) C57489 C83509 SST C82792 C83650 HINT:

69. 0.7 to 1.3 mm (0.028 to 0.051 in.) C50351 Use a torque wrench with a fulcrum length of 160 mm (6.30 in.). If the preload is too large, inspect the transfer RH bearing retainer sub-assy. SST C83691 INSTALL TRANSFER RH BEARING RETAINER OIL SEAL (a) Using SST, install the transfer RH bearing retainer oil seal to the transfer RH bearing retainer sub-assy to the position as shown in the illustration. SST 09223-4601 1 NOTICE: Install the oil seal carefully so that it will not be tilted. (b) Apply MP grease to the oil seal lip. Author
: Date
: 3108 31-31 TRANSFER - TRANSFER ASSY (4WD) 70. (a) SST 8.7 to 9.3 mm INSTALL TRANSFER CASE OIL SEAL Using SST, install the transfer case oil seal to the transfer case at the position as shown as in the illustration. SST 09387-00010, 09950-70010 (09951-07150) NOTICE: Install the oil seal carefully so that it will not be tilted. (b) Apply small amount of MP grease to the oil seal lip. (0.343 to 0.366 in.) C50353 C83631 71. INSTALL CTR DIFFERENTIAL LOCK SLEEVE (a) Coat a new O-ring with hypoid gear oil. (b) Install the O-ring to the CTR differential lock sleeve. NOTICE: Be careful not to twist the O-ring but to fit it properly in the retainer’s groove. C50354 (c) Using SST, install the CTR differential lock sleeve to the transfer case. SST 09950- 60010 (09951- 00610), 09950- 70010 (09951-07150) SST C51160 C83692 (d) Using snap ring pliers, install the shaft snap ring. NOTICE: Check that the snap ring is fitted in the groove of the ring gear mounting case. C50365 C83693 72. 1.1 to 1.9 mm (0.043 to 0.075 in.) SST C50355 C83694 INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL (a) Using SST, install the transfer extension housing type T oil seal to the transfer extension housing at the position as shown in the illustration. SST 09950- 60010 (09951- 00380, 09951- 00580, 09952-06010), 09950-70010 (09951-07150) NOTICE: Install the oil seal carefully so that it will not be tilted. (b) Apply small amount of MP grease No.2 to the oil seal lip. Author
: Date
: 3109 31-32 TRANSFER 73. SST (a) C50356 - TRANSFER ASSY (4WD) INSTALL TRANSFER EXTENSION HOUSING DUST DEFLECTOR Using SST and a press, install a new transfer extension housing dust deflector to the transfer extension housing sub-assy . SST 09950- 60020 (09951- 00710), 09950- 70010 (09951-07150) C83695 74. Sealant C83047 C83696 INSTALL TRANSFER EXTENSION HOUSING SUB-ASSY (a) Apply sealant 1281 to the transfer extension housing sub-assy in continuous beaded form of 1.2 mm diameter as shown in the illustration. NOTICE:
Wipe any grease off from the attaching surfaces.
Install the transfer extension housing sub-assy within 10 minutes after applying the sealant. (b) (c) Install the transfer extension housing sub-assy to the transfer case with the 4 bolts. Torque: 26 N⋅m (260 kgf⋅cm, 19 ft⋅lbf) Remove the transfer assy from the overhaul attachment. C82800 75. Sealantcoated part C50332 INSTALL TRANSFER & TRANSAXLE SETTING STUD BOLT (a) Install the 4 transfer & transaxle setting stud bolts to the parts of the transfer case as shown in the illustration. Torque: 39 N⋅m (400 kgf⋅cm, 30 ft⋅lbf) NOTICE: Install the sealant-coated side of the transfer & transaxle stud bolt to the transfer case. D31105 Author
: Date
: 3110 31-33 TRANSFER - TRANSFER ASSY (4WD) 76. (a) INSTALL TRANSFER CASE STRAIGHT PIN Using a plastic hammer, install the 4 transfer case straight pins to the transfer case as shown in the illustration. 77. (a) INSTALL TRANSFER DYNAMIC DAMPER Install the transfer dynamic damper to the transfer extension housing sub-assy with the 3 bolts. Torque: 26 N⋅m (260 kgf⋅cm, 19 ft⋅lbf) 6.5 to 7.5 mm (0.256 to 0.295 in.) 10.8 to 11.8 mm (0.425 to 0.465 in.) C83712 C69282 C51143 78. (a) INSTALL BREATHER OIL DEFLECTOR Install the breather oil deflector to the transfer case cover No.1 with the bolt. Torque: 6.5 N⋅m (66 kgf⋅cm, 57 in.⋅lbf) NOTICE: Be careful of the direction of the deflector’s fold. C67686 79. (a) INSTALL TRANSFER CASE COVER NO.1 Apply sealant 1281 to the transfer case cover No.1 in a continuous bead of 1.2 mm diameter as shown in the illustration. NOTICE:
Wipe any grease off from the attaching surfaces.
Install the transfer case cover No.1 within 10 minutes after application of the sealant. Sealant C67689 C83713 Author
: Date
: 3111 31-34 TRANSFER - TRANSFER ASSY (4WD) (b) Install the transfer case cover No.1 to the transfer case with the 8 bolts. Torque: 20 N⋅m (200 kgf⋅cm, 14 ft⋅lbf) 80. (a) TRANSFER CASE BREATHER PLUG Using SST and a hammer, install the transfer case breather plug to the transfer case cover No.1. SST 09612-10061) 81. (a) INSTALL TRANSFER COVER GASKET Install a new transfer cover gasket to the transfer case. C83507 SST D30774 C82798 82. (a) Driving Plug INSTALL TRANSFER ASSY Apply sealant 1281 to the transaxle assy and the transfer assy in continuous beaded form of 1.2 mm diameter as shown in the illustration. NOTICE:
Wipe any grease off from the attaching surfaces.
Install it within 10 minutes after applying the sealant.
Sealant stuck on the gasket, case oil seal and driving plug may cause oil leakage and seizure due to oil shortage. Care must be taken. Sealant Gasket C51159 C83714 Author
: Date
: 3112 31-35 TRANSFER - TRANSFER ASSY (4WD) (b) 83. (a) Install the transfer assy to the transaxle assy with the 2 bolts and 6 nuts. Torque: 69 N⋅m (700 kgf⋅cm, 51 ft⋅lbf) NOTICE:
Check that the gasket is installed to the transfer assy before instaling them to the transaxle assy.
Install the transfer assy to the transaxle assy without tilting.
When moving the transfer assy, do not hold the oil C82785 seal on the both sides. INSTALL ENGINE MOUNTING BRACKET RR (2AZ-FE ENGINE TYPE) Install the engine mounting bracket RR with the 3 bolts. Torque: 64 N⋅m (652 kgf⋅cm, 47 ft⋅lbf) 84. (a) INSTALL TRANSFER STIFFENER PLATE RH (2AZ-FE ENGINE TYPE) Install the stiffener plate RH with the 5 bolts. Torque: 34 N⋅m (350 kgf⋅cm, 25 ft⋅lbf) F45388 85. 86. 87. INSTALL AUTOMATIC TRANSMISSION W/TRANSFER (3MZ-FE ENGINE TYPE) (SEE PAGE 40-20 ) INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 ) INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (2AZ-FE ENGINE TYPE) (SEE PAGE 14-24 ) No.2 Plug No.1 Plug 88. (a) 89. (a) Drain Plug C82977 90. (a) INSTALL TRANSFER DRAIN PLUG Install the transfer drain plug with a new drain gasket. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) INSTALL TRANSFER CASE NO.2 PLUG Install the transfer case No.2 plug with a new gasket No.2. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) INSTALL TRANSFER CASE NO.1 PLUG Add oil up to 0 to 5 mm below the lower side of the plug hole. Oil quantity: 0.9 L (0.95 US qts, 0.79 lmp. qts) HINT: When adding oil, pour it slowly. (b) Install the transfer case No.1 plug with a new gasket No.1. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) Author
: Date
: 3113 31-3 TRANSFER - TRANSFER (4WD) TRANSFER (4WD) 3100R-05 COMPONENTS Transfer Case Breather Plug Transfer Case Cover No. 1
Center Differential Case Tapered Roller Bearing RH Inner Race Breather Oil Deflector x8 20 (200, 14) 6.5 (66, 57 in.⋅lbf)
Right Bearing Retainer O-ring
Transfer RH Bearing Retainer Oil Seal 78 (790, 57)
Center Differential Case Tapered Roller Bearing LH Inner Race x12 Ring Gear
Center Differential Case Tapered Roller Bearing LH Outer Race
O-ring Transfer Ring Gear Mounting Case Ring Gear Mounting Case Plate Washer x7 Transfer Ring Gear Mounting Case Washer No. 2 28 (286, 21) Transfer RH Bearing
Center Differential Case Tapered Roller Bearing RH Outer Race
Transfer Cover Gasket Transfer Case Straight Pin Transfer Transfer Case CTR Differential Lock Sleeve Retainer Sub-assy Case No.2 Plug 49 (500, 36)
Transfer Case Oil Seal Side Gear Shaft
Gasket No. 1
Gasket No. 2
O-ring Holder Bearing Side Gear Shaft Holder Hole Snap Ring
Transfer RH Bearing Retainer Oil Seal No. 2 Transfer Case Shaft Snap Ring
Drain Gasket x4 Transfer Case Straight Pin No.1 Plug 49 (500, 36) Transfer Drain Plug 49 (500, 36) Transfer Driven Pinion Rear Bearing Outer Race Transfer Driven Pinion Rear 26 (260, 19) Bearing Inner Race Transfer & Transaxle Setting Stud Bolt
39 (400, 29) Transfer Gear Nut 295 to 403 (3,008 to 4,109, 218 to 297 ) *277 to 378 (2,820 to 3,855, 204 to 279) Transfer Extension Housing Sub-assy
Transfer Extension
Transfer Extension Housing Type T Oil Seal Driven Pinion Transfer Driven Pinion Front Bearing Inner Race Housing Dust Deflector 26 (260, 19) Transfer Driven Pinion Front Bearing Outer Race N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part *For use with SST 26 (260, 19) Transfer Output Washer Transfer Dynamic Damper
Transfer Pinion Bearing Spacer D30404 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3081 32-1 BRAKE - BRAKE SYSTEM BRAKE SYSTEM 320WA-03 PRECAUTION NOTICE:
Care must be taken to replace each part properly as it could affect the performance of the brake system and result in a driving hazard. Replace the parts with parts having the same part number or equivalent.
It is very important to keep parts and the area clean when repairing the brake system.
If the vehicle is equipped with a mobile communication system, refer to the precaution in the INTRODUCTION section. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3114 32-2 BRAKE - BRAKE SYSTEM 320WB-07 PROBLEM SYMPTOMS TABLE HINT: Refer to the table below to help find the cause of the problem. The numbers indicate the priority of the possible cause of problem. Check each part in order. If necessary, replace these parts. Symptom Low pedal or spongy pedal Suspected Area See page 7. Fluid leaks in brake system 8. Air in brake system 9. Piston seals (Worn or damaged) 32-4 32-23 32-29 32-14 32-14 10.Master cylinder (Faulty) 11.Booster push rod (Out of adjustment) 1. Brake pedal free play (Minimal) 2. Parking brake pedal travel (Out of adjustment) 3. Parking brake wire (Sticking) 4. Parking brake shoe clearance (Out of adjustment) 5. Pad (Cracked or distorted) Brake drag 6. Piston (Stuck) 7. Piston (Frozen) 8. Booster push rod (Out of adjustment) 9. Vacuum leaks in booster system 10. Master cylinder (Faulty) 1. Piston (Stuck) 32-23 32-29 32-23 32-29 32-23 32-29 32-23 32-29 32-23 32-29 2. Pad (Oily) Brake pull 3. Piston (Frozen) 4. Disc (Scored) 5. Pad (Cracked or distorted) 1. Fluid leaks in brake system 2. Air in brake system 3. Pad (Worn) 32-4 32-23 32-29 32-23 32-29 32-23 32-29 32-23 32-29 32-23 32-29 32-14 32-17 4. Pad (Cracked or distorted) Hard pedal but brake inefficient 32-8 33-2 33-10 33-14 33-19 32-23 32-29 32-23 32-29 32-23 32-29 32-14 32-17 32-14 5. Pad (Oily) 6. Pad (Glanzed) 7. Disc (Scored) 8. Booster push rod (Out of adjustment) 9. Vacuum leaks in booster system 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3115 32-3 BRAKE - BRAKE SYSTEM 1. Pad (Cracked or distorted) 32-23 32-29 32-23 32-29 32-23 32-29 32-23 32-29 32-23 32-29 32-23 32-29 32-23 32-29 32-23 32-29 2. Installation bolt (Loose) 3. Disc (Scored) 4. Pad support plate (Loose) Brake noise 5. Sliding pin (Worn) 6. Pad (Dirty) 7. Pad (Glanzed) 8. Anti-squeal shim (Damaged) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3116 32-40 BRAKE - SPEED SENSOR FRONT LH SPEED SENSOR FRONT LH 3215T-01 REPLACEMENT HINT:

1. 2. Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. REMOVE FRONT WHEEL REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSY LH 3. (a) REMOVE SPEED SENSOR FRONT LH Disconnect the speed sensor connector. (b) Remove the 2 bolts and the clamp from the body and the shock absorber assy. F40298 F40299 (c) Remove the bolt and the speed sensor front. NOTICE: Prevent foreign matter from attaching to the sensor tip. F40300 4. (a) INSTALL SPEED SENSOR FRONT LH Install the speed sensor front with the bolt. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) NOTICE: Prevent foreign matter from attaching to the sensor tip. F40300 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3153 32-41 BRAKE - SPEED SENSOR FRONT LH (b) Install the speed sensor front with the 2 bolts and the clamp. Torque: Bolt A: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) Bolt B: 19 N⋅m (192 kgf⋅cm, 14 ft⋅lbf) NOTICE: Do not twist the sensor wire when installing the sensor. Bolt A Bolt B Clamp F40299 (c) Connect the speed sensor connector. F40298 5. 6. 7. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSY LH INSTALL FRONT WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) CHECK ABS SPEED SENSOR SIGNAL (SEE PAGE 05-765 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3154 32-42 BRAKE - SKID CONTROL SENSOR (FF) SKID CONTROL SENSOR (FF) 320WO-03 REPLACEMENT HINT:

1. 2. (a) 3. 4. 5. Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. REMOVE REAR WHEEL DISCONNECT SKID CONTROL SENSOR WIRE Disconnect the connector from the skid control sensor. SEPARATE REAR DISC BRAKE CALIPER ASSY LH (SEE PAGE 30-53 ) REMOVE REAR DISC (SEE PAGE 30-53 ) REMOVE REAR AXLE HUB & BEARING ASSY LH (SEE PAGE 30-53 ) 6. REMOVE SKID CONTROL SENSOR (a) Mount the hub & bearing assy on a soft jaw vise. NOTICE: Replace the hub & bearing assy if it is dropped or receives a strong shock. (b) Using a pin punch and hammer, drive out the 2 pins and remove the 2 attachments from SST. (c) Using SST and 2 bolts (Diameter: 12 mm, pitch: 1.5 mm), remove the skid control sensor from the hub & bearing assy. SST 09520- 00031 (09520- 00040), 09521- 00020, 09950-00020 NOTICE:
If damage is inflicted to the sensor rotor, replace the hub & bearing assy.
Do not scratch the contacting surface of the hub & bearing assy and the skid control sensor. SST Bolt SST SST F40303 LH: 7. (a) INSTALL SKID CONTROL SENSOR Clean the contacting surface of the rear axle hub and a assy and a new skid control sensor. NOTICE: Prevent foreign matter from attaching to the sensor rotor. (b) Place the skid control sensor on the rear axle hub so that the connector makes the lowest position under the onvehicle condition. RH: Connector F45440 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3155 32-43 BRAKE - SKID CONTROL SENSOR (FF) (c) SST F45370 8. 9. 10. 11. 12. 13. (a) 14. 15. 16. Using SST and a press, install the skid control sensor onto the hub & bearing assy. SST 09214-7601 1 NOTICE:
Do not tap the skid control sensor with a hammer directly.
Check that there is no foreign matter on the skid control sensor detection portion.
Press in the skid control sensor straight and slowly. INSTALL REAR AXLE HUB & BEARING ASSY LH (SEE PAGE 30-53 ) INSPECT BEARING BACKLASH (SEE PAGE 30-53 ) INSPECT AXLE HUB DEVIATION (SEE PAGE 30-53 ) INSTALL REAR DISC (SEE PAGE 30-53 ) INSTALL REAR DISC BRAKE CALIPER ASSY LH (SEE PAGE 30-53 ) CONNECT SKID CONTROL SENSOR WIRE Connect the connector to the skid control sensor. INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT AND ADJUST REAR WHEEL ALIGNMENT (SEE PAGE 27-5 ) CHECK ABS SPEED SENSOR SIGNAL (SEE PAGE 05-765 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3156 32-8 BRAKE - BRAKE PEDAL SUB-ASSY BRAKE PEDAL SUB-ASSY 3203C-05 ADJUSTMENT 1. (a) Stop Lamp Switch Lock Nut (b) Stop Lamp Switch Assy Push Rod Push Rod Lock Nut F45502 Pedal Height F47533 CHECK AND ADJUST BRAKE PEDAL HEIGHT Check brake pedal height. Pedal height from asphalt sheet: 150 to 160 mm (5.906 to 6.299 in.) Adjust brake pedal height. (1) Disconnect the connector from the stop lamp switch assy. (2) Loosen the stop lamp switch lock nut and remove the stop lamp switch assy. (3) Loosen the push rod lock nut. (4) Adjust the pedal height by turning the pedal push rod. (5) Tighten the push rod lock nut. Torque: 26 N⋅m (265 kgf⋅cm, 19 ft⋅lbf) (6) Install the stop lamp switch assy. (7) Connect the connector to the stop lamp switch assy. (8) Push the brake pedal in 5 to 10 mm (0.20 to 0.39 in.) and turn the stop lamp switch assy to lock the nut in the position where the stop lamp goes off. (9) After installation, push the brake pedal in 5 to 10 mm (0.20 to 0.39 in.), and check that the stop lamp comes on. (10) Tighten the stop lamp switch lock nut. Torque: 17 N⋅m (173 kgf⋅cm, 13 ft⋅lbf) 2. (a) CHECK PEDAL FREE PLAY Stop the engine and depress the brake pedal several times until no vacuum remains in the booster. (b) Press the pedal until resistance is felt. Measure the distance as shown in the illustration. Pedal free play: 2.0 to 3.0 mm (0.079 to 0.118 in.) If incorrect, proceed to the following step. (1) Check the stop lamp switch clearance. Stop lamp switch clearance: 0.5 to 2.6 mm (0.020 to 0.102 in.) If the clearance is OK, then troubleshoot the brake system. If incorrect, adjust the stop lamp switch clearance. Pedal Free play F45503 F47534 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3121 32-9 BRAKE - BRAKE PEDAL SUB-ASSY 3. (a) (b) Pedal Reserve Distance CHECK PEDAL RESERVE DISTANCE Release the parking brake pedal. With engine running, depress the pedal and measure the pedal reserve distance, as shown in the illustration. Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf): More than 83 mm (3.3 in.) If incorrect, troubleshoot the brake system. R00934 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3122 32-10 BRAKE - BRAKE PEDAL SUB-ASSY 320WD-03 COMPONENTS 20 (204, 15) Brake Pedal Support Sub-assy Brake Pedal Shaft 37 (375, 27) Stop Lamp Switch Assy Connector 17 (173, 13) Stop Lamp Switch Lock Nut 13 (130, 9)
Brake Pedal Bush
Brake Pedal Bush Brake Pedal Shaft Collar Stop Lamp Switch Cushion Brake Master Cylinder Push Rod Clevis Connector Push Rod Pin Clip Brake Pedal Sub-assy Brake Pedal Return Spring N⋅m (kgf⋅cm, ft⋅lbf) Brake Pedal Pad : Specified torque
Non-reusable part Lithium soap base glycol grease F46190 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3123 32-1 1 BRAKE - BRAKE PEDAL SUB-ASSY 320WE-03 REPLACEMENT 1. 2. (a) REMOVE INSTRUMENT PANEL FINISH PANEL SUB-ASSY LOWER (SEE PAGE 71-10 ) REMOVE BRAKE PEDAL RETURN SPRING Remove the brake pedal return spring. Brake Master Cylinder Push Rod Clevis Pedal Force Switch Connector 3. (a) (b) (c) Clip REMOVE PUSH ROD PIN Remove the clip and the push rod pin. Disconnect the stop lamp switch connector. Disconnect the pedal force switch connector and release the clip of the pedal force switch. Push Rod Pin F45787 4. 5. 6. 7. 8. REMOVE REMOVE REMOVE REMOVE REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY CENTER (SEE PAGE 71-10 ) INSTRUMENT PANEL FINISH PANEL LOWER (SEE PAGE 71-10 ) INSTRUMENT CLUSTER FINISH PANEL GARNISH (SEE PAGE 71-10 ) INSTRUMENT CLUSTER FINISH PANEL ASSY (SEE PAGE 71-10 ) COMBINATION METER ASSY (SEE PAGE 71-10 ) 9. REMOVE BRAKE PEDAL SUPPORT ASSY Nut Bolt (a) Remove the bolt, the 4 nuts and the brake pedal support assy. F46191 10. (a) 11. (a) 12. (a) REMOVE BRAKE PEDAL SUB-ASSY Remove the nut, the brake pedal shaft and the brake pedal sub-assy from the brake pedal support sub-assy . REMOVE BRAKE PEDAL PAD Remove the brake pedal pad from the brake pedal sub-assy. REMOVE STOP LAMP SWITCH ASSY Loosen the stop lamp switch lock nut and remove the stop lamp switch assy. 13. (a) Shaft Collar Pedal Bush Pedal Bush 14. (a) REMOVE BRAKE PEDAL BUSH Remove the 2 brake pedal bushes from the brake pedal sub-assy . REMOVE BRAKE PEDAL SHAFT COLLAR Remove the brake pedal shaft collar from the brake pedal sub-assy . F45786 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3124 32-12 BRAKE 15. (a) 16. (a) - BRAKE PEDAL SUB-ASSY REMOVE STOP LAMP SWITCH CUSHION Remove the stop lamp switch cushion from the brake pedal sub-assy. INSTALL STOP LAMP SWITCH CUSHION Install the stop lamp switch cushion to the brake pedal sub-assy. 17. (a) Shaft Collar Pedal Bush (b) Pedal Bush Lithium soap base glycol grease F45786 18. (a) (b) INSTALL BRAKE PEDAL SHAFT COLLAR Apply lithium soap base glycol grease to the ends and sides of brake pedal shaft collar. Install the brake pedal shaft collar to the brake pedal subassy. INSTALL BRAKE PEDAL BUSH Apply lithium soap base glycol grease to the ends and sides of 2 new brake pedal bushes. Install the brake pedal bushes to the brake pedal subassy. 19. INSTALL STOP LAMP SWITCH ASSY (a) Install the stop lamp switch assy with the stop lamp switch lock nut. HINT: After adjusting the brake pedal height, torque the lock nut. 20. INSTALL BRAKE PEDAL PAD (a) Install the brake pedal pad to the brake pedal sub-assy. 21. INSTALL BRAKE PEDAL SUB-ASSY (a) Install the brake pedal sub-assy with the brake pedal shaft and the nut. Torque: 37 N⋅m (375 kgf⋅cm, 27 ft⋅lbf) Nut 22. (a) Bolt INSTALL BRAKE PEDAL SUPPORT ASSY Install the brake pedal support assy with the bolt and the 4 nuts. Torque: Bolt: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) Nut: 13 N⋅m (130 kgf⋅cm, 9 ft⋅lbf) F46191 23. 24. 25. 26. 27. INSTALL COMBINATION METER ASSY INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSY INSTALL INSTRUMENT CLUSTER FINISH PANEL GARNISH INSTALL INSTRUMENT PANEL FINISH PANEL LOWER INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY CENTER 28. INSTALL PUSH ROD PIN Brake Master Cylinder Push Rod Clevis (a) Apply lithium soap base glycol grease to the clevis pin. (b) Install the clevis pin and the clip. Pedal Force Switch (c) Connect the pedal force switch connector and install the Connector clip of the pedal force switch to the brake pedal support Clip sub-assy . Push Rod Pin (d) Connect the stop lamp switch connector. Lithium soap base glycol grease F45787 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3125 32-13 BRAKE 29. (a) 30. 31. 32. 33. - BRAKE PEDAL SUB-ASSY INSTALL BRAKE PEDAL RETURN SPRING Install the brake pedal return spring. CHECK AND ADJUST BRAKE PEDAL HEIGHT (SEE PAGE 32-8 ) CHECK PEDAL FREE PLAY (SEE PAGE 32-8 ) CHECK PEDAL RESERVE DISTANCE (SEE PAGE 32-8 ) INSTALL INSTRUMENT PANEL FINISH PANEL SUB-ASSY LOWER 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3126 32-44 BRAKE - SPEED SENSOR REAR LH (4WD) SPEED SENSOR REAR LH (4WD) 320WP-03 REPLACEMENT HINT:

1. 2. Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. REMOVE DECK TRIM SIDE PANEL ASSY LH (SEE PAGE 76-21 ) REMOVE REAR WHEEL 3. REMOVE SPEED SENSOR REAR LH (a) Disconnect the speed sensor connector. NOTICE: Be careful not to damage the wire harness. C95580 (b) (b) Pull out the sensor wire harness with the grommet. NOTICE: Do not pull sensor wire. (c) Remove the 2 bolts holding the sensor harness from the body and the shock absorber assy. (c) (c) G23207 (d) Remove the bolt and the speed sensor rear. NOTICE: Prevent foreign matter from attaching to the sensor tip. G23208 4. (a) INSTALL SPEED SENSOR REAR LH Install the speed sensor rear with the bolt. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) NOTICE: Prevent foreign matter from attaching to the sensor tip. G23208 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3157 32-45 BRAKE - SPEED SENSOR REAR LH (4WD) (b) G23207 Install the sensor harness clamps with the 2 bolts to the body and the shock absorber assy. Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) NOTICE: Do not twist the sensor wire when installing the sensor. (c) Push in the sensor wire harness with grommet. NOTICE: When grommet is set to body, pull the grommet. Do not pull sensor wire. (d) Connect the speed sensor connector. C95580 5. 6. 7. INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSTALL DECK TRIM SIDE PANEL ASSY LH CHECK ABS SPEED SENSOR SIGNAL (SEE PAGE 05-765 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3158 32-46 BRAKE - YAWRATE SENSOR YAWRATE SENSOR 320WQ-03 REPLACEMENT NOTICE:
Do not use the yawrate sensor if it is dropped or damaged.
Prevent foreign matter from attaching between the yawrate sensor bracket and body.
Confirm the sensor direction is correct. 1. REMOVE FRONT SEAT ASSEMBLY RH (SEE PAGE 72-1 1 or 72-19 ) 2. REMOVE FRONT DOOR SCUFF PLATE RH (SEE PAGE 76-21 ) 3. REMOVE REAR DOOR SCUFF PLATE RH (SEE PAGE 76-21 ) 4. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH (SEE PAGE 76-21 ) 5. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH (SEE PAGE 76-21 ) 6. REMOVE CENTER PILLAR GARNISH LOWER RH (SEE PAGE 76-21 ) 7. (a) REMOVE YAWRATE SENSOR PROTECTOR Remove the bolt and the sensor protector. G23199 8. REMOVE YAWRATE SENSOR (a) Disconnect the connector. (b) Remove the 2 bolts and the yawrate sensor. NOTICE: Do not remove the yawrate sensor from the yawrate sensor bracket. G23200 9. (a) (b) INSTALL YAWRATE SENSOR Install the yawrate sensor with the 2 bolts. Torque: 14 N⋅m (143 kgf⋅cm, 10 ft.⋅lbf) Connect the connector. G23200 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3159 32-47 BRAKE 10. (a) - YAWRATE SENSOR INSTALL YAWRATE SENSOR PROTECTOR Install the sensor protector with the bolt. Torque: 14 N⋅m (143 kgf⋅cm, 10 ft.⋅lbf) G23199 11. 12. 13. 14. 15. 16. 17. 18. INSTALL CENTER PILLAR GARNISH LOWER RH INSTALL REAR DOOR OPENING TRIM WEATHERSTRIP RH INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH INSTALL REAR DOOR SCUFF PLATE RH INSTALL FRONT DOOR SCUFF PLATE RH INSTALL FRONT SEAT ASSEMBLY RH (SEE PAGE 72-1 1 or 72-19 ) PERFORM YAWRATE SENSOR ZERO POINT CALIBRATION (SEE PAGE 05-765 ) CHECK IN THE TEST MODE (SEE PAGE 05-765 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3160 32-48 BRAKE - STEERING SENSOR STEERING SENSOR 320WR-05 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. PRECAUTION (SEE PAGE 60-1 ) DISCONNECT BATTERY NEGATIVE TERMINAL PLACE FRONT WHEELS FACING STRAIGHT AHEAD REMOVE HORN BUTTON ASSY (SEE PAGE 60-17 ) REMOVE STEERING WHEEL ASSY (SEE PAGE 50-8 ) SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021) REMOVE STEERING COLUMN COVER UPR (SEE PAGE 50-8 ) REMOVE SPIRAL CABLE SUB-ASSY (SEE PAGE 60-26 ) 8. (a) Claw Claw F45898 9. INSTALL STEERING SENSOR (a) Install the steering sensor to the spiral cable. NOTICE:
Install the claw securely.
Do not damage the claw. Claw Claw 10. 11. 12. 13. 14. 15. 16. 17. 18. REMOVE STEERING SENSOR Release 6 claw fittings and remove the steering sensor from the spiral cable. F45898 ADJUST CENTER FRONT WHEEL INSTALL SPIRAL CABLE SUB-ASSY (SEE PAGE 60-26 ) CENTER SPIRAL CABLE (SEE PAGE 60-26 ) INSTALL STEERING WHEEL ASSY (SEE PAGE 50-8 ) INSTALL HORN BUTTON ASSY (SEE PAGE 60-17 ) INSPECT STEERING WHEEL CENTER POINT INSPECT HORN BUTTON ASSY (SEE PAGE 60-1 1) CONNECT BATTERY NEGATIVE TERMINAL INSPECT SRS WARNING LIGHT (SEE PAGE 05-1207 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3161 33-2 PARKING BRAKE - PARKING BRAKE SYSTEM 330CI-04 ADJUSTMENT 1. 2. 3. 4. (a) (b) (c) REMOVE REAR WHEEL ADJUST PARKING BRAKE SHOE CLEARANCE (SEE PAGE 33-19 ) INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT PARKING BRAKE PEDAL TRAVEL Strongly step on the parking brake pedal. Release the parking brake. Once more, slowly depress the parking brake pedal all the way, and count the number of clicks. Parking brake pedal travel: 5 to 7 clicks at 300 N (31 kgf, 67.46 lbf) 5. (a) (b) (c) Lock Nut (d) (e) Parking Brake Adjusting Nut (f) G24942 (g) (h) (i) ADJUST PARKING BRAKE PEDAL TRAVEL Remove the instrument panel finish panel sub-assy lower.(see page 71-10 ) Remove the instrument PNL insert sub- assy LWR LH.(see page 71-10 ) Depress the parking brake pedal 5 clicks to make room for the procedure, and loosen the lock nut with fixing adjusting nut by wrench. Release the parking brake pedal to the original position. Turn the paking brake wire adjusting nut until the parking brake pedal travel is correct. Using a spanner or equivalent to hold the parking brake adjusting nut, tighten the lock nut. Torque: 6.0 N⋅m (61 kgf⋅cm, 53 in.⋅lbf) Count the number of clicks after depressing and canceling the parking brake pedal 3 to 4 times. Check whether the parking brake drags or not. When operating the parking brake pedal, check that the parking brake pedal indicator light is lit. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3163 33-1 PARKING BRAKE - PARKING BRAKE SYSTEM PARKING BRAKE SYSTEM 330CH-04 PROBLEM SYMPTOMS TABLE Use the table below to help find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Suspect Area See page 1. Parking brake pedal travel (Out of adjustment) 2. Parking brake wire (Sticking) Brake drag 3. Parking brake shoe clearance (Out of adjustment) 4. Parking brake shoe lining (Cracked or distorted) 5. Tension or return spring (Damaged) 33-2 33-10 33-14 33-19 33-19 33-19 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3162 33-3 PARKING BRAKE - PARKING BRAKE CONTROL PEDAL ASSY PARKING BRAKE CONTROL PEDAL ASSY 330CL-04 COMPONENTS Parking Brake Pedal Assy 39 (400, 29) Parking Brake Switch Assy Clip 39 (400, 29) Parking Brake Wire Adjusting Nut No.1 39 (400, 29) Parking Pedal Pad 6.0 (61, 53 in.⋅lbf) Lock Nut Parking Brake Cable Assy No.1 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque F46471 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3164 33-4 PARKING BRAKE - PARKING BRAKE CONTROL PEDAL ASSY 6.0 (61, 53 in.⋅lbf) 8.5 (87, 75 in.⋅lbf) FR Floor Footrest Parking Brake Equalizer Parking Brake Cable Assy No.1 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque F45547 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3165 33-5 PARKING BRAKE - PARKING BRAKE CONTROL PEDAL ASSY 330FC-01 OVERHAUL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. (a) PRECAUTION (W/ SIDE AIRBAG) (SEE PAGE 60-1 ) DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60-1 ) REMOVE INSTRUMENT PANEL FINISH PANEL SUB-ASSY LOWER (SEE PAGE 71-10 ) REMOVE INSTRUMENT PNL INSERT SUB-ASSY LWR LH (SEE PAGE 71-10 ) REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSY CENTER (SEE PAGE 71-10 ) REMOVE FLOOR CARPET COVER CENTER RH (SEE PAGE 71-10 ) REMOVE FLOOR CARPET COVER CENTER LH (SEE PAGE 71-10 ) REMOVE FRONT SEAT ASSEMBLY RH REMOVE FRONT SEAT ASSEMBLY LH (SEE PAGE 72-1 1, 72-19 ) REMOVE CONSOLE BOX ASSY (SEE PAGE 71-10 ) DISCONNECT TURN SIGNAL FLASHER ASSY REMOVE FR FLOOR FOOTREST Remove the front floor footrest from the floor. 13. (a) (b) (c) (d) (e) REMOVE PARKING BRAKE CONTROL PEDAL ASSY Disconnect the connectors. Remove the 2 nuts. Separate the instrument panel junction block assy. Release the parking brake pedal to the original position. Remove the 2 bolts and nuts, and separate the parking brake cable assy No.1 from the floor. F46488 Nut Nut Bolt F46472 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3166 33-6 PARKING BRAKE (f) (g) (h) (i) - PARKING BRAKE CONTROL PEDAL ASSY Remove the parking brake cable assy No.1 from the parking brake equalizer. Disconnect the parking brake switch connector. Remove the 3 nuts and separate the instrument panel junction block assy w/ bracket from the body. Remove the 3 nuts and parking brake control pedal assy. F46473 14. 15. (a) 16. (a) 17. (a) 18. (a) 19. REMOVE PARKING BRAKE CABLE ASSY NO.1 (SEE PAGE 33-10 ) REMOVE PARKING BRAKE SWITCH ASSY Remove the screw and parking brake switch assy. REMOVE PARKING PEDAL PAD Remove the parking pedal pad. INSTALL PARKING PEDAL PAD Install the parking pedal pad. INSTALL PARKING BRAKE SWITCH ASSY Install the parking brake switch assy with the screw. INSTALL PARKING BRAKE CABLE ASSY NO.1 (SEE PAGE 33-10 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3167 33-7 PARKING BRAKE 20. (a) (b) (c) (d) (e) - PARKING BRAKE CONTROL PEDAL ASSY INSTALL PARKING BRAKE CONTROL PEDAL ASSY Install the parking brake control pedal assy with the 3 nuts. Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) Connect the parking brake switch connector. Connect the instrument panel junction block assy w/ bracket with the 3 nuts. Attach the parking brake cable assy No.1 to the parking brake equalizer and slide boot stopper of No.1 cable should be inserted into groove of T-Metal fitting. Install the parking brake cable assy No.1 with the 2 bolts and 2 nuts. Torque: Bolt: 8.5 N⋅m (87 kgf⋅cm, 75 in.⋅lbf) Nut: 6.0 N⋅m (61 kgf⋅cm, 53 in.⋅lbf) F46473 Slide Boot Nut Nut Bolt F46472 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3168 33-8 PARKING BRAKE - PARKING BRAKE CONTROL PEDAL ASSY (f) Install the instrument panel junction block assy with the 2 nuts. Torque: 7.3 N⋅m (74 kgf⋅cm, 65 in.⋅lbf) (g) Connect the connectors. F46488 21. (a) 22. 23. 24. 25. 26. 27. 28. 29. 30. INSTALL FR FLOOR FOOTREST Install the front floor footrest on the floor. INSTALL FRONT SEAT ASSEMBLY RH INSTALL FRONT SEAT ASSEMBLY LH (SEE PAGE 72-1 1, 72-19 ) REMOVE REAR WHEEL ADJUST PARKING BRAKE SHOE CLEARANCE (SEE PAGE 33-19 ) INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT PARKING BRAKE PEDAL TRAVEL (SEE PAGE 33-2 ) ADJUST PARKING BRAKE PEDAL TRAVEL (SEE PAGE 33-2 ) CONNECT BATTERY NEGATIVE TERMINAL INSPECT SRS WARNING LIGHT (W/ SIDE AIRBAG) (SEE PAGE 05-1207 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3169 33-9 PARKING BRAKE - PARKING BRAKE CABLE ASSY NO.1 PARKING BRAKE CABLE ASSY NO.1 330CN-04 COMPONENTS Parking Brake Pedal Assy 39 (400, 29) Clip 39 (400, 29) Parking Brake Wire Adjusting Nut No.1 Lock Nut 6.0 (61, 53 in.⋅lbf) 39 (400, 29) 6.0 (61, 53 in.⋅lbf) 8.5 (87, 75 in.⋅lbf) FR Floor Footrest Parking Brake Equalizer Parking Brake Cable Assy No.1 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque F46475 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3170 33-10 PARKING BRAKE - PARKING BRAKE CABLE ASSY NO.1 330CO-03 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. PRECAUTION (W/ SIDE AIRBAG) (SEE PAGE 60-1 ) DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60-1 ) REMOVE INSTRUMENT PANEL FINISH PANEL SUB-ASSY LOWER (SEE PAGE 71-10 ) REMOVE INSTRUMENT PNL INSERT SUB-ASSY LWR LH (SEE PAGE 71-10 ) REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSY CENTER (SEE PAGE 71-10 ) REMOVE FLOOR CARPET COVER CENTER RH (SEE PAGE 71-10 ) REMOVE FLOOR CARPET COVER CENTER LH (SEE PAGE 71-10 ) REMOVE FRONT SEAT ASSEMBLY RH REMOVE FRONT SEAT ASSEMBLY LH (SEE PAGE 72-1 1, 72-19 ) REMOVE CONSOLE BOX ASSY (SEE PAGE 71-10 ) REMOVE FR FLOOR FOOTREST (SEE PAGE 33-5 ) REMOVE PARKING BRAKE CONTROL PEDAL ASSY (SEE PAGE 33-5 ) 13. REMOVE PARKING BRAKE CABLE ASSY NO.1 (a) Using a screwdriver, disengage the claw. NOTICE: Be careful not to damage the parking brake cable assy No.1. G24943 Parking Brake Wire Adjusting Nut No.1 (b) (c) Remove the clip from the parking brake pedal assy. Remove the lock nut and parking brake wire adjusting nut No.1. 14. (a) (b) INSTALL PARKING BRAKE CABLE ASSY NO.1 Install the parking brake cable assy No.1 with the clip. Temporarily install the parking brake wire adjusting nut No.1 and lock nut. Clip Lock Nut G24944 Parking Brake Wire Adjusting Nut No.1 Clip Lock Nut G24944 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3171 33-1 1 PARKING BRAKE - PARKING BRAKE CABLE ASSY NO.1 (c) Bend the claw. NOTICE: Bend the claw fully. G24943 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. INSTALL PARKING BRAKE CONTROL PEDAL ASSY (SEE PAGE 33-5 ) INSTALL FR FLOOR FOOTREST (SEE PAGE 33-5 ) INSTALL FRONT SEAT ASSEMBLY RH INSTALL FRONT SEAT ASSEMBLY LH (SEE PAGE 72-1 1, 72-19 ) REMOVE REAR WHEEL ADJUST PARKING BRAKE SHOE CLEARANCE (SEE PAGE 33-19 ) INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT PARKING BRAKE PEDAL TRAVEL (SEE PAGE 33-2 ) ADJUST PARKING BRAKE PEDAL TRAVEL (SEE PAGE 33-2 ) CONNECT BATTERY NEGATIVE TERMINAL INSPECT SRS WARNING LIGHT (W/ SIDE AIRBAG) (SEE PAGE 05-1207 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3172 33-12 PARKING BRAKE - PARKING BRAKE CABLE ASSY NO.3 PARKING BRAKE CABLE ASSY NO.3 330CP-04 COMPONENTS FF: 8.0 (82, 71 in.⋅lbf) Parking Brake Cable Assy No.2 6.0 (61, 53 in.⋅lbf) Parking Brake Cable Assy No.3 Parking Brake Cable Support Bracket 6.0 (61, 53 in.⋅lbf) 39 (400, 29) Parking Brake Cable Support Bracket 6.0 (61, 53 in.⋅lbf) 6.0 (61, 53 in.⋅lbf) 6.0 (61, 53 in.⋅lbf) 39 (400, 29) 8.0 (82, 71 in.⋅lbf) 8.5 (87, 75 in.⋅lbf) Parking Brake Cable Support Bracket No.1 Parking Brake Equalizer 6.0 (61, 53 in.⋅lbf) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque G24937 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3173 33-13 PARKING BRAKE - PARKING BRAKE CABLE ASSY NO.3 4WD: Rear Axle Hub & Bearing Assy RH 75 (765, 55)
Rear Axle Shaft Nut 294 (3,000, 217) Parking Brake Hole RH 75 (765, 55) 8.0 (82, 71 in.⋅lbf) 6.0 (61, 53 in.⋅lbf) 8.0 (82, 71 in.⋅lbf) Speed Sensor RR RH Parking Brake Cable Assy No.2 Parking Brake Cable Assy No.3 6.0 (61, 53 in.⋅lbf) 6.0 (61, 53 in.⋅lbf) 39 (400, 29) Parking Brake Cable Support Bracket Parking Brake Cable Support Bracket 6.0 (61, 53 in.⋅lbf) 6.0 (61, 53 in.⋅lbf) 39 (400, 29) Parking Brake Cable Support Bracket No.1 8.5 (87, 75 in.⋅lbf) Parking Brake Equalizer 6.0 (61, 53 in.⋅lbf) Rear Axle Hub & Bearing Assy LH Speed Sensor RR LH
Rear Axle Shaft Nut 294 (3,000, 217) 75 (765, 55) 8.0 (82, 71 in.⋅lbf) Parking Brake Hole LH N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part 8.0 (82, 71 in.⋅lbf) 75 (765, 55) G24939 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3174 33-14 PARKING BRAKE - PARKING BRAKE CABLE ASSY NO.3 330CQ-04 REPLACEMENT HINT: For parking brake cable No.2, employ the same procedure to the No.3 side. 1. REMOVE REAR WHEEL 2. SEPARATE REAR DISC BRAKE CALIPER ASSY LH (a) Remove the 2 bolts and separate the rear disc brake caliper assy LH. HINT: Do not disconnect the flexible hose from the rear brake caliper assy LH. 3. REMOVE REAR DISC (SEE PAGE 33-19 ) 4. REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING (SEE PAGE 33-19 ) 5. REMOVE PARKING BRAKE SHOE STRUT LH (SEE PAGE 33-19 ) 6. REMOVE PARKING BRAKE SHOE ASSY LH NO.1 (SEE PAGE 33-19 ) 7. REMOVE PARKING BRAKE SHOE ADJUSTING SCREW SET (SEE PAGE 33-19 ) 8. REMOVE PARKING BRAKE SHOE ASSY LH NO.2 (SEE PAGE 33-19 ) 9. SEPARATE SPEED SENSOR REAR LH (4WD DRIVE TYPE) (SEE PAGE 30-60 ) 10. REMOVE REAR AXLE SHAFT LH NUT (4WD DRIVE TYPE) (SEE PAGE 30-60 ) 11. REMOVE REAR AXLE HUB & BEARING ASSY LH (4WD DRIVE TYPE) (SEE PAGE 30-60 ) 12. (a) FF: REMOVE PARKING BRAKE CABLE ASSY NO.3 Remove the 2 bolts and separate the parking brake cable assy No.3 from the backing plate. 4WD: F45450 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3175 33-15 PARKING BRAKE (b) (c) (d) - PARKING BRAKE CABLE ASSY NO.3 Remove the 4 nuts and 2 bolts and separate the parking brake cable assy No.3 from the body. Separate the parking brake cable assy No.3 from the equalizer and remove the parking brake cable assy No.3. Remove the parking brake cable support bracket No.1 from the parking brake cable assy No.3. Bolt A Nut Nut Bolt B Parking Brake Cable Support Bracket No.1 Nut G24918 13. (a) (b) (c) INSTALL PARKING BRAKE CABLE ASSY NO.3 Attach the parking brake cable support bracket No.1 to the parking brake cable assy No.3. Connect the parking brake cable assy No.3 to the equalizer and slide boot stopper of No.1 cable should be inserted into groove of T-Metal fitting. Install the 4 nuts, 2 bolts and parking brake cable assy No.3 to the body. Torque: Bolt A: 8.5 N⋅m (87 kgf⋅cm, 75 in.⋅lbf) Bolt B: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) Nut: 6.0 N⋅m (61 kgf⋅cm, 53 in.⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3176 33-16 PARKING BRAKE (d) FF: - PARKING BRAKE CABLE ASSY NO.3 Connect the parking brake cable assy No.3 to the backing plate with the 2 bolts. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 4WD: F45450 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. (a) 27. 28. (a) 29. 30. 31. 32. APPLY HIGH TEMPERATURE GREASE (SEE PAGE 33-19 ) INSTALL REAR AXLE HUB & BEARING ASSY LH (4WD DRIVE TYPE) (SEE PAGE 30-60 ) INSTALL REAR AXLE SHAFT LH NUT (4WD DRIVE TYPE) (SEE PAGE 30-60 ) INSTALL SPEED SENSOR REAR LH (4WD DRIVE TYPE) (SEE PAGE 30-60 ) INSTALL PARKING BRAKE SHOE ASSY LH NO.2 (SEE PAGE 33-19 ) INSTALL PARKING BRAKE SHOE ADJUSTING SCREW SET (SEE PAGE 33-19 ) INSTALL PARKING BRAKE SHOE ASSY LH NO.1 (SEE PAGE 33-19 ) INSTALL PARKING BRAKE SHOE STRUT LH (SEE PAGE 33-19 ) INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING (SEE PAGE 33-19 ) CHECK PARKING BRAKE INSTALLATION (SEE PAGE 33-19 ) INSPECT BEARING BACKLASH (4WD DRIVE TYPE) (SEE PAGE 30-3 ) INSPECT AXLE HUB DEVIATION (4WD DRIVE TYPE) (SEE PAGE 30-3 ) INSTALL REAR DISC Aligning the matchmarks, install the rear disc. ADJUST PARKING BRAKE SHOE CLEARANCE (SEE PAGE 33-19 ) CONNECT REAR DISC BRAKE CALIPER ASSY LH Install the rear disc brake caliper assy LH with the 2 bolts. Torque: 78 N⋅m (800 kgf⋅cm, 58 ft⋅lbf) INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT PARKING BRAKE PEDAL TRAVEL (SEE PAGE 33-2 ) ADJUST PARKING BRAKE PEDAL TRAVEL (SEE PAGE 33-2 ) CHECK ABS SPEED SENSOR SIGNAL (4WD DRIVE TYPE) (SEE PAGE 05-765 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3177 33-17 PARKING BRAKE - PARKING BRAKE ASSY PARKING BRAKE ASSY 330CR-03 COMPONENTS FF: Parking Brake Shoe Strut LH Rear Disc Brake Caliper Assy LH Parking Brake Shoe Strut Compression Spring Parking Brake Shoe Assy LH No.2 78 (800, 58) Parking Brake Shoe Hold Down Spring Pin No.2 Parking Brake Shoe Hold Down Spring Cup No.2 Parking Brake Shoe Return Tension Spring No.1 Shim Parking Brake Shoe Hold Down Spring
C-W asher Parking Brake Shoe Lever Parking Brake Shoe Hold Down Spring Cup No.1 Parking Brake Shoe Hold Down Spring Pin No.1 Parking Brake Shoe Assy LH No.1 Parking Brake Shoe Adjusting Screw Set Parking Brake Shoe Return Tension Spring No.2 Parking Brake Shoe Hold Down Spring Cup No.2 Parking Brake Shoe Hold Down Spring Parking Brake Shoe Hold Down Spring Cup No.1 Rear Disc Parking Brake Shoe Adjusting Hole Plug N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part High Temperature grease F47274 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3178 33-18 PARKING BRAKE - PARKING BRAKE ASSY 4WD: Speed Sensor RR LH Rear Disc Brake Caliper Assy LH 78 (800, 58) 8.0 (82, 71 in.⋅lbf) Parking Brake Shoe Strut Compression Spring 78 (800, 58) Parking Brake Shoe Strut LH Parking Brake Shoe Hold Down Spring Pin No.2 Parking Brake Shoe Assy LH No.2 Parking Brake Shoe Return Tension Spring No.1
C-W asher Parking Brake Shoe Hold Down Spring Cup No.2 Shim Parking Brake Shoe Lever Parking Brake Shoe Hold Down Spring Parking Brake Shoe Hold Down Spring Cup No.1 Parking Brake Shoe Hold Down Spring Pin No.1 75 (765, 55) Parking Brake Shoe Assy LH No.1
Rear Axle Shaft Nut 294 (3,000, 217) Parking Brake Shoe ReturnTension Spring No.2 Parking Brake Shoe Adjusting Screw Set 75 (765, 55) Parking Brake Shoe Hold Down Spring Cup No.2 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part High Temperature grease Parking Brake Shoe Hold Down Spring Rear Disc Rear Axle Hub & Bearing Assy LH Parking Brake Shoe Adjusting Hole Plug F47275 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3179 33-19 PARKING BRAKE - PARKING BRAKE ASSY 330CS-04 OVERHAUL HINT:

Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. REMOVE REAR WHEEL SEPARATE REAR DISC BRAKE CALIPER ASSY LH Remove the 2 bolts and separate the rear disc brake caliper assy LH. 1. 2. (a) HINT: Do not disconnect the flexible hose from the disc brake caliper assy LH. 3. REMOVE REAR DISC (a) Release the parking brake, and remove the rear disc. HINT: If the disc cannot be removed easily, turn the shoe adjuster until the wheel turns freely. Contract D28126 (b) (c) Machmarks Place machmarks on the rear disc and the axle hub. Remove the rear disc. F41543 4. (a) INSPECT BRAKE DISC INSIDE DIAMETER Using a brake drum gauge or equivalent tool, measure the inside diameter of the rear disc. Standard inside diameter: 190 mm (7.480 in.) Maximum inside diameter: 191 mm (7.520 in.) If the inside diameter exceeds the maximum, replace the brake disc. F06409 5. (a) REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING Using needle-nose pliers, remove the 2 parking brake shoe return tension springs No.1. D28127 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3180 33-20 PARKING BRAKE 6. (a) - PARKING BRAKE ASSY REMOVE PARKING BRAKE SHOE STRUT LH Remove the parking brake shoe strut LH and the parking brake shoe strut compression spring. 7. (a) (b) (c) G25968 8. Adjusting Screw Set (a) (b) REMOVE PARKING BRAKE SHOE ASSY LH NO.1 Remove the parking brake shoe hold down spring cup No.1, parking brake shoe hold down spring and parking brake shoe hold down spring cup No.2. FF: Remove the parking brake shoe hold down spring pin No.1. Disconnect the parking brake shoe return spring No.2 and remove the parking brake shoe assy LH No.1. REMOVE PARKING BRAKE SHOE ADJUSTING SCREW SET Remove the parking brake shoe adjusting screw set. Remove the parking brake shoe return tension spring No.2. Return tension Spring F45549 9. (a) (b) REMOVE PARKING BRAKE SHOE ASSY LH NO.2 Remove the parking brake shoe hold down spring cup No.1, parking brake shoe hold down spring, parking brake shoe hold down spring cup No.2 and parking brake shoe hold down spring pin No.2. Remove the parking brake shoe assy LH No.2. G25969 (c) Using needle-nose pliers, disconnect the parking brake cable No.3 from the parking brake cable shoe lever. NOTICE: Be careful not to damage parking brake cable No.3. R00310 10. 11. 12. SEPARATE SPEED SENSOR REAR LH (4WD DRIVE TYPE) (SEE PAGE 30-60 ) REMOVE REAR AXLE SHAFT LH NUT (4WD DRIVE TYPE) (SEE PAGE 30-60 ) SST 09930-00010 REMOVE REAR AXLE HUB & BEARING ASSY LH (4WD DRIVE TYPE) (SEE PAGE 30-60 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3181 33-21 PARKING BRAKE 13. (a) - PARKING BRAKE ASSY REMOVE PARKING BRAKE SHOE HOLD DOWN SPRING PIN (4WD DRIVE TYPE) Remove the parking brake shoe hold down spring pin No.1. G24920 14. (a) (b) REMOVE PARKING BRAKE SHOE TYPE C WASHER Using a screwdriver, remove the C-washer. Remove the shim and parking brake shoe lever from parking brake shoe assy LH No.2. F41058 15. INSPECT PARKING BRAKE SHOE LINING THICKNESS (a) Using a ruler, measure the thickness of the shoe lining. Standard thickness: 2.5 mm (0.098 in.) Minimum thickness: 1.0 mm (0.039 in.) If the lining thickness is less than or equal to the minimum, or if there is severe or uneven wear, replace the brake shoe. R00311 16. INSPECT BRAKE DISC AND PARKING BRAKE SHOE LINING FOR PROPER CONTACT (a) Apply chalk to the inside surface of the disc, then grind down the brake shoe lining to fit disc. If the contact between the brake disc and the shoe lining is improper, repair it using a brake shoe grinder or replace the brake shoe assembly. BR0828 17. (a) INSTALL PARKING BRAKE SHOE TYPE C WASHER Using a feeler gauge, measure the clearance. Standard clearance: Less than 0.35 mm (0.014 in.) If the clearance is not within the specifications, replace the shim with one of the correct size. Shim Thickness Shim Thickness 0.3 mm (0.012 in.) 0.9 mm (0.035 in.) 0.6 mm (0.024 in.) - R00343 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3182 33-22 PARKING BRAKE - PARKING BRAKE ASSY (b) Using pliers, install the parking brake shoe lever LH and the shim with a new C-washer. 18. (a) APPLY HIGH TEMPERATURE GREASE Apply high temperature grease to the shaded parts shown in the illustration of the backing plate which make contact with the shoe. 19. INSTALL PARKING BRAKE SHOE HOLD DOWN SPRING PIN (4WD DRIVE TYPE) Install the parking brake shoe hold down spring pin No.1. C64144 High Temperature Grease C97930 (a) G24920 20. 21. 22. INSTALL REAR AXLE HUB & BEARING ASSY LH (4WD DRIVE TYPE) (SEE PAGE 30-60 ) INSTALL REAR AXLE SHAFT LH NUT (4WD DRIVE TYPE) (SEE PAGE 30-60 ) INSTALL SPEED SENSOR REAR LH (4WD DRIVE TYPE) (SEE PAGE 30-60 ) 23. (a) INSTALL PARKING BRAKE SHOE ASSY LH NO.2 Using needle-nose pliers, connect the parking brake cable No.3 to the parking brake cable shoe lever. NOTICE: Be careful not to damage the parking brake cable No.3. R00310 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3183 33-23 PARKING BRAKE - PARKING BRAKE ASSY (b) Install the parking brake shoe assy LH No.2 with the parking brake shoe hold down spring, parking brake shoe hold down spring cup No.1, parking brake shoe hold down spring cup No.2 and parking brake shoe hold down spring pin No.2. 24. INSTALL PARKING BRAKE SHOE ADJUSTING SCREW SET Apply high temperature grease to the parking brake shoe adjusting bolt and piece. G25969 (a) Piece Adjusting Bolt High Temperature Grease F41705 (b) Adjusting Screw Set Return tension Spring (c) Adjusting Screw Set Attach the parking brake shoe return tension spring No.2 to parking brake shoe assy LH No.1 and parking brake shoe assy LH No.2. Attach the parking brake shoe adjusting screw set to the parking brake shoe assy LH No.1 and parking brake shoe assy LH No.2. F45550 25. (a) (b) INSTALL PARKING BRAKE SHOE ASSY LH NO.1 FF: Install the parking brake shoe hold down spring pin No.1. Install the parking brake shoe assy LH No.1 with the parking brake shoe hold down spring, parking brake shoe hold down spring cup No.2, parking brake shoe hold down spring cup No.2. G25968 26. (a) INSTALL PARKING BRAKE SHOE STRUT LH Attach the parking brake shoe strut LH and the parking brake shoe strut compression spring to parking brake shoe assy LH No.2 and parking brake shoe assy LH No.1. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3184 33-24 PARKING BRAKE 27. (a) - PARKING BRAKE ASSY INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING Using needle-nose pliers, install the 2 return tension springs No.1 as shown in the illustration. HINT: First install the front side spring then the rear side spring. D28127 28. CHECK PARKING BRAKE INSTALLATION (a) Check that each part is installed properly. NOTICE: There should be no oil or grease on the friction surface of the shoe lining and disc. RH Front C88601 29. 30. 31. (a) LH Front F45453 INSPECT BEARING BACKLASH (4WD DRIVE TYPE) (SEE PAGE 30-3 ) INSPECT AXLE HUB DEVIATION (4WD DRIVE TYPE) (SEE PAGE 30-3 ) INSTALL REAR DISC Aligning the matchmarks, install the rear disc. 32. (a) (b) Expand (c) (d) (e) Contract ADJUST PARKING BRAKE SHOE CLEARANCE Temporarily install the hub nuts. Remove the hole plug, turn the adjuster and expand the shoes until the disc locks. Contract the shoe adjuster until the disc rotates smoothly. Standard : Return 8 notches Check that the shoe has no brake drag. Install the hole plug. F45452 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3185 33-25 PARKING BRAKE 33. (a) 34. 35. 36. 37. - PARKING BRAKE ASSY CONNECT REAR DISC BRAKE CALIPER ASSY LH Install the rear disc brake caliper assy LH with the 2 bolts. Torque: 78 N⋅m (800 kgf⋅cm, 58 ft⋅lbf) INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT PARKING BRAKE PEDAL TRAVEL (SEE PAGE 33-2 ) ADJUST PARKING BRAKE PEDAL TRAVEL (SEE PAGE 33-2 ) CHECK ABS SPEED SENSOR SIGNAL (4WD DRIVE TYPE) (SEE PAGE 05-765 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3186 32-4 BRAKE - BRAKE FLUID BRAKE FLUID 320WC-05 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. Brake Fluid FILL RESERVOIR WITH BRAKE FLUID Fluid: SAE J1703 or FMVSS No. 116 DOT3 F46187 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. F46188 (c) (d) (e) Cover the outer holes with your fingers, and release the brake pedal. Repeat (b) and (c) 3 or 4 times. Using SST, connect the brake lines from the master cylinder. SST 09023-00101 Torque: 15 N⋅m (155 kgf⋅cm, 11 ft⋅lbf) F46189 3. (a) (b) (c) (d) C80826 (e) BLEED BRAKE LINE Connect the vinyl tube to the bleeder plug. Depress the brake pedal several times, then loosen the bleeder plug with the pedal depressed. At the point when fluid stops coming out, tighten the bleeder plug, then release the brake pedal. Repeat (b) and (c) until all the air in the fluid is completely bled out. Tighten the bleeder plug completely. Torque: 8.3 N⋅m (85 kgf⋅cm, 73 in.⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3117 32-5 BRAKE - BRAKE FLUID (f) Hand-held Tester DLC3 G23361 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 engine 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 ”AIR BLEEDING” on the hand-held tester. HINT: Please refer to the hand-held tester operator’s manual for further details. (d) Bleed the air out of the regular brake line when ”Step 1: Increase” 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) C80826 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 completely bled out. (5) Tighten the bleeder plug completely. Torque: 8.3 N⋅m (85 kgf⋅cm, 73 in.⋅lbf) (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 ”Step 2: Inhalation” 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. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3118 32-6 BRAKE (1) (2) F47332 F47333 BRAKE FLUID Connect the vinyl tube to the bleeder plug at the right front wheel or the right rear wheel and loosen the bleeder plug. Operate the brake actuator assy to bleed the air using 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 completely bled out. (5) Tighten the bleeder plug completely. Torque: 8.3 N⋅m (85 kgf⋅cm, 73 in.⋅lbf) (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 ”Step 3: Decrease” 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) Hold - Using the hand-held tester, operate the brake actuator 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. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3119 32-7 BRAKE - BRAKE FLUID (4) Release F47334 Tighten the bleeder plug, then release the brake pedal. (5) Repeat (2) to (4) until all the air in the fluid is completely bled out. (6) Tighten the bleeder plug completely. Torque: 8.3 N⋅m (85 kgf⋅cm, 73 in.⋅lbf) (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 ”Step 4: Increase” 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) C80826 5. (a) 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 completely bled out. (5) Tighten the bleeder plug completely. Torque: 8.3 N⋅m (85 kgf⋅cm, 73 in.⋅lbf) (6) Repeat the above procedures for each wheel to bleed the air out of the brake line. CHECK FLUID LEVEL IN RESERVOIR Check the fluid level and add fluid if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT3 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3120 32-14 BRAKE - BRAKE MASTER W/PLATE CYLINDER SUB-ASSY BRAKE MASTER W/PLATE CYLINDER SUB-ASSY 320WF-05 REPLACEMENT HINT: COMPONENTS: See page 32-18 . 1. (a) REMOVE FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER Remove the 4 nuts and the front suspension brace subassy upper center. F46629 2. 3. 4. REMOVE AIR CLEANER ASSY (2AZ-FE ENGINE TYPE) (SEE PAGE 14-24 ) REMOVE AIR CLEANER CAP SUB-ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 ) REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 ) 5. REMOVE AIR CLEANER CASE (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 ) 6. DRAIN BRAKE FLUID NOTICE: Wash brake fluid off immediately if it adheres to any painted surface. 7. (a) (b) REMOVE BRAKE MASTER W/PLATE CYLINDER SUB-ASSY Using SST, disconnect the 2 brake tubes from the brake master w/plate cylinder sub-assy. SST 09023-00101 Disconnect the brake fluid level warning switch connector. F46630 (c) Remove the 2 nuts, then pull at the check valve bracket and the brake master w/plate cylinder assy. F46631 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3127 32-15 BRAKE - BRAKE MASTER W/PLATE CYLINDER SUB-ASSY 8. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD NOTICE: Make an adjustment with the brake booster assy having no vacuum. (Depress the brake pedal several times with the engine stopped.) HINT: Adjustment of the brake booster push rod is performed when the brake master cylinder sub-assy is replaced with a new one. The adjustment is not necessary when the brake master cylinder sub-assy is reinstalled and the brake booster assy is replaced with a new one. (a) Apply the chalk to the tip of an accessory tool. HINT: An accessory tool is enclosed with a new brake master cylinder sub-assy . (b) (c) Accessory Tool F47053 HINT: Adjust the clearance in following cases:
If there is a clearance between the accessory tool and the shell of the brake booster (floating accessory tool), the push rod is protruding too far.
If the chalk does not stick on the tip of the brake booster push rod, the push rod protrusion is insufficient. (d) SST Place the accessory tool to the brake booster assy. Measure the clearance between the brake booster push rod and accessory tool. Clearance: 0 mm (0 in.) If clearance is outside the specified range, fix the push rod using SST and adjust the length of the protruding adjusting bolt. SST 09737-00020 HINT: When adjusting the push rod, depress the brake pedal sufficiently so that the push rod sticks out. F40006 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3128 32-16 BRAKE 9. (a) - BRAKE MASTER W/PLATE CYLINDER SUB-ASSY INSTALL BRAKE MASTER W/PLATE CYLINDER SUB-ASSY Install the brake master w/ plate cylinder sub-assy and the check valve bracket with the 2 nuts. Torque: 13 N⋅m (130 kgf⋅cm, 9 ft⋅lbf) F46631 (b) (c) Using SST, connect the 2 brake tubes to the brake master w/ plate cylinder assy. SST 09023-00101 Torque: 15 N⋅m (155 kgf⋅cm, 11 ft⋅lbf) Connect the brake fluid level warning switch connector. F46630 10. 11. 12. 13. 14. 15. 16. 17. 18. FILL RESERVOIR WITH BRAKE FLUID (SEE PAGE 32-4 ) BLEED MASTER CYLINDER (SEE PAGE 32-4 ) SST 09023-00101 BLEED BRAKE LINE (SEE PAGE 32-4 ) BLEED BRAKE ACTUATOR ASSY (SEE PAGE 32-4 ) CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4 ) INSTALL AIR CLEANER ASSY (2AZ-FE ENGINE TYPE) (SEE PAGE 14-24 ) INSTALL AIR CLEANER CASE (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 ) INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 ) INSTALL AIR CLEANER CAP SUB-ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 ) 19. (a) INSTALL FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER Install the front suspension brace sub-assy upper center with the 4 nuts. Torque: 80 N⋅m (816 kgf⋅cm, 59 ft⋅lbf) F46629 20. 21. CHECK BRAKE FLUID LEAKAGE CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3129 32-18 BRAKE - BRAKE BOOSTER ASSY 320WG-04 COMPONENTS Clamp Clamp Front Brake Tube No.6 15 (155, 11) Front Brake Tube No.7 Brake Master Cylinder Push Rod Clevis 15 (155, 11) Vacuum Hose Brake Vacuum Check Valve Assy Clip Push Rod Pin Grommet Check Valve Bracket Push Rod Lock Nut Clip 26 (265, 19 ) 13 (130, 9) 13 (130, 9)
Brake Booster Gasket
O-ring Brake Pedal Return Spring Brake Booster Assy 13 (130, 9) Brake Master w/Plate Cylinder Sub-assy N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part Lithium soap base glycol grease F47750 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3131 32-17 BRAKE - BRAKE BOOSTER ASSY BRAKE BOOSTER ASSY 3203F-11 ON-VEHICLE INSPECTION GOOD 1st 2nd 1. (a) NO GOOD 3rd BR2238 HINT: If the pedal can be depressed (to the floor) the first time, but cannot be depressed as far on the 2nd or 3rd time, the booster is airtight. (2) Depress the brake pedal while the engine is running, and stop the engine with the pedal depressed. HINT: If there is no change in the pedal reserve distance while holding the pedal for 30 seconds, the booster is airtight. (b) BR2237 Ventilation No Ventilation INSPECT BRAKE BOOSTER Airtightness check. (1) Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal several times slowly. Operating check. (1) Depress the brake pedal several times with the ignition switch off and check that there is no change in the pedal reserve distance. (2) Start the engine with the brake pedal depressed. HINT: If the pedal goes down slightly, operation is normal. 2. INSPECT VACUUM CHECK VALVE (a) Check vacuum check valve. (1) Slide the clip and disconnect the vacuum hose. (2) Remove the vacuum check valve. (3) (4) Check that there is ventilation from the booster to engine, and no ventilation from the engine to the booster. If any fault is found, replace the vacuum check valve. F40007 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3130 32-19 BRAKE - BRAKE BOOSTER ASSY 3215Q-04 REPLACEMENT 1. 2. 3. 4. REMOVE FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER (SEE PAGE 32-14 ) REMOVE AIR CLEANER ASSY (2AZ-FE ENGINE TYPE) (SEE PAGE 14-24 ) REMOVE AIR CLEANER CAP SUB-ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 ) REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 ) 5. REMOVE AIR CLEANER CASE (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 ) 6. DRAIN BRAKE FLUID NOTICE: Wash brake fluid off immediately if it adheres to any painted surface. 7. REMOVE BRAKE MASTER W/PLATE CYLINDER SUB-ASSY (SEE PAGE 32-14 ) SST 09023-00101 8. REMOVE INSTRUMENT PANEL FINISH PANEL SUB-ASSY LOWER (SEE PAGE 71-10 ) 9. REMOVE BRAKE PEDAL RETURN SPRING (a) Remove the brake pedal return spring. Push Rod Lock Nut Brake Master Cylinder Push Rod Clevis 10. (a) (b) Clip REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS Remove the clip and the push rod pin. Loosen the push rod lock nut and remove the push rod clevis. Push Rod Pin G24409 11. (a) SEPARATE BRAKE TUBE Release the 2 claw fittings of the clamp and separate the 2 brake tubes from the body. SST 09023-00101 NOTICE: Be careful not to damage the brake tubes. Clamp Brake Tube Front Side To Master Cylinder F46633 12. (a) Clip REMOVE BRAKE BOOSTER ASSY Slide the clip and disconnect the vacuum hose from the check valve assy. Vacuum Hose F47054 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3132 32-20 BRAKE - BRAKE BOOSTER ASSY (b) Remove the 4 nuts and pull out the brake booster assy. NOTICE: Be careful not to damage the brake tubes and the wire harness. BR3753 13. (a) REMOVE BRAKE BOOSTER GASKET Remove the brake booster gasket from the brake booster assy. 14. (a) Grommet 15. (a) Brake Vacuum Check Valve Assy REMOVE BRAKE VACUUM CHECK VALVE ASSY Remove the check valve assy and the grommet from the brake booster assy. INSTALL BRAKE VACUUM CHECK VALVE ASSY Install the grommet and the check valve assy to the brake booster assy. F45790 16. (a) INSTALL BRAKE BOOSTER GASKET Install a new brake booster gasket to the brake booster assy. 17. (a) INSTALL BRAKE BOOSTER ASSY Install the brake booster assy with the 4 nuts. Torque: 13 N⋅m (130 kgf⋅cm, 9 ft⋅lbf) NOTICE: Be careful not to damage the brake tubes and the wire harness. BR3753 (b) Clip Connect the vacuum hose to the brake booster assy and slide the clip. Vacuum Hose F47054 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3133 32-21 BRAKE - BRAKE BOOSTER ASSY 18. (a) INSTALL BRAKE TUBE Install the 2 clamps of the brake tube to the body. SST 09023-00101 NOTICE: Be careful not to damage the brake tubes. Clamp Brake Tube Front Side To Master Cylinder F46633 Push Rod Lock Nut Brake Master Cylinder Push Rod Clevis Clip Push Rod Pin Lithium soap base glycol grease 20. (a) 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 19. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS Install the push rod clevis and the push rod lock nut. (a) HINT: After adjusting the brake pedal height, torque the lock nut. (b) Apply lithium soap base glycol grease to the clevis pin. (c) Install the push rod pin and the clip. G24409 INSTALL BRAKE PEDAL RETURN SPRING Install the brake pedal return spring. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD (SEE PAGE 32-14 ) SST 09737-00020 INSTALL BRAKE MASTER W/PLATE CYLINDER SUB-ASSY (SEE PAGE 32-14 ) SST 09023-00101 FILL RESERVOIR WITH BRAKE FLUID (SEE PAGE 32-4 ) BLEED MASTER CYLINDER (SEE PAGE 32-4 ) SST 09023-00101 BLEED BRAKE LINE (SEE PAGE 32-4 ) BLEED BRAKE ACTUATOR ASSY (SEE PAGE 32-4 ) CHECK BRAKE FLUID LEAKAGE CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4 ) CHECK AND ADJUST BRAKE PEDAL HEIGHT (SEE PAGE 32-8 ) INSTALL INSTRUMENT PANEL FINISH PANEL SUB-ASSY LOWER INSTALL AIR CLEANER ASSY (2AZ-FE ENGINE TYPE) (SEE PAGE 14-24 ) INSTALL AIR CLEANER CASE (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 ) INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 ) INSTALL AIR CLEANER CAP SUB-ASSY (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149 ) INSTALL FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER (SEE PAGE 32-14 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3134 32-22 BRAKE - FRONT BRAKE FRONT BRAKE 3215R-01 COMPONENTS Front Disc Front Disc Brake Bleeder Plug Cap Front Disc Brake Bleeder Plug 8.3 (85, 73 in.⋅lbf) 34 (350, 25) Front Disc Brake Cylinder Slide Pin (Upper) Flexible Hose Front Disc Brake Cylinder Sub-assy
Front Disc Brake Bush Dust Boot Front Disc Brake Pad Support Plate (No.1)
Gasket 107 (1,090, 79) 29 (300, 21)
Set Ring
Piston Seal 34 (350, 25) Front Disc Brake Piston
Cylinder Boot Front Disc Brake Cylinder Slide Pin (Lower)
Front Disc Brake Cylinder Slide Bush Anti Squeal Shim Kit Front Pad Wear Indicator
Front Disc Brake Bush Dust Boot Front Disc Brake Cylinder Mounting LH Front Disc Brake Pad Support Plate (No.2) Disc Brake Pad Kit Front Anti Squeal Shim Kit Front N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part Lithium soap base glycol grease Disc brake grease F47535 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3135 32-23 BRAKE - FRONT BRAKE 3215S-03 OVERHAUL HINT:

Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. 1. REMOVE FRONT WHEEL 2. DRAIN BRAKE FLUID NOTICE: Wash brake fluid off immediately if it adheres to any painted surface. 3. REMOVE FRONT DISC BRAKE CYLINDER SUB-ASSY (a) Remove the union bolt and gasket from the disc brake cylinder sub-assy, then disconnect the flexible hose. (b) Remove the 2 bolts and disc brake cylinder sub-assy. 4. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY) (a) Remove the 2 brake pads with anti-squeal shim. 5. REMOVE ANTI SQUEAL SHIM KIT FRONT (a) Remove the anti-squeal shim and pad wear indicator plate from inner pad. (b) Remove the anti-squeal shim from outer pad. 6. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE (a) Remove the front disc brake pad support plate (No.1) and front disc brake pad support plate (No.2) from the disk brake cylinder mounting LH. 7. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN (a) Remove the 2 front disc brake cylinder slide pins from the front disc brake cylinder mounting LH. Front Disc Brake Cylinder Slide Bush 8. (a) Front Disc Brake Cylinder Slide Pin (Lower) 9. (a) 10. (a) REMOVE FRONT DISC BRAKE CYLINDER SLIDE BUSH Using a screwdriver, remove the front disc brake cylinder slide bush from the front disc brake cylinder slide pin (lower). F45433 REMOVE FRONT DISC BRAKE BUSH DUST BOOT Remove the 2 front disc brake bush dust boots from the front disc brake cylinder mounting. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING LH Remove the 2 bolts and front disc brake cylinder mounting LH. 11. (a) REMOVE CYLINDER BOOT Using a screwdriver, remove the set ring and cylinder boot. NOTICE: Do not damage the inner cylinder and cylinder groove. R09298 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3136 32-24 BRAKE - FRONT BRAKE 12. (a) Shop Rag C64095 REMOVE FRONT DISC BRAKE PISTON Place a piece of shop rag or equivalent between the front disc brake piston and the front disc brake cylinder subassy. (b) Use compressed air to remove the front disc brake piston from the front disc brake cylinder sub-assy. CAUTION: Do not place your fingers in front of the piston when using compressed air. NOTICE: Do not spatter the brake fluid. 13. (a) REMOVE PISTON SEAL Using a screwdriver, remove the piston seal from the front disc brake cylinder sub-assy. NOTICE: Do not damage the inner cylinder and cylinder groove. G23223 14. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP (a) Remove the front disc brake bleeder plug cap from the front disc brake bleeder plug. 15. REMOVE FRONT DISC BRAKE BLEEDER PLUG (a) Remove the front disc brake bleeder plug from the front disc brake cylinder sub-assy. 16. INSPECT BRAKE CYLINDER AND PISTON (a) Check the cylinder bore and front disc brake piston for rust or scoring. If necessary, replace the front disc brake cylinder sub-assy and front disc brake piston. 17. (a) INSPECT PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 12.7 mm (0.500 in.) Minimum thickness: 1.0 mm (0.039 in.) If the pad lining thickness is equal to the minimum thickness or less, replace the brake pad. R02951 18. (a) INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE Inspect the front disc brake pad support plate (No.1) and front disc brake pad support plate (No.2). (1) Make sure that both have sufficient rebound, have no deformation, cracks or wear, and that all rust and dirt is cleaned off. If necessary, replace the brake pad support plate. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3137 32-25 BRAKE - FRONT BRAKE 19. (a) INSPECT DISC THICKNESS Using a micrometer, measure the disc thickness. Standard thickness: 28.0 mm (1.102 in.) Minimum thickness: 26.0 mm (1.024 in.) If the disc thickness is less than the minimum, replace the disc. F41542 20. (a) (b) Matchmarks REMOVE FRONT DISC Put matchmarks on the disc and the axle hub. Remove the disc. F47749 21. INSTALL FRONT DISC (a) Aligning the matchmarks, install the front disc. HINT: When replacing the disc with a new one, select the installation position where the front disc has the minimum runout. 22. INSPECT DISC RUNOUT (a) Temporarily fasten the disc with hub nuts. Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) (b) Using a dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the disc. Maximum disc runout: 0.05 mm (0.0020 in.) (c) If the runout exceeds the maximum value, change the installation positions of the disc and axle so that the runout will become minimal. If the runout exceeds the maxiC83569 mum even when the installation positions are changed, check the bearing play in the axial direction and the axle hub runout (see page 30-3 ). If the bearing play and the axle hub runout are normal and if the disc thickness is not within the specified range, shave the disc. If the disc thickness is less than the minimum, replace the disc. 23. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG (a) Temporarily tighten the front disc brake bleeder plug to the front disc brake cylinder sub-assy. 24. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP (a) Install the front disc brake bleeder plug cap to the front disc brake bleeder plug. 25. INSTALL PISTON SEAL (a) Apply lithium soap base glycol grease to a new piston seal. (b) Install the piston seal to the front disc brake cylinder sub-assy. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3138 32-26 BRAKE - FRONT BRAKE 26. (a) INSTALL FRONT DISC BRAKE PISTON Apply lithium soap base glycol grease to the front disc brake piston. (b) Install the front disc brake piston to the front disc brake cylinder sub-assy smoothly. NOTICE: Do not install the front disc brake piston forcibly in the front disc brake cylinder sub-assy. F45434 27. (a) INSTALL CYLINDER BOOT Apply lithium soap base glycol grease to a new cylinder boot. Install the cylinder boot to the front disc brake cylinder sub-assy. HINT: Install the boot securely to the grooves of the cylinder and piston. (b) Using a screwdriver, install a new set ring. NOTICE: C82871
Install the boot securely to the grooves of the cylinder and piston.
Do not damage the cylinder boot. 28. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING LH (a) Install the front disc brake cylinder mounting LH with the 2 bolts. Torque: 107 N⋅m (1,090 kgf⋅cm, 79 ft⋅lbf) 29. INSTALL FRONT DISC BRAKE BUSH DUST BOOT (a) Apply lithium soap base glycol grease to seal surface of 2 new front disc brake bush dust boots. (b) Install the 2 front disc brake bush dust boots to the front disc brake cylinder mounting LH. 30. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH (a) Apply lithium soap base glycol grease to a new front disc brake cylinder slide bush. (b) Install the front disc brake cylinder slide bush to the front disc brake cylinder slide pin (lower). 31. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN (a) Apply lithium soap base glycol grease to the sliding part and the seal surface of the 2 front disc brake cylinder slide pins. (b) Install the 2 front disc brake cylinder slide pins to the front disc brake cylinder mounting LH. NOTICE: Insert the slide pin with slide bush into the lower side. 32. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE (a) Install the front disc brake pad support plate (No.1) and front disc brake pad support plate (No.2) to the front disc brake cylinder mounting LH. 33. INSTALL ANTI SQUEAL SHIM KIT FRONT NOTICE:
If necessary, replace the anti squeal shim kit when replacing the brake pad.
Install the shims in the correct position and direction. (a) Apply disc brake grease to inside of each anti-squeal shim. (b) Install anti-squeal shims on each pad. (c) Install the pad wear indicator plate to the inner pad. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3139 32-27 BRAKE - FRONT BRAKE 34. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY) (a) Install the inner pad with the pad wear indicator plate facing upward, and install the outer pad. NOTICE: There should be no oil or grease on the friction surface of the pads and the disc. 35. INSTALL FRONT DISC BRAKE CYLINDER SUB-ASSY (a) Install the front disc brake cylinder sub-assy with the 2 bolts. Torque: 34 N⋅m (350 kgf⋅cm, 25 ft⋅lbf) (b) Install a new gasket and flexible hose with the union bolt. Torque: 29 N⋅m (300 kgf⋅cm, 21 ft⋅lbf) NOTICE: Install the flexible hose lock securely in the lock hole in the disc brake cylinder. 36. FILL RESERVOIR WITH BRAKE FLUID (SEE PAGE 32-4 ) 37. BLEED MASTER CYLINDER (SEE PAGE 32-4 ) SST 09023-00101 38. BLEED BRAKE LINE (SEE PAGE 32-4 ) 39. BLEED BRAKE ACTUATOR ASSY (SEE PAGE 32-4 ) 40. CHECK BRAKE FLUID LEAKAGE 41. CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4 ) 42. INSTALL FRONT WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3140 32-28 BRAKE - REAR BRAKE REAR BRAKE 320E7-05 COMPONENTS Rear Disc Brake Bleeder Plug Cap Rear LH Flexible Hose Rear Disc Brake Cylinder Slide Pin 43 (440, 32) Union Bolt Rear Disc Brake Bleeder Plug 29 (300, 21) 8.3 (85, 73 in.⋅lbf) Disc Brake Cylinder Assy Rear LH
Gasket
Rear Disc Brake Bush Dust Boot Rear Disc Brake Cylinder Slide Pin No.2 43 (440, 32) Anti Squeal Shim No.1 Rear Disc Brake Piston
Rear Disc Brake Cylinder Slide Bush
Cylinder Boot
Piston Seal Anti Squeal Shim No.2 Rear Disc Brake Pad Support Plate (No.1) Rear Disc Brake Pad Rear Disc Brake Pad Support Plate (No.2) Rear Disc Brake Pad 78 (800, 58) Pad Wear Indicator Rear Disc Brake Cylinder Mounting LH Pad Wear Indicator Rear Disc Anti Squeal Shim No.1 Anti Squeal Shim No.2 Parking Brake Shoe Adjusting Hole Plug N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part Lithium soap base glycol grease Disc brake grease F45443 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3141 32-29 BRAKE - REAR BRAKE 320WK-05 OVERHAUL HINT:

Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. 1. REMOVE REAR WHEEL 2. DRAIN BRAKE FLUID NOTICE: Wash brake fluid off immediately if it adheres to any painted surface. 3. DISCONNECT REAR LH FLEXIBLE HOSE (a) Remove the union bolt and gasket from the rear disc brake cylinder, then disconnect the flexible hose from the rear disc brake cylinder. Slide Pin 4. (a) REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN Remove the rear disc brake cylinder slide pin and rear disc brake cylinder slide pin No.2. 5. (a) REMOVE DISC BRAKE CYLINDER ASSY REAR LH Remove the disc brake cylinder assy rear LH. Slide Pin No.2 G21633 F45897 6. (a) 7. (a) (b) 8. (a) REMOVE DISC BRAKE PAD KIT REAR (PAD ONLY) Remove the 2 brake pads with the anti squeal shim. REMOVE ANTI SQUEAL SHIM KIT REAR Remove the 4 anti squeal shims from each pad. Using a screwdriver, remove the 2 pad wear indicators from each pad. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE Remove the rear disc brake pad support plate (No.1) and the rear disc brake pad support plate (No.2) from the rear disc brake cylinder mounting LH. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3142 32-30 BRAKE Rear Disc Brake Cylinder Mounting - REAR BRAKE 9. (a) REMOVE REAR DISC BRAKE BUSH DUST BOOT Remove the 2 rear disc brake bush dust boots from the rear disc brake cylinder mounting LH. 10. REMOVE REAR DISC BRAKE CYLINDER MOUNTING LH Remove the 2 bolts and the rear disc brake cylinder mounting LH. Bush Dust Boot F45436 (a) G21636 11. Cylinder Slide Bush Cylinder Slide Pin No.2 REMOVE REAR DISC BRAKE CYLINDER SLIDE BUSH (a) Using a screwdriver, remove the rear disc brake cylinder slide bush from the rear disc brake cylinder slide pin No.2. NOTICE: Do not damage the front disc brake cylinder slide pin No.2. F45430 12. REMOVE CYLINDER BOOT (a) Using a screwdriver, remove the cylinder boot. NOTICE: Do not damage the inner cylinder and cylinder groove. F45444 13. (a) Shop Rag C95599 REMOVE REAR DISC BRAKE PISTON Place a shop rag between the rear disc brake piston and the disc brake cylinder assy rear LH. (b) Use compressed air to remove the rear disc brake piston from the disc brake cylinder assy rear LH. CAUTION: Do not place your fingers in front of the brake piston when using compressed air. NOTICE: Do not spatter the brake fluid. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3143 32-31 BRAKE - REAR BRAKE 14. (a) REMOVE PISTON SEAL Using a screwdriver, remove the piston seal from the disc brake cylinder assy rear LH. NOTICE: Do not damage the inner cylinder and the cylinder groove. G23223 15. REMOVE REAR DISC BRAKE BLEEDER PLUG CAP (a) Remove the rear disc brake bleeder plug cap from the rear disc brake bleeder plug. 16. REMOVE REAR DISC BRAKE BLEEDER PLUG (a) Remove the rear disc brake bleeder plug from the disc brake cylinder assy rear LH. 17. INSPECT BRAKE CYLINDER AND PISTON (a) Inspect the cylinder bore and the brake piston for rust or scoring. If necessary, replace the brake cylinder and piston. 18. (a) INSPECT PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 10.0 mm (0.394 in.) Minimum thickness: 1.0 mm (0.039 in.) If the pad lining thickness is equal to the minimum thickness or less, replace the brake pad. F45498 19. (a) INSPECT REAR DISC BRAKE PAD SUPPORT PLATE Inspect the rear disc brake pad support plate (No.1) and the rear disc brake pad support plate (No.2). (1) Make sure that both have sufficient rebound, have no deformation, cracks or wear, and that all rust and dirt are cleaned off. If necessary, replace the rear disc brake pad support plate. 20. INSPECT DISC THICKNESS (a) Using a micrometer, measure the disc thickness. Standard thickness: 10.0 mm (0.394 in.) Minimum thickness: 8.5 mm (0.335 in.) If the disc thickness is less than the minimum, replace the disc. F45504 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3144 32-32 BRAKE 21. (a) Matchmarks - REAR BRAKE REMOVE REAR DISC Put matchmarks on the rear disc and the axle hub. F45499 (b) Release the parking brake, and remove the rear disc. HINT: If the disc cannot be removed easily, turn the shoe adjuster until the wheel turns freely. Contract D28126 22. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG (a) Remove the parking brake shoe adjusting hole plug from the rear disc. 23. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG (a) Install the parking brake shoe adjusting hole plug to the rear disc. 24. INSTALL REAR DISC (a) Aligning the matchmarks, install the rear disc. HINT: When replacing the rear disc with a new one, select the installation position where the rear disc has the minimum runout. 25. (a) 26. 27. (a) 28. (a) INSPECT DISC RUNOUT Temporarily fasten the rear disc with hub nuts. Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) (b) Using a dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the rear disc. Maximum disc runout: 0.15 mm (0.0059 in.) (c) If the runout exceeds the maximum value, change the installation positions of the disc and axle so that the runout will become minimal. If the runout exceeds the maxiC83570 mum even when the installation positions are changed, check the bearing play in the axial direction and the axle hub runout (see page 30-3 ). If the bearing play and the axle hub runout are normal and if the disc thickness is not within the specified range, shave the disc. If the disc thickness is less than the minimum, replace the disc. ADJUST PARKING BRAKE SHOE CLEARANCE (SEE PAGE 33-19 ) TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG Temporarily tighten the rear disc brake bleeder plug to the disc brake cylinder assy rear LH. INSTALL REAR DISC BRAKE BLEEDER PLUG CAP Install the rear disc brake bleeder plug cap to the rear disc brake bleeder plug. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3145 32-33 BRAKE 29. (a) (b) - REAR BRAKE INSTALL PISTON SEAL Apply lithium soap base glycol grease to a new piston seal. Install the piston seal to the disc brake cylinder assy rear LH. 30. (a) INSTALL REAR DISC BRAKE PISTON Apply lithium soap base glycol grease to the rear disc brake piston and a new cylinder boot. (b) Install the cylinder boot to the rear disc brake piston. (c) Install the piston to the disc brake cylinder assy rear LH. NOTICE: Do not install the piston forcibly in the disc brake cylinder. Cylinder Boot Piston Lithium soap base glycol grease F45750 31. (a) INSTALL CYLINDER BOOT Install the cylinder boot to the disc brake cylinder assy rear LH. NOTICE:
Install the boot securely onto the grooves of the cylinder and the piston.
Do not damage the cylinder boot. Piston Cylinder Boot Groove Cylinder G24324 Slide Pin No.2 32. (a) Cylinder Slide Bush (b) INSTALL REAR DISC BRAKE CYLINDER SLIDE BUSH Apply lithium soap base glycol grease to a new rear disc brake cylinder slide bush. Install the rear disc brake cylinder slide bush to the rear disc brake cylinder slide pin No.2. Lithium soap base glycol grease F45796 33. (a) INSTALL REAR DISC BRAKE CYLINDER MOUNTING LH Install the rear disc brake cylinder mounting LH with the 2 bolts. Torque: 78 N⋅m (800 kgf⋅cm, 58 ft⋅lbf) G21636 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3146 32-34 BRAKE Rear Disc Brake Cylinder Mounting 34. (a) (b) - REAR BRAKE INSTALL REAR DISC BRAKE BUSH DUST BOOT Apply lithium soap base glycol grease to the seal surface of 2 new rear disc brake bush dust boots. Install the 2 rear disc brake bush dust boots to the rear disc brake cylinder mounting LH. Bush Dust Boot Lithium soap base glycol grease 35. (a) F45436 INSTALL REAR DISC BRAKE PAD SUPPORT PLATE Install the rear disc brake pad support plate (No.1) and the rear disc brake pad support plate (No.2) to the rear disc brake cylinder mounting LH. 36. (a) Anti Squeal Shim Anti Squeal Shim Disc brake grease F45500 INSTALL ANTI SQUEAL SHIM KIT REAR Apply disc brake grease to the inside of the anti squeal shims and install them and the pad wear indicators to each of the 2 brake pads. NOTICE:
When replacing worn pads, the anti squeal shims must be replaced together with the pads.
Install the pad wear indicator and anti squeal shims in the correct positions and directions. 37. INSTALL DISC BRAKE PAD KIT REAR (PAD ONLY) (a) Install the 2 brake pads with anti squeal shims to the rear disc brake cylinder mounting LH. NOTICE: There should be no oil or grease on the friction surface of the pads and the disc. 38. (a) INSTALL DISC BRAKE CYLINDER ASSY REAR LH Install the disc brake cylinder assy rear LH. 39. (a) INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN Apply lithium soap base glycol grease to the sliding part and the seal surface of the 2 slide pins. Install the rear disc brake cylinder slide pin. Install the rear disc brake cylinder slide pin No.2 to the bottom side of the rear disc brake cylinder mounting LH. F45897 Cylinder Slide Pin Cylinder Slide Pin No.2 Lithium soap base glycol grease (b) (c) G24410 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3147 32-35 BRAKE (d) Slide Pin - REAR BRAKE Fully tighten the rear disc brake cylinder slide pin and the rear disc brake cylinder slide pin No.2. Torque: 43 N⋅m (440 kgf⋅cm, 32 ft⋅lbf) Slide Pin No.2 G21633 40. (a) 41. 42. 43. 44. 45. 46. 47. CONNECT REAR LH FLEXIBLE HOSE Connect the flexible hose with the union bolt and a new gasket. Torque: 29 N⋅m (300 kgf⋅cm, 21 ft⋅lbf) FILL RESERVOIR WITH BRAKE FLUID (SEE PAGE 32-4 ) BLEED MASTER CYLINDER (SEE PAGE 32-4 ) SST 09023-00101 BLEED BRAKE LINE (SEE PAGE 32-4 ) BLEED BRAKE ACTUATOR ASSY (SEE PAGE 32-4 ) CHECK BRAKE FLUID LEAKAGE CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4 ) INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3148 32-36 BRAKE - BRAKE ACTUATOR ASSY BRAKE ACTUATOR ASSY 320WL-05 ON-VEHICLE INSPECTION Hand-Held Tester DLC3 1. CONNECT HAND-HELD TESTER: (a) Connect the hand-held tester to the DLC3. (b) Start the engine and run at idle. (c) Select the ACTIVE TEST mode on the hand-held tester. HINT: Please refer to the hand-held tester operator’s manual for further details. G23361 2. (a) (b) (c) INSPECT ACTUATOR MOTOR OPERATION With the motor relay on, check the actuator motor operation noise. Turn the motor relay off. Depress the brake pedal and hold it for about 15 seconds. Check that the brake pedal cannot be depressed. (d) With the motor relay on, check that the pedal does not pulsate. NOTICE: Do not keep a motor relay on for more than 5 seconds continuously. When operating it continuously, set an interval of more than 20 seconds. (e) Turn the motor relay off and release the brake pedal. 3. INSPECT RIGHT FRONT WHEEL OPERATION NOTICE: Never turn on the solenoids in a manner different to those described below. (a) With the brake pedal depressed, perform the following operations. (b) Turn the SFRH and SFRR solenoids on simultaneously, and check that the pedal cannot be depressed. NOTICE: Do not keep a solenoid turned on for more than 10 seconds continuously. When operating it continuously, set an interval of more than 20 seconds. (c) Turn the SFRH and SFRR solenoids off simultaneously, and check that the pedal can be depressed. (d) Turn the motor relay on, and check that the pedal returns. NOTICE: Do not keep a motor relay turned on for more than 5 seconds continuously. When operating it continuously, set an interval of more than 20 seconds. (e) Turn the motor relay off and release the brake pedal. 4. INSPECT OTHER WHEEL OPERATION (a) Using the same procedure, check the solenoids of the other wheels. HINT: Left front wheel: SFLH, SFLR Right rear wheel: SRRH, SRRR Left rear wheel: SRLH, SRLR 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3149 32-37 BRAKE - BRAKE ACTUATOR ASSY 320WM-10 REPLACEMENT 1. DISCONNECT BATTERY NEGATIVE TERMINAL 2. DRAIN BRAKE FLUID NOTICE: Wash brake fluid off immediately if it adheres to any painted surface. 3. (a) REMOVE BRAKE ACTUATOR WITH BRACKET Using SST, disconnect the 6 brake tubes from the actuator with bracket. SST 09023-00101 (b) Use tags or make a memo to identify the places to reconnect. (c) (d) Pull the lock lever upward. Disconnect the actuator connector. F46635 From M/C Rear From M/C Front To FL W/C To RR W/C F46636 (c) To FR W/C To RL W/C F47079 (d) F46637 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3150 32-38 BRAKE - BRAKE ACTUATOR ASSY (e) Remove the 2 bolts, the nut and the actuator with bracket. NOTICE: Be careful not to damage the brake tubes and wire harness. F46638 4. (a) 5. (a) REMOVE BRAKE ACTUATOR ASSY Remove the 2 nuts and the brake actuator assy from the brake actuator bracket. INSTALL BRAKE ACTUATOR ASSY Install the brake actuator assy with the 2 nuts. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) 6. INSTALL BRAKE ACTUATOR WITH BRACKET (a) Install the actuator with bracket and the 2 bolts and the nut. Torque: 19 N⋅m (194 kgf⋅cm, 14 ft⋅lbf) NOTICE: Be careful not to damage the brake tubes and wire harness. (b) Connect the actuator connector. F46638 (c) From M/C Front To FL W/C To RR W/C F46636 7. 8. 9. 10. 11. 12. 13. 14. From M/C Rear Using SST, connect each brake tube to correct positions of the actuator with bracket, as shown in the illustration. SST 09023-00101 Torque: 15 N⋅m (155 kgf⋅cm, 11 ft⋅lbf) To FR W/C To RL W/C F47079 FILL RESERVOIR WITH BRAKE FLUID (SEE PAGE 32-4 ) BLEED MASTER CYLINDER (SEE PAGE 32-4 ) SST 09023-00101 BLEED BRAKE LINE (SEE PAGE 32-4 ) BLEED BRAKE ACTUATOR ASSY (SEE PAGE 32-4 ) CHECK BRAKE FLUID LEAKAGE CHECK FLUID LEVEL IN RESERVOIR (SEE PAGE 32-4 ) CONNECT BATTERY NEGATIVE TERMINAL PERFORM YAWRATE SENSOR ZERO POINT CALIBRATION (SEE PAGE 05-765 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3151 32-39 BRAKE 15. - BRAKE ACTUATOR ASSY CHECK BRAKE ACTUATOR WITH HAND-HELD TESTER (SEE PAGE 32-36 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3152 33-2 PARKING BRAKE - PARKING BRAKE SYSTEM 330CI-04 ADJUSTMENT 1. 2. 3. 4. (a) (b) (c) REMOVE REAR WHEEL ADJUST PARKING BRAKE SHOE CLEARANCE (SEE PAGE 33-19 ) INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT PARKING BRAKE PEDAL TRAVEL Strongly step on the parking brake pedal. Release the parking brake. Once more, slowly depress the parking brake pedal all the way, and count the number of clicks. Parking brake pedal travel: 5 to 7 clicks at 300 N (31 kgf, 67.46 lbf) 5. (a) (b) (c) Lock Nut (d) (e) Parking Brake Adjusting Nut (f) G24942 (g) (h) (i) ADJUST PARKING BRAKE PEDAL TRAVEL Remove the instrument panel finish panel sub-assy lower.(see page 71-10 ) Remove the instrument PNL insert sub- assy LWR LH.(see page 71-10 ) Depress the parking brake pedal 5 clicks to make room for the procedure, and loosen the lock nut with fixing adjusting nut by wrench. Release the parking brake pedal to the original position. Turn the paking brake wire adjusting nut until the parking brake pedal travel is correct. Using a spanner or equivalent to hold the parking brake adjusting nut, tighten the lock nut. Torque: 6.0 N⋅m (61 kgf⋅cm, 53 in.⋅lbf) Count the number of clicks after depressing and canceling the parking brake pedal 3 to 4 times. Check whether the parking brake drags or not. When operating the parking brake pedal, check that the parking brake pedal indicator light is lit. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3163 33-1 PARKING BRAKE - PARKING BRAKE SYSTEM PARKING BRAKE SYSTEM 330CH-04 PROBLEM SYMPTOMS TABLE Use the table below to help find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Suspect Area See page 1. Parking brake pedal travel (Out of adjustment) 2. Parking brake wire (Sticking) Brake drag 3. Parking brake shoe clearance (Out of adjustment) 4. Parking brake shoe lining (Cracked or distorted) 5. Tension or return spring (Damaged) 33-2 33-10 33-14 33-19 33-19 33-19 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3162 33-3 PARKING BRAKE - PARKING BRAKE CONTROL PEDAL ASSY PARKING BRAKE CONTROL PEDAL ASSY 330CL-04 COMPONENTS Parking Brake Pedal Assy 39 (400, 29) Parking Brake Switch Assy Clip 39 (400, 29) Parking Brake Wire Adjusting Nut No.1 39 (400, 29) Parking Pedal Pad 6.0 (61, 53 in.⋅lbf) Lock Nut Parking Brake Cable Assy No.1 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque F46471 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3164 33-4 PARKING BRAKE - PARKING BRAKE CONTROL PEDAL ASSY 6.0 (61, 53 in.⋅lbf) 8.5 (87, 75 in.⋅lbf) FR Floor Footrest Parking Brake Equalizer Parking Brake Cable Assy No.1 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque F45547 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3165 33-5 PARKING BRAKE - PARKING BRAKE CONTROL PEDAL ASSY 330FC-01 OVERHAUL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. (a) PRECAUTION (W/ SIDE AIRBAG) (SEE PAGE 60-1 ) DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60-1 ) REMOVE INSTRUMENT PANEL FINISH PANEL SUB-ASSY LOWER (SEE PAGE 71-10 ) REMOVE INSTRUMENT PNL INSERT SUB-ASSY LWR LH (SEE PAGE 71-10 ) REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSY CENTER (SEE PAGE 71-10 ) REMOVE FLOOR CARPET COVER CENTER RH (SEE PAGE 71-10 ) REMOVE FLOOR CARPET COVER CENTER LH (SEE PAGE 71-10 ) REMOVE FRONT SEAT ASSEMBLY RH REMOVE FRONT SEAT ASSEMBLY LH (SEE PAGE 72-1 1, 72-19 ) REMOVE CONSOLE BOX ASSY (SEE PAGE 71-10 ) DISCONNECT TURN SIGNAL FLASHER ASSY REMOVE FR FLOOR FOOTREST Remove the front floor footrest from the floor. 13. (a) (b) (c) (d) (e) REMOVE PARKING BRAKE CONTROL PEDAL ASSY Disconnect the connectors. Remove the 2 nuts. Separate the instrument panel junction block assy. Release the parking brake pedal to the original position. Remove the 2 bolts and nuts, and separate the parking brake cable assy No.1 from the floor. F46488 Nut Nut Bolt F46472 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3166 33-6 PARKING BRAKE (f) (g) (h) (i) - PARKING BRAKE CONTROL PEDAL ASSY Remove the parking brake cable assy No.1 from the parking brake equalizer. Disconnect the parking brake switch connector. Remove the 3 nuts and separate the instrument panel junction block assy w/ bracket from the body. Remove the 3 nuts and parking brake control pedal assy. F46473 14. 15. (a) 16. (a) 17. (a) 18. (a) 19. REMOVE PARKING BRAKE CABLE ASSY NO.1 (SEE PAGE 33-10 ) REMOVE PARKING BRAKE SWITCH ASSY Remove the screw and parking brake switch assy. REMOVE PARKING PEDAL PAD Remove the parking pedal pad. INSTALL PARKING PEDAL PAD Install the parking pedal pad. INSTALL PARKING BRAKE SWITCH ASSY Install the parking brake switch assy with the screw. INSTALL PARKING BRAKE CABLE ASSY NO.1 (SEE PAGE 33-10 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3167 33-7 PARKING BRAKE 20. (a) (b) (c) (d) (e) - PARKING BRAKE CONTROL PEDAL ASSY INSTALL PARKING BRAKE CONTROL PEDAL ASSY Install the parking brake control pedal assy with the 3 nuts. Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) Connect the parking brake switch connector. Connect the instrument panel junction block assy w/ bracket with the 3 nuts. Attach the parking brake cable assy No.1 to the parking brake equalizer and slide boot stopper of No.1 cable should be inserted into groove of T-Metal fitting. Install the parking brake cable assy No.1 with the 2 bolts and 2 nuts. Torque: Bolt: 8.5 N⋅m (87 kgf⋅cm, 75 in.⋅lbf) Nut: 6.0 N⋅m (61 kgf⋅cm, 53 in.⋅lbf) F46473 Slide Boot Nut Nut Bolt F46472 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3168 33-8 PARKING BRAKE - PARKING BRAKE CONTROL PEDAL ASSY (f) Install the instrument panel junction block assy with the 2 nuts. Torque: 7.3 N⋅m (74 kgf⋅cm, 65 in.⋅lbf) (g) Connect the connectors. F46488 21. (a) 22. 23. 24. 25. 26. 27. 28. 29. 30. INSTALL FR FLOOR FOOTREST Install the front floor footrest on the floor. INSTALL FRONT SEAT ASSEMBLY RH INSTALL FRONT SEAT ASSEMBLY LH (SEE PAGE 72-1 1, 72-19 ) REMOVE REAR WHEEL ADJUST PARKING BRAKE SHOE CLEARANCE (SEE PAGE 33-19 ) INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT PARKING BRAKE PEDAL TRAVEL (SEE PAGE 33-2 ) ADJUST PARKING BRAKE PEDAL TRAVEL (SEE PAGE 33-2 ) CONNECT BATTERY NEGATIVE TERMINAL INSPECT SRS WARNING LIGHT (W/ SIDE AIRBAG) (SEE PAGE 05-1207 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3169 33-9 PARKING BRAKE - PARKING BRAKE CABLE ASSY NO.1 PARKING BRAKE CABLE ASSY NO.1 330CN-04 COMPONENTS Parking Brake Pedal Assy 39 (400, 29) Clip 39 (400, 29) Parking Brake Wire Adjusting Nut No.1 Lock Nut 6.0 (61, 53 in.⋅lbf) 39 (400, 29) 6.0 (61, 53 in.⋅lbf) 8.5 (87, 75 in.⋅lbf) FR Floor Footrest Parking Brake Equalizer Parking Brake Cable Assy No.1 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque F46475 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3170 33-10 PARKING BRAKE - PARKING BRAKE CABLE ASSY NO.1 330CO-03 REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. PRECAUTION (W/ SIDE AIRBAG) (SEE PAGE 60-1 ) DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60-1 ) REMOVE INSTRUMENT PANEL FINISH PANEL SUB-ASSY LOWER (SEE PAGE 71-10 ) REMOVE INSTRUMENT PNL INSERT SUB-ASSY LWR LH (SEE PAGE 71-10 ) REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSY CENTER (SEE PAGE 71-10 ) REMOVE FLOOR CARPET COVER CENTER RH (SEE PAGE 71-10 ) REMOVE FLOOR CARPET COVER CENTER LH (SEE PAGE 71-10 ) REMOVE FRONT SEAT ASSEMBLY RH REMOVE FRONT SEAT ASSEMBLY LH (SEE PAGE 72-1 1, 72-19 ) REMOVE CONSOLE BOX ASSY (SEE PAGE 71-10 ) REMOVE FR FLOOR FOOTREST (SEE PAGE 33-5 ) REMOVE PARKING BRAKE CONTROL PEDAL ASSY (SEE PAGE 33-5 ) 13. REMOVE PARKING BRAKE CABLE ASSY NO.1 (a) Using a screwdriver, disengage the claw. NOTICE: Be careful not to damage the parking brake cable assy No.1. G24943 Parking Brake Wire Adjusting Nut No.1 (b) (c) Remove the clip from the parking brake pedal assy. Remove the lock nut and parking brake wire adjusting nut No.1. 14. (a) (b) INSTALL PARKING BRAKE CABLE ASSY NO.1 Install the parking brake cable assy No.1 with the clip. Temporarily install the parking brake wire adjusting nut No.1 and lock nut. Clip Lock Nut G24944 Parking Brake Wire Adjusting Nut No.1 Clip Lock Nut G24944 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3171 33-1 1 PARKING BRAKE - PARKING BRAKE CABLE ASSY NO.1 (c) Bend the claw. NOTICE: Bend the claw fully. G24943 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. INSTALL PARKING BRAKE CONTROL PEDAL ASSY (SEE PAGE 33-5 ) INSTALL FR FLOOR FOOTREST (SEE PAGE 33-5 ) INSTALL FRONT SEAT ASSEMBLY RH INSTALL FRONT SEAT ASSEMBLY LH (SEE PAGE 72-1 1, 72-19 ) REMOVE REAR WHEEL ADJUST PARKING BRAKE SHOE CLEARANCE (SEE PAGE 33-19 ) INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT PARKING BRAKE PEDAL TRAVEL (SEE PAGE 33-2 ) ADJUST PARKING BRAKE PEDAL TRAVEL (SEE PAGE 33-2 ) CONNECT BATTERY NEGATIVE TERMINAL INSPECT SRS WARNING LIGHT (W/ SIDE AIRBAG) (SEE PAGE 05-1207 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3172 33-12 PARKING BRAKE - PARKING BRAKE CABLE ASSY NO.3 PARKING BRAKE CABLE ASSY NO.3 330CP-04 COMPONENTS FF: 8.0 (82, 71 in.⋅lbf) Parking Brake Cable Assy No.2 6.0 (61, 53 in.⋅lbf) Parking Brake Cable Assy No.3 Parking Brake Cable Support Bracket 6.0 (61, 53 in.⋅lbf) 39 (400, 29) Parking Brake Cable Support Bracket 6.0 (61, 53 in.⋅lbf) 6.0 (61, 53 in.⋅lbf) 6.0 (61, 53 in.⋅lbf) 39 (400, 29) 8.0 (82, 71 in.⋅lbf) 8.5 (87, 75 in.⋅lbf) Parking Brake Cable Support Bracket No.1 Parking Brake Equalizer 6.0 (61, 53 in.⋅lbf) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque G24937 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3173 33-13 PARKING BRAKE - PARKING BRAKE CABLE ASSY NO.3 4WD: Rear Axle Hub & Bearing Assy RH 75 (765, 55)
Rear Axle Shaft Nut 294 (3,000, 217) Parking Brake Hole RH 75 (765, 55) 8.0 (82, 71 in.⋅lbf) 6.0 (61, 53 in.⋅lbf) 8.0 (82, 71 in.⋅lbf) Speed Sensor RR RH Parking Brake Cable Assy No.2 Parking Brake Cable Assy No.3 6.0 (61, 53 in.⋅lbf) 6.0 (61, 53 in.⋅lbf) 39 (400, 29) Parking Brake Cable Support Bracket Parking Brake Cable Support Bracket 6.0 (61, 53 in.⋅lbf) 6.0 (61, 53 in.⋅lbf) 39 (400, 29) Parking Brake Cable Support Bracket No.1 8.5 (87, 75 in.⋅lbf) Parking Brake Equalizer 6.0 (61, 53 in.⋅lbf) Rear Axle Hub & Bearing Assy LH Speed Sensor RR LH
Rear Axle Shaft Nut 294 (3,000, 217) 75 (765, 55) 8.0 (82, 71 in.⋅lbf) Parking Brake Hole LH N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part 8.0 (82, 71 in.⋅lbf) 75 (765, 55) G24939 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3174 33-14 PARKING BRAKE - PARKING BRAKE CABLE ASSY NO.3 330CQ-04 REPLACEMENT HINT: For parking brake cable No.2, employ the same procedure to the No.3 side. 1. REMOVE REAR WHEEL 2. SEPARATE REAR DISC BRAKE CALIPER ASSY LH (a) Remove the 2 bolts and separate the rear disc brake caliper assy LH. HINT: Do not disconnect the flexible hose from the rear brake caliper assy LH. 3. REMOVE REAR DISC (SEE PAGE 33-19 ) 4. REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING (SEE PAGE 33-19 ) 5. REMOVE PARKING BRAKE SHOE STRUT LH (SEE PAGE 33-19 ) 6. REMOVE PARKING BRAKE SHOE ASSY LH NO.1 (SEE PAGE 33-19 ) 7. REMOVE PARKING BRAKE SHOE ADJUSTING SCREW SET (SEE PAGE 33-19 ) 8. REMOVE PARKING BRAKE SHOE ASSY LH NO.2 (SEE PAGE 33-19 ) 9. SEPARATE SPEED SENSOR REAR LH (4WD DRIVE TYPE) (SEE PAGE 30-60 ) 10. REMOVE REAR AXLE SHAFT LH NUT (4WD DRIVE TYPE) (SEE PAGE 30-60 ) 11. REMOVE REAR AXLE HUB & BEARING ASSY LH (4WD DRIVE TYPE) (SEE PAGE 30-60 ) 12. (a) FF: REMOVE PARKING BRAKE CABLE ASSY NO.3 Remove the 2 bolts and separate the parking brake cable assy No.3 from the backing plate. 4WD: F45450 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3175 33-15 PARKING BRAKE (b) (c) (d) - PARKING BRAKE CABLE ASSY NO.3 Remove the 4 nuts and 2 bolts and separate the parking brake cable assy No.3 from the body. Separate the parking brake cable assy No.3 from the equalizer and remove the parking brake cable assy No.3. Remove the parking brake cable support bracket No.1 from the parking brake cable assy No.3. Bolt A Nut Nut Bolt B Parking Brake Cable Support Bracket No.1 Nut G24918 13. (a) (b) (c) INSTALL PARKING BRAKE CABLE ASSY NO.3 Attach the parking brake cable support bracket No.1 to the parking brake cable assy No.3. Connect the parking brake cable assy No.3 to the equalizer and slide boot stopper of No.1 cable should be inserted into groove of T-Metal fitting. Install the 4 nuts, 2 bolts and parking brake cable assy No.3 to the body. Torque: Bolt A: 8.5 N⋅m (87 kgf⋅cm, 75 in.⋅lbf) Bolt B: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) Nut: 6.0 N⋅m (61 kgf⋅cm, 53 in.⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3176 33-16 PARKING BRAKE (d) FF: - PARKING BRAKE CABLE ASSY NO.3 Connect the parking brake cable assy No.3 to the backing plate with the 2 bolts. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 4WD: F45450 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. (a) 27. 28. (a) 29. 30. 31. 32. APPLY HIGH TEMPERATURE GREASE (SEE PAGE 33-19 ) INSTALL REAR AXLE HUB & BEARING ASSY LH (4WD DRIVE TYPE) (SEE PAGE 30-60 ) INSTALL REAR AXLE SHAFT LH NUT (4WD DRIVE TYPE) (SEE PAGE 30-60 ) INSTALL SPEED SENSOR REAR LH (4WD DRIVE TYPE) (SEE PAGE 30-60 ) INSTALL PARKING BRAKE SHOE ASSY LH NO.2 (SEE PAGE 33-19 ) INSTALL PARKING BRAKE SHOE ADJUSTING SCREW SET (SEE PAGE 33-19 ) INSTALL PARKING BRAKE SHOE ASSY LH NO.1 (SEE PAGE 33-19 ) INSTALL PARKING BRAKE SHOE STRUT LH (SEE PAGE 33-19 ) INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING (SEE PAGE 33-19 ) CHECK PARKING BRAKE INSTALLATION (SEE PAGE 33-19 ) INSPECT BEARING BACKLASH (4WD DRIVE TYPE) (SEE PAGE 30-3 ) INSPECT AXLE HUB DEVIATION (4WD DRIVE TYPE) (SEE PAGE 30-3 ) INSTALL REAR DISC Aligning the matchmarks, install the rear disc. ADJUST PARKING BRAKE SHOE CLEARANCE (SEE PAGE 33-19 ) CONNECT REAR DISC BRAKE CALIPER ASSY LH Install the rear disc brake caliper assy LH with the 2 bolts. Torque: 78 N⋅m (800 kgf⋅cm, 58 ft⋅lbf) INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT PARKING BRAKE PEDAL TRAVEL (SEE PAGE 33-2 ) ADJUST PARKING BRAKE PEDAL TRAVEL (SEE PAGE 33-2 ) CHECK ABS SPEED SENSOR SIGNAL (4WD DRIVE TYPE) (SEE PAGE 05-765 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3177 33-17 PARKING BRAKE - PARKING BRAKE ASSY PARKING BRAKE ASSY 330CR-03 COMPONENTS FF: Parking Brake Shoe Strut LH Rear Disc Brake Caliper Assy LH Parking Brake Shoe Strut Compression Spring Parking Brake Shoe Assy LH No.2 78 (800, 58) Parking Brake Shoe Hold Down Spring Pin No.2 Parking Brake Shoe Hold Down Spring Cup No.2 Parking Brake Shoe Return Tension Spring No.1 Shim Parking Brake Shoe Hold Down Spring
C-W asher Parking Brake Shoe Lever Parking Brake Shoe Hold Down Spring Cup No.1 Parking Brake Shoe Hold Down Spring Pin No.1 Parking Brake Shoe Assy LH No.1 Parking Brake Shoe Adjusting Screw Set Parking Brake Shoe Return Tension Spring No.2 Parking Brake Shoe Hold Down Spring Cup No.2 Parking Brake Shoe Hold Down Spring Parking Brake Shoe Hold Down Spring Cup No.1 Rear Disc Parking Brake Shoe Adjusting Hole Plug N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part High Temperature grease F47274 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3178 33-18 PARKING BRAKE - PARKING BRAKE ASSY 4WD: Speed Sensor RR LH Rear Disc Brake Caliper Assy LH 78 (800, 58) 8.0 (82, 71 in.⋅lbf) Parking Brake Shoe Strut Compression Spring 78 (800, 58) Parking Brake Shoe Strut LH Parking Brake Shoe Hold Down Spring Pin No.2 Parking Brake Shoe Assy LH No.2 Parking Brake Shoe Return Tension Spring No.1
C-W asher Parking Brake Shoe Hold Down Spring Cup No.2 Shim Parking Brake Shoe Lever Parking Brake Shoe Hold Down Spring Parking Brake Shoe Hold Down Spring Cup No.1 Parking Brake Shoe Hold Down Spring Pin No.1 75 (765, 55) Parking Brake Shoe Assy LH No.1
Rear Axle Shaft Nut 294 (3,000, 217) Parking Brake Shoe ReturnTension Spring No.2 Parking Brake Shoe Adjusting Screw Set 75 (765, 55) Parking Brake Shoe Hold Down Spring Cup No.2 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part High Temperature grease Parking Brake Shoe Hold Down Spring Rear Disc Rear Axle Hub & Bearing Assy LH Parking Brake Shoe Adjusting Hole Plug F47275 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3179 33-19 PARKING BRAKE - PARKING BRAKE ASSY 330CS-04 OVERHAUL HINT:

Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. REMOVE REAR WHEEL SEPARATE REAR DISC BRAKE CALIPER ASSY LH Remove the 2 bolts and separate the rear disc brake caliper assy LH. 1. 2. (a) HINT: Do not disconnect the flexible hose from the disc brake caliper assy LH. 3. REMOVE REAR DISC (a) Release the parking brake, and remove the rear disc. HINT: If the disc cannot be removed easily, turn the shoe adjuster until the wheel turns freely. Contract D28126 (b) (c) Machmarks Place machmarks on the rear disc and the axle hub. Remove the rear disc. F41543 4. (a) INSPECT BRAKE DISC INSIDE DIAMETER Using a brake drum gauge or equivalent tool, measure the inside diameter of the rear disc. Standard inside diameter: 190 mm (7.480 in.) Maximum inside diameter: 191 mm (7.520 in.) If the inside diameter exceeds the maximum, replace the brake disc. F06409 5. (a) REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING Using needle-nose pliers, remove the 2 parking brake shoe return tension springs No.1. D28127 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3180 33-20 PARKING BRAKE 6. (a) - PARKING BRAKE ASSY REMOVE PARKING BRAKE SHOE STRUT LH Remove the parking brake shoe strut LH and the parking brake shoe strut compression spring. 7. (a) (b) (c) G25968 8. Adjusting Screw Set (a) (b) REMOVE PARKING BRAKE SHOE ASSY LH NO.1 Remove the parking brake shoe hold down spring cup No.1, parking brake shoe hold down spring and parking brake shoe hold down spring cup No.2. FF: Remove the parking brake shoe hold down spring pin No.1. Disconnect the parking brake shoe return spring No.2 and remove the parking brake shoe assy LH No.1. REMOVE PARKING BRAKE SHOE ADJUSTING SCREW SET Remove the parking brake shoe adjusting screw set. Remove the parking brake shoe return tension spring No.2. Return tension Spring F45549 9. (a) (b) REMOVE PARKING BRAKE SHOE ASSY LH NO.2 Remove the parking brake shoe hold down spring cup No.1, parking brake shoe hold down spring, parking brake shoe hold down spring cup No.2 and parking brake shoe hold down spring pin No.2. Remove the parking brake shoe assy LH No.2. G25969 (c) Using needle-nose pliers, disconnect the parking brake cable No.3 from the parking brake cable shoe lever. NOTICE: Be careful not to damage parking brake cable No.3. R00310 10. 11. 12. SEPARATE SPEED SENSOR REAR LH (4WD DRIVE TYPE) (SEE PAGE 30-60 ) REMOVE REAR AXLE SHAFT LH NUT (4WD DRIVE TYPE) (SEE PAGE 30-60 ) SST 09930-00010 REMOVE REAR AXLE HUB & BEARING ASSY LH (4WD DRIVE TYPE) (SEE PAGE 30-60 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3181 33-21 PARKING BRAKE 13. (a) - PARKING BRAKE ASSY REMOVE PARKING BRAKE SHOE HOLD DOWN SPRING PIN (4WD DRIVE TYPE) Remove the parking brake shoe hold down spring pin No.1. G24920 14. (a) (b) REMOVE PARKING BRAKE SHOE TYPE C WASHER Using a screwdriver, remove the C-washer. Remove the shim and parking brake shoe lever from parking brake shoe assy LH No.2. F41058 15. INSPECT PARKING BRAKE SHOE LINING THICKNESS (a) Using a ruler, measure the thickness of the shoe lining. Standard thickness: 2.5 mm (0.098 in.) Minimum thickness: 1.0 mm (0.039 in.) If the lining thickness is less than or equal to the minimum, or if there is severe or uneven wear, replace the brake shoe. R00311 16. INSPECT BRAKE DISC AND PARKING BRAKE SHOE LINING FOR PROPER CONTACT (a) Apply chalk to the inside surface of the disc, then grind down the brake shoe lining to fit disc. If the contact between the brake disc and the shoe lining is improper, repair it using a brake shoe grinder or replace the brake shoe assembly. BR0828 17. (a) INSTALL PARKING BRAKE SHOE TYPE C WASHER Using a feeler gauge, measure the clearance. Standard clearance: Less than 0.35 mm (0.014 in.) If the clearance is not within the specifications, replace the shim with one of the correct size. Shim Thickness Shim Thickness 0.3 mm (0.012 in.) 0.9 mm (0.035 in.) 0.6 mm (0.024 in.) - R00343 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3182 33-22 PARKING BRAKE - PARKING BRAKE ASSY (b) Using pliers, install the parking brake shoe lever LH and the shim with a new C-washer. 18. (a) APPLY HIGH TEMPERATURE GREASE Apply high temperature grease to the shaded parts shown in the illustration of the backing plate which make contact with the shoe. 19. INSTALL PARKING BRAKE SHOE HOLD DOWN SPRING PIN (4WD DRIVE TYPE) Install the parking brake shoe hold down spring pin No.1. C64144 High Temperature Grease C97930 (a) G24920 20. 21. 22. INSTALL REAR AXLE HUB & BEARING ASSY LH (4WD DRIVE TYPE) (SEE PAGE 30-60 ) INSTALL REAR AXLE SHAFT LH NUT (4WD DRIVE TYPE) (SEE PAGE 30-60 ) INSTALL SPEED SENSOR REAR LH (4WD DRIVE TYPE) (SEE PAGE 30-60 ) 23. (a) INSTALL PARKING BRAKE SHOE ASSY LH NO.2 Using needle-nose pliers, connect the parking brake cable No.3 to the parking brake cable shoe lever. NOTICE: Be careful not to damage the parking brake cable No.3. R00310 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3183 33-23 PARKING BRAKE - PARKING BRAKE ASSY (b) Install the parking brake shoe assy LH No.2 with the parking brake shoe hold down spring, parking brake shoe hold down spring cup No.1, parking brake shoe hold down spring cup No.2 and parking brake shoe hold down spring pin No.2. 24. INSTALL PARKING BRAKE SHOE ADJUSTING SCREW SET Apply high temperature grease to the parking brake shoe adjusting bolt and piece. G25969 (a) Piece Adjusting Bolt High Temperature Grease F41705 (b) Adjusting Screw Set Return tension Spring (c) Adjusting Screw Set Attach the parking brake shoe return tension spring No.2 to parking brake shoe assy LH No.1 and parking brake shoe assy LH No.2. Attach the parking brake shoe adjusting screw set to the parking brake shoe assy LH No.1 and parking brake shoe assy LH No.2. F45550 25. (a) (b) INSTALL PARKING BRAKE SHOE ASSY LH NO.1 FF: Install the parking brake shoe hold down spring pin No.1. Install the parking brake shoe assy LH No.1 with the parking brake shoe hold down spring, parking brake shoe hold down spring cup No.2, parking brake shoe hold down spring cup No.2. G25968 26. (a) INSTALL PARKING BRAKE SHOE STRUT LH Attach the parking brake shoe strut LH and the parking brake shoe strut compression spring to parking brake shoe assy LH No.2 and parking brake shoe assy LH No.1. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3184 33-24 PARKING BRAKE 27. (a) - PARKING BRAKE ASSY INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING Using needle-nose pliers, install the 2 return tension springs No.1 as shown in the illustration. HINT: First install the front side spring then the rear side spring. D28127 28. CHECK PARKING BRAKE INSTALLATION (a) Check that each part is installed properly. NOTICE: There should be no oil or grease on the friction surface of the shoe lining and disc. RH Front C88601 29. 30. 31. (a) LH Front F45453 INSPECT BEARING BACKLASH (4WD DRIVE TYPE) (SEE PAGE 30-3 ) INSPECT AXLE HUB DEVIATION (4WD DRIVE TYPE) (SEE PAGE 30-3 ) INSTALL REAR DISC Aligning the matchmarks, install the rear disc. 32. (a) (b) Expand (c) (d) (e) Contract ADJUST PARKING BRAKE SHOE CLEARANCE Temporarily install the hub nuts. Remove the hole plug, turn the adjuster and expand the shoes until the disc locks. Contract the shoe adjuster until the disc rotates smoothly. Standard : Return 8 notches Check that the shoe has no brake drag. Install the hole plug. F45452 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3185 33-25 PARKING BRAKE 33. (a) 34. 35. 36. 37. - PARKING BRAKE ASSY CONNECT REAR DISC BRAKE CALIPER ASSY LH Install the rear disc brake caliper assy LH with the 2 bolts. Torque: 78 N⋅m (800 kgf⋅cm, 58 ft⋅lbf) INSTALL REAR WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) INSPECT PARKING BRAKE PEDAL TRAVEL (SEE PAGE 33-2 ) ADJUST PARKING BRAKE PEDAL TRAVEL (SEE PAGE 33-2 ) CHECK ABS SPEED SENSOR SIGNAL (4WD DRIVE TYPE) (SEE PAGE 05-765 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3186 40-32 AUTOMATIC TRANSMISSION / TRANS - SPEED SENSOR (U151E/U151F) SPEED SENSOR (U151E/U151F) 40060-09 REPLACEMENT 1. 2. 3. REMOVE BATTERY REMOVE AIR CLEANER ASSY REMOVE AIR CLEANER HOSE NO.1 4. (a) (b) REMOVE SPEED SENSOR (NT SENSOR) Disconnect the speed sensor connector. Remove the bolt and speed sensor. 5. (a) (b) REMOVE SPEED SENSOR (NC SENSOR) Disconnect the speed sensor connector. Remove the bolt and speed sensor. 6. (a) (b) INSTALL SPEED SENSOR (NC SENSOR) Coat the O-ring with ATF. Install the speed sensor with the bolt. Torque: 11 N⋅m (115 kgf⋅cm, 8 ft⋅lbf) C90569 C90570 HINT: Make sure of the sensor manufacturer’s name. (c) Connect the speed sensor connector. C90570 7. (a) (b) INSTALL SPEED SENSOR (NT SENSOR) Coat the O-ring with ATF. Install the speed sensor with the bolt. Torque: 11 N⋅m (115 kgf⋅cm, 8 ft⋅lbf) HINT: Make sure of the sensor manufacturer’s name. (c) Connect the speed sensor connector. C90569 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3218 40-33 AUTOMATIC TRANSMISSION / TRANS 8. 9. 10. 11. - SPEED SENSOR (U151E/U151F) INSTALL AIR CLEANER HOSE NO.1 INSTALL AIR CLEANER ASSY INSTALL BATTERY PERFORM INITIALIZATION(SEE PAGE 01-4 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3219 40-37 AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION WIRE (U151E/U151F) TRANSMISSION WIRE (U151E/U151F) 400FS-04 REPLACEMENT 1. 2. (a) (b) REMOVE ENGINE UNDER COVER NO.1 DRAIN AUTOMATIC TRANSAXLE FLUID Remove the drain plug and gasket, and drain ATF. Install a new gasket and the drain plug. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) 3. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSY (a) Remove the 18 bolts, oil pan and gasket. NOTICE: Some fluid will remain in the oil pan. Remove all of the oil pan bolts, and carefully remove the oil pan assembly. C91925 (b) Remove the 2 magnets from the oil pan. (c) Examine the particles in the oil pan. (1) Remove the magnets and use them to collect any steel chips. Look at the chips and particles in the pan and on the magnet carefully to see the type of wear which might be found in the transaxle. Steel (magnetic): bearing, gear and plate wear Brass (non-magnetic): bearing wear 4. (a) (b) DISCONNECT TRANSMISSION WIRE Disconnect the 7 shift solenoid valve connectors. Remove the bolt and lock plate, and disconnect the ATF temperature sensor. D30865 AT0103 C91927 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3223 40-38 AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION WIRE (U151E/U151F) 5. (a) (b) REMOVE TRANSMISSION WIRE Disconnect the transmission wire connectors. Remove the bolt and transmission wire. 6. (a) INSTALL TRANSMISSION WIRE Coat an O-ring of the transmission wire connector with ATF. (b) Install the transmission wire and bolt. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) 7. (a) (b) CONNECT TRANSMISSION WIRE Coat an O-ring of the ATF temperature sensor with ATF. Install the ATF temperature sensor with the lock plate and bolt. Torque: 6.6 N⋅m (67 kgf⋅cm, 58 in.⋅lbf) Connect the 7 shift solenoid valve connectors. D30866 D30867 D30866 (c) C91927 8. Magnet (a) (b) INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSY Install the 2 magnets in the oil pan. Apply the seal packing or equivalent to the 18 bolts. Seal packing: THREE BOND 1344 or equivalent D30865 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3224 40-39 AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION WIRE (U151E/U151F) (c) Install a new gasket, oil pan and 18 bolts to the transaxle case. Torque: 7.8 N⋅m (80 kgf⋅cm, 69 in.⋅lbf) NOTICE: Apply the seal packing or equivalent to the bolts and tighten them within 10 minutes of application. C91925 9. 10. 11. 12. ADD AUTOMATIC TRANSAXLE FLUID INSPECT AUTOMATIC TRANSAXLE FLUID (SEE PAGE 40-2 ) INSTALL ENGINE UNDER COVER NO.1 RESET MEMORY (SEE PAGE 05-1005 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3225 40-44 AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION VALVE BODY ASSY (U151E/U151F) TRANSMISSION VALVE BODY ASSY (U151E/U151F) 400FT-04 REPLACEMENT 1. 2. (a) (b) REMOVE ENGINE UNDER COVER NO.1 DRAIN AUTOMATIC TRANSAXLE FLUID Remove the drain plug and gasket, and drain ATF. Install a new gasket and the drain plug. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) 3. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSY (a) Remove the 18 bolts, oil pan and gasket. NOTICE: Some fluid will remain in the oil pan. Remove all of the oil pan bolts, and carefully remove the oil pan assembly. C91925 (b) Remove the 2 magnets from the oil pan. (c) Examine the particles in the oil pan. (1) Remove the magnets and use them to collect any steel chips. Look at the chips and particles in the pan and on the magnet carefully to see the type of wear which might be found in the transaxle. Steel (magnetic): bearing, gear and plate wear Brass (non-magnetic): bearing wear 4. (a) (b) DISCONNECT TRANSMISSION WIRE Disconnect the 7 shift solenoid valve connectors. Remove the bolt and lock plate, and disconnect the ATF temperature sensor. D30865 AT0103 C91927 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3230 40-45 AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION VALVE BODY ASSY (U151E/U151F) 5. REMOVE VALVE BODY OIL STRAINER ASSY (a) Remove the 3 bolts and oil strainer. NOTICE: Be careful that some fluid will come out of the oil strainer. C91931 (b) Remove the O-ring from the oil strainer. C91932 6. (a) REMOVE TRANSMISSION VALVE BODY ASSY Support the valve body assy and remove the 17 bolts and the valve body assy. NOTICE: Be careful not to drop the check valve body, spring and accumulator piston. C91933 (b) Remove the check ball body and spring. F46566 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3231 40-46 AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION VALVE BODY ASSY (U151E/U151F) (c) Remove the 5 bolts, 3 lock plates and 7 shift solenoid valves. 7. (a) INSTALL TRANSMISSION VALVE BODY ASSY Install the spring and check ball body. (b) Install the 7 shift solenoid valves and 3 lock plates with the 5 bolts. Torque: Bolts A, B: 11 N·m (110 kgf·cm, 8 ft.⋅lbf) Bolts C, D: 6.6 N·m (67 kgf·cm, 58 in. lbf) Bolt length: Bolt A: 16 mm (0.63 in.) Bolt B: 57 mm (2.2 in.) Bolt C: 20 mm (0.9 in.) Bolt D: 12 mm (0.47 in.) D30644 F46566 B A B C D D30644 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3232 40-47 AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION VALVE BODY ASSY (U151E/U151F) (c) C
A B B B C B A
B C C C C91933 Align the groove of the manual valve with the pin of the lever. (d) Install the 17 bolts. Torque: 11 N⋅m (110 kgf⋅cm, 8 ft⋅lbf) NOTICE:  Push the valve body against the accumulator piston spring and the check ball body to install it.  First, temporarily tighten those bolts marked by
in the illustration because they are positioning bolts. Bolt length: Bolts A: 25 mm (0.984 in.) Bolts B: 57 mm (2.244 in.) Bolts C: 41 mm (1.614 in.) 8. (a) (b) INSTALL VALVE BODY OIL STRAINER ASSY Coat a new O-ring with ATF. Install the O-ring to the oil strainer. (c) Install the oil strainer with the 3 bolts. Torque: 11 N⋅m (110 kgf⋅cm, 8 ft⋅lbf) 9. (a) (b) CONNECT TRANSMISSION WIRE Coat an O-ring with ATF. Install the ATF temperature sensor with the lock plate and bolt. Torque: 6.6 N⋅m (67 kgf⋅cm, 58 in.⋅lbf) Connect the 7 shift solenoid valve connectors. C91932 C91931 (c) C91927 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3233 40-48 AUTOMATIC TRANSMISSION / TRANS 10. Magnet (a) (b) - TRANSMISSION VALVE BODY ASSY (U151E/U151F) INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSY Install the 2 magnets to the oil pan. Apply the seal packing or equivalent to the 18 bolts. Seal packing: THREE BOND 1344 or equivalent D30865 (c) Install a new gasket, the oil pan and 18 bolts to the transaxle case. Torque: 7.8 N⋅m (80 kgf⋅cm, 69 in.⋅lbf) NOTICE: Apply seal packing or equivalent to the bolts and tighten them within 10 minutes of application. C91925 11. 12. 13. 14. ADD AUTOMATIC TRANSAXLE FLUID INSPECT AUTOMATIC TRANSAXLE FLUID (SEE PAGE 40-2 ) INSTALL ENGINE UNDER COVER NO.1 RESET MEMORY (SEE PAGE 05-1005 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3234 40-55 AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL OIL SEAL (U151E) FRONT DIFFERENTIAL OIL SEAL (U151E) 40066-10 REPLACEMENT 1. 2. 3. (a) (b) 4. 5. REMOVE FRONT WHEELS REMOVE ENGINE UNDER COVER NO.1 DRAIN AUTOMATIC TRANSAXLE FLUID Remove the drain plug, gasket and drain ATF. Install a new gasket and the drain plug. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) REMOVE FRONT DRIVE SHAFT ASSY LH (SEE PAGE 30-21 ) SST 09520-01010, 09520-24010 (09520-32040) REMOVE FRONT DRIVE SHAFT ASSY RH (2WD DRIVE TYPE) (SEE PAGE 30-21 ) SST 6. (a) REMOVE TRANSAXLE HOUSING OIL SEAL Using SST, pull out the oil seal. SST 09308-00010 7. REMOVE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL Using SST, pull out the oil seal. SST 09308-00010 D25831 SST (a) D25832 8. (a) SST (b) INSTALL TRANSAXLE HOUSING OIL SEAL Using SST and a hammer, drive in a new oil seal. SST 09316-6001 1 (09316-00011) Oil seal drive in depth: 0
0.5 mm (0
0.020 in.) Coat the lip of the oil seal with MP grease. D25833 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3241 40-56 AUTOMATIC TRANSMISSION / TRANS 9. (a) (b) - FRONT DIFFERENTIAL OIL SEAL (U151E) INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL Using SST and a hammer, drive in a new oil seal. SST 09223-15020, 09950-70010 (09951-07150) Oil seal drive in depth: 0
0.5 mm (0
0.020 in.) Coat the lip of the oil seal with MP grease. SST D25834 10. 11. 12. 13. 14. 15. 16. INSTALL FRONT DRIVE SHAFT ASSY LH (SEE PAGE 30-21 ) INSTALL FRONT DRIVE SHAFT ASSY RH (2WD DRIVE TYPE) (SEE PAGE 30-21 ) INSTALL FRONT WHEELS Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) ADD AUTOMATIC TRANSAXLE FLUID INSPECT AUTOMATIC TRANSAXLE FLUID (SEE PAGE 40-2 ) INSTALL ENGINE UNDER COVER NO.1 CHECK ABS SPEED SENSOR SIGNAL (SEE PAGE 05-765 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3242 40-71 AUTOMATIC TRANSMISSION / TRANS - SHIFT LEVER ASSY (ATM) 40128-02 ADJUSTMENT 1. (a) With the brake pedal depressed, shift while holding the shift lever knob button in. (The ignition switch must be in ON position.) Shift while holding the shift lever knob button in. (b) INSPECT SHIFT LEVER POSITION When shifting the shift lever to each position, make sure that it moves smoothly, can be moderately operated and the position indicator displays correctly. Positions which can be operated without pressing the shift lever knob button R → N → D, L → 2 → 3 → D → N Positions which can be operated only while pressing the shift lever knob button D → 3 → 2 → L, N → R → P Positions which can be operated only while pressing the shift lever knob button, ignition switch ON and brake pedal depressed P→R When starting the engine, make sure that the vehicle moves forward when shifting from N to D position, and moves backward when shifting to R position. Shift normally F46552 2. (a) ADJUST SHIFT LEVER POSITION Loosen the nut on the control shaft lever. (b) (c) (d) (e) Push the control shaft fully downward. Return the control shaft lever 2 notches to N position. Set the shift lever to N position. While holding the shift lever lightly toward the R position side, tighten the shift lever nut. Torque: 14.7 N·m (150 kgf·cm, 10 ft·lbf) Start the engine and make sure that the vehicle moves forward when shifting the lever from the N to D position and moves backward when shifting it to the R position. D25118 (f) D25119 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3257 40-61 AUTOMATIC TRANSMISSION / TRANS - SHIFT LEVER ASSY (ATM) SHIFT LEVER ASSY (ATM) 4016Z-01 COMPONENTS Shift Lever Knob Shift Lever Knob Cover No.1 Spring Shift Lever Knob Cover Transmission Control Switch Shift Lock Release Cover Shift Lever Knob Button Control Position Indicator Plate Shift Lock Release Button Position Indicator Housing Upper Spring Position Indicator Slide Cover Position Indicator Slide Cover No.2 Position Indicator Housing Lower Position Indicator Light Guide Transmission Shift Main Switch Indicator Lamp Cap Shift Lever Knob Sleeve Indicator Lamp Bulb Pattern Select Switch Assy No.1 Indicator Lamp Wire Sub-assy Apply MP grease F46553 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3247 40-62 AUTOMATIC TRANSMISSION / TRANS - SHIFT LEVER ASSY (ATM) 40170-02 OVERHAUL HINT: COMPONENTS: SHIFT LEVER ASSY (See page 40-61 ) 1. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSY CENTER (SEE PAGE71-10 ) 2. REMOVE FLOOR CARPET COVER CENTER RH (SEE PAGE71-10 ) 3. REMOVE FLOOR CARPET COVER CENTER LH (SEE PAGE71-10 ) 4. REMOVE CONSOLE BOX ASSY (SEE PAGE71-10 ) 5. (a) DISCONNECT TRANSMISSION CONTROL CABLE ASSY Disconnect the floor shift transmission control cable assy end from the floor shift assy. Floor Shift Transmission Control Cable D25449 Front 6. (a) (b) REMOVE FLOOR SHIFT ASSY Disconnect the 3 connectors. Remove the 4 nuts and dismount the floor shift assy from the vehicle. 7. (a) REMOVE SHIFT LEVER KNOB SUB-ASSY Releasing the lock by pressing the click, disconnect the indicator lamp wire connector from the shift lever plate. (b) (c) Using a screwdriver, release the stopper of the connector. Using a small screwdriver, disengage the locking lug of the terminals 2 and 6, and pull the terminals out from the rear. Disconnect the 2 wire harnesses of the transmission control switch from the clamp. D31757 Front D31758 Stopper (d) G30611 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3248 40-63 AUTOMATIC TRANSMISSION / TRANS (e) (f) - SHIFT LEVER ASSY (ATM) Lower the shift lever knob cover. Remove the 2 screws and shift lever knob from the shift lever. D25427 8. (a) REMOVE FLOOR SHIFT SHIFT LEVER KNOB COVER Remove the shift lever knob cover from the shift lever. 9. (a) REMOVE SHIFT LEVER KNOB BUTTON Using a screwdriver, release the claw and remove the shift lever knob button and spring from the shift lever knob. 10. (a) REMOVE TRANSMISSION CONTROL SWITCH Remove the screw from the shift lever knob, detach the transmission control switch together with the shift lever knob cover No.1. (b) Using a screwdriver, release the 2 claws and remove the transmission control switch from the shift lever knob cover No.1. Shift Lever Knob Button D25426 D25428 D25431 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3249 40-64 AUTOMATIC TRANSMISSION / TRANS Stopper - SHIFT LEVER ASSY (ATM) 11. (a) (b) REMOVE INDICATOR LAMP WIRE SUB-ASSY Using a screwdriver, release the stopper of the connector. Using a small screwdriver, disengage the locking lug of the terminals 3 and 7, and pull the terminals out from the rear. (c) Remove the indicator lamp wire from the position indicator housing lower. Remove the indicator lamp cap and indicator lamp bulb from the indicator lamp wire. D31759 (d) F46549 12. (a) REMOVE SHIFT LOCK RELEASE BUTTON COVER Using a small screwdriver, remove the shift lock release cover from the control position indicator plate. 13. (a) REMOVE CONTROL POSITION INDICATOR PLATE Using a screwdriver, release the 4 claws and remove the control position indicator plate from the position indicator housing lower. 14. (a) REMOVE POSITION INDICATOR HOUSING LOWER Remove the 4 screws, detach the position indicator housing lower from the shift lever plate. F46550 D25429 G30569 D31850 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3250 40-65 AUTOMATIC TRANSMISSION / TRANS - SHIFT LEVER ASSY (ATM) 15. (a) REMOVE SHIFT LOCK RELEASE BUTTON While pressing the 2 claws, remove the shift lock release button and spring from the position indicator housing lower. 16. (a) REMOVE PATTERN SELECT SWITCH ASSY NO.1 Using a screwdriver, release the 4 claws and remove the pattern select switch assy No.1 from the position indicator housing lower. 17. (a) REMOVE POSITION INDICATOR HOUSING UPPER Using a screwdriver,release the 4 claws and remove the position indicator housing upper from the position indicator housing loweh. 18. (a) REMOVE POSITION INDICATOR SLIDE COVER Remove the position indicator slide cover from the position indicator housing lower. Remove the position indicator light guide from the position indicator lower. D25433 C83287 D31851 (b) D31852 19. (a) REMOVE POSITION INDICATOR SLIDE COVER Remove the position indicator slide cover No.2 from the position indicator slide cover. D31853 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3251 40-66 AUTOMATIC TRANSMISSION / TRANS - SHIFT LEVER ASSY (ATM) 20. (a) REMOVE TRANSMISSION SHIFT MAIN SWITCH Remove the screw and transmission shift main switch from the position indicator housing lower. 21. (a) REMOVE SHIFT LEVER KNOB SLEEVE Remove the shift lever knob sleeve from the shift lever. 22. (a) INSTALL SHIFT LEVER KNOB SLEEVE Apply MP grease to the shown part of the shift lever knob sleeve and install it to the shift lever. 23. (a) INSTALL TRANSMISSION SHIFT MAIN SWITCH Install the transmission shift main switch to the position indicator housing lower with the screw. 24. (a) INSTALL POSITION INDICATOR SLIDE COVER Install the position indicator slide cover No.2 to the position indicator slide cover. D31854 Shift Lever Knob Sleeve C83299 Shift Lever Knob Sleeve C83299 D31854 D31853 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3252 40-67 AUTOMATIC TRANSMISSION / TRANS 25. (a) (b) - SHIFT LEVER ASSY (ATM) INSTALL POSITION INDICATOR SLIDE COVER Install the position indicator slide cover to the position indicator housing lower. Install the position indicator light guide to the position indicator housing lower. D31852 26. (a) INSTALL POSITION INDICATOR HOUSING UPPER Install the position indicator housing upper to the position indicator housing lower. 27. (a) INSTALL PATTERN SELECT SWITCH ASSY NO.1 Install the pattern select switch assy No. 1 to the position indicator housing lower. D31851 HINT: Fit the claws securely. C83287 28. (a) INSTALL SHIFT LOCK RELEASE BUTTON Install the shift lock release button and greased spring to the position indicator housing lower. HINT: Fit the claws securely. D25433 29. (a) INSTALL POSITION INDICATOR HOUSING LOWER Install the position indicator housing lower to the shift lever plate with 4 screws. D31850 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3253 40-68 AUTOMATIC TRANSMISSION / TRANS 30. (a) - SHIFT LEVER ASSY (ATM) INSTALL CONTROL POSITION INDICATOR PLATE Install the control position indicator plate to the position indicator housing lower. HINT: Fit the claws securely. D25429 G30569 31. (a) INSTALL SHIFT LOCK RELEASE BUTTON COVER Install the shift lock release cover to the control position indicator plate. 32. (a) INSTALL INDICATOR LAMP WIRE SUB-ASSY Install the indicator lamp bulb and indicator lamp cap to the indicator lamp wire. Install the indicator lamp wire to the position indicator housing lower. F46550 (b) F46549 33. (a) INSTALL TRANSMISSION CONTROL SWITCH Install the transmission control switch to the shift lever knob cover No.1. HINT: Fit the claws securely. D25431 (b) Install the shift lever knob cover No.1 to the shift lever knob with a screw. D25428 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3254 40-69 AUTOMATIC TRANSMISSION / TRANS 34. (a) - SHIFT LEVER ASSY (ATM) INSTALL SHIFT LEVER KNOB BUTTON Apply MP grease to the shift lever knob button and spring and install them to the shift lever knob. D25426 35. (a) INSTALL SHIFT LEVER KNOB COVER NO.1 Install the shift lever knob cover to the shift lever. 36. (a) INSTALL SHIFT LEVER KNOB SUB-ASSY Install the wire harness of the transmission control switch as shown in the illustration. (b) (c) (d) Install the shift lever knob to the shift lever with 2 screws. Install the shift lever knob cover to shift lever knob. Install the 2 wire harnesses of the transmission control switch. (e) Install the indicator lamp wire harness and connector as shown in the illustration. G30617 D25427 D31758 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3255 40-70 AUTOMATIC TRANSMISSION / TRANS 37. (a) B A - SHIFT LEVER ASSY (ATM) INSTALL FLOOR SHIFT ASSY Install the floor shift assy to the vehicle with the 4 nuts. Torque: 12 N⋅m (122 kgf⋅cm, 9 ft⋅lbf) HINT: Tighten them in the order, A, B, C and D. (b) Connect the 3 connectors. D C D31757 38. (a) INSTALL TRANSMISSION CONTROL CABLE ASSY Connect the floor shift transmission control cable end to the floor shift assy. HINT: Install it with the uneven surface facing up. Floor Shift Transmission Control Cable D25449 39. 40. INSPECT SHIFT LEVER POSITION (SEE PAGE40-71 ) ADJUST SHIFT LEVER POSITION (SEE PAGE40-71 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3256 40-57 AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL OIL SEAL (U151F) FRONT DIFFERENTIAL OIL SEAL (U151F) 4012E-04 REPLACEMENT HINT: When replacing the front differential oil seal (LH) or (RH), perform step 1 to 11 or 12 to 23 respectively. 1. REMOVE FRONT WHEEL 2. REMOVE ENGINE UNDER COVER NO.1 3. DRAIN AUTOMATIC TRANSAXLE FLUID (a) Remove the drain plug, gasket and drain ATF. (b) Install a new gasket and the drain plug. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) 4. REMOVE FRONT DRIVE SHAFT ASSY LH (SEE PAGE 30-21 ) SST 09520-01010, 09520-24010 (09520-32040) 5. SST (a) REMOVE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL Using SST, pull out the oil seal. SST 09308-00010 D25832 6. (a) (b) INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL Using SST and a hammer, drive in a new oil seal. SST 09223-15020, 09950-70010 (09951-07200) Oil seal drive in depth: 0
0.5 mm (0
0.020 in.) Coat the lip of the oil seal with MP grease. SST D25834 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. INSTALL FRONT DRIVE SHAFT ASSY LH (SEE PAGE 30-21 ) INSTALL FRONT WHEEL ADD AUTOMATIC TRANSAXLE FLUID INSPECT AUTOMATIC TRANSAXLE FLUID (SEE PAGE 40-2 ) INSTALL ENGINE UNDER COVER NO.1 REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (SEE PAGE 14-149 ) REMOVE FRONT DRIVE SHAFT ASSY RH (SEE PAGE 30-21 ) SST 09520-01010, 09520-24010 (09520-32040) REMOVE TRANSFER STIFFENER PLATE RH (SEE PAGE 40-20 ) REMOVE AUTOMATIC TRANSMISSION W/TRANSFER (SEE PAGE 40-20 ) REMOVE TRANSFER ASSY (SEE PAGE 31-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3243 40-58 AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL OIL SEAL (U151F) 17. (a) REMOVE TRANSAXLE HOUSING OIL SEAL Using a screwdriver with vinyl tape wrapped around its tip, remove the oil seal. NOTICE: Be careful not to damage the housing. D30693 A 18. (a) (b) INSTALL TRANSAXLE HOUSING OIL SEAL Using SST and a hammer, drive in a new oil seal. SST 09649-17010, 09950-70010 (09951-07200) Oil seal drive in depth: 6.0
0.5 mm (0.236
0.020 in.) Coat the lip of the oil seal with MP grease. SST D30913 19. 20. 21. 22. 23. 24. 25. INSTALL TRANSFER ASSY (SEE PAGE 31-9 ) INSTALL AUTOMATIC TRANSMISSION W/TRANSFER (SEE PAGE 40-20 ) INSTALL TRANSFER STIFFENER PLATE RH (SEE PAGE 40-20 ) INSTALL FRONT DRIVE SHAFT ASSY RH (SEE PAGE 30-21 ) INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (SEE PAGE 14-149 ) RESET MEMORY (SEE PAGE 05-1005 ) PERFORM INITIALIZATION (SEE PAGE 01-4 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3244 40-50 AUTOMATIC TRANSMISSION / TRANS - OIL W/HOSE COOLER ASSY (U151E/U151F) OIL W/HOSE COOLER ASSY (U151E/U151F) 4012F-02 REPLACEMENT 1. 2. (a) (b) REMOVE FRONT BUMPER COVER (SEE PAGE 76-2 ) DRAIN AUTOMATIC TRANSAXLE FLUID Remove the drain plug and gasket, and drain ATF. Install a new gasket and the drain plug. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) 3. (a) (b) REMOVE OIL COOLER ASSY Disconnect the 2 oil cooler hoses. Remove the bolt, nut and oil cooler assy. D25421 4. INSTALL OIL COOLER ASSY (a) Install the oil cooler assy, bolt A and nut B. HINT: After temporarily tightening the bolt A, fully tighten in order of the nut B, bolt A. Torque: 7.0 N⋅m (71 kgf⋅cm, 62 in.⋅lbf) (b) Connect the 2 oil cooler hoses. B A D25421 5. 6. 7. INSTALL FRONT BUMPER COVER (SEE PAGE 76-2 ) ADD AUTOMATIC TRANSAXLE FLUID INSPECT AUTOMATIC TRANSAXLE FLUID (SEE PAGE 40-2 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3236 40-1 AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (ATM) AUTOMATIC TRANSAXLE ASSY (ATM) 4005T-09 PRECAUTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. The automatic transaxle is composed of highly precision-finished parts, necessitating careful inspection before reassembly because even a small nick could cause fluid leakage or affect the performance. The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion from similar-looking parts of different sub-assemblies being on your workbench at the same time. The component groups are inspected and repaired from the converter housing side. As much as possible, complete the inspection, repair and reassembly before proceeding to the next component group. If a defect is found in a certain component group during reassembly, inspect and repair this group immediately. If a component group cannot be assembled because parts are being ordered, be sure to keep all parts of the group in a separate container while proceeding with disassembly, inspection, repair and reassembly of other component groups. Recommended ATF: T-IV All disassembled parts should be washed clean and any fluid passages and holes should be blown through with compressed air. Dry all parts with compressed air, never use shop rags. When using compressed air, always aim away from yourself to prevent accidentally spraying ATF or kerosene on your face. The recommended automatic transaxle fluid or kerosene should be used for cleaning. After cleaning, the parts should be arranged in the correct order for efficient inspection, repairs, and reassembly. When disassembling a valve body, be sure to match each valve together with the corresponding spring. New discs for the brakes and clutches that are to be used for replacement must be soaked in ATF for at least 15 minutes before reassembly. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with ATF prior to reassembly. All gaskets and rubber O-rings should be replaced. Do not apply adhesive cements to gaskets and similar parts. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the groove correctly. If a worn bushing is to be replaced, the sub-assembly containing the bushing must also be replaced. Check thrust bearings and races for wear or damage. Replace if necessary. Use petroleum jelly to keep parts in place. When working with FIPG material, you must observe the following. Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surface. Thoroughly clean all components to remove all the loose material. Clean both sealing surfaces with a non-residue solvent. Parts must be reassembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3187 40-2 AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE FLUID (ATM) AUTOMATIC TRANSAXLE FLUID (ATM) 4005R-09 ON-VEHICLE INSPECTION 1. CHECK FLUID LEVEL HINT: Drive the vehicle so that the engine and transaxle are at normal operating temperature. Fluid temperature: 70 - 80°C (158 - 176°F) (1) OK if hot Add if hot D25120 Park the vehicle on a level surface and set the parking brake. (2) With the engine idling and the brake pedal depressed, shift the shift lever into all positions from P to L position and return to P position. (3) Pull out the dipstick and wipe it clean. (4) Push it back fully into the pipe. (5) Pull it out and check that the fluid level is in the HOT position. If there are leaks, it is necessary to repair or replace O-rings, FIPGs, oil seals, plugs or other parts. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3188 40-31 AUTOMATIC TRANSMISSION / TRANS - SPEED SENSOR (U241E/U140F) SPEED SENSOR (U241E/U140F) 400TX-02 REPLACEMENT 1. 2. 3. REMOVE BATTERY REMOVE AIR CLEANER ASSY REMOVE AIR CLEANER HOSE NO.1 4. (a) (b) REMOVE SPEED SENSOR (NT SENSOR) Disconnect the connector. Remove the bolt and speed sensor. 5. (a) (b) REMOVE SPEED SENSOR (NC SENSOR) Disconnect the connector. Remove the bolt and speed sensor. 6. (a) (b) INSTALL SPEED SENSOR (NC SENSOR) Coat O-ring with ATF. Install the speed sensor with the bolt. Torque: 11.3 N⋅m (115 kgf⋅cm, 8 ft⋅lbf) D25412 D25413 HINT: Make sure of the manufacturer’s name. (c) Connect the connector. D25413 7. (a) (b) D25412 INSTALL SPEED SENSOR (NT SENSOR) Coat O-ring with ATF. Install the speed sensor with the bolt. Torque: 11.3 N⋅m (115 kgf⋅cm, 8 ft⋅lbf) HINT: Make sure of the manufacturer’s name. (c) Connect the connector. 8. INSTALL AIR CLEANER ASSY Torque: 5.0 N⋅m (51 kgf⋅cm, 44 in.⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3217 AUTOMATIC TRANSMISSION / TRANS - TORQUE CONVERTER CLUTCH AND DRIVE PLATE (ATM) 40-29 TORQUE CONVERTER CLUTCH AND DRIVE PLATE (ATM) 40063-11 INSPECTION 1. (a) SST INSPECT TORQUE CONVERTER CLUTCH ASSY Inspect the one-way clutch. (1) Install SST into the inner race of the one- way clutch. SST 09350-32014 (09351-32010) (2) Install SST so that it fits in the notch of the converter hub and outer race of the one-way clutch. SST 09350-32014 (09351-32020) AT0953 (3) Hold Lock Turn Free With the torque converter clutch setting up on its side, check that the one-way clutch locks when it is turned counterclockwise, and rotates smoothly clockwise. If necessary, clean the converter and retest the one- way clutch. Replace the converter if the one-way clutch still fails the test. AT3306 (b) Sample showing minimum amount of powders in ATF Actual Size D25367 Determine the condition of the torque converter clutch assy. (1) If the inspection result of the torque converter clutch assy meets the following item, replace the torque converter clutch. Malfunction item: Any metallic sound is heard from the torque converter clutch during stall test or when the shift lever is in neutral position. One-way clutch is free or locked in both directions. Fine powders exceeding the sample limit is identified in ATF. (See the sample.) HINT: The sample shows the auto fluid of approx. 0.25 liters (0.26 US qts, 0.22 Imp. qts) that is taken out from the removed torque converter clutch (c) Replace the ATF in the torque converter clutch. (1) If the ATF is discolored and/or has a foul odor, completely stir the ATF in the torque converter clutch and drain it with the face for installation facing up. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3215 40-30 AUTOMATIC TRANSMISSION / TRANS (d) - TORQUE CONVERTER CLUTCH AND DRIVE PLATE (ATM) Clean and check the oil cooler and oil pipe line. (1) If the torque converter clutch is inspected or the ATF is exchanged, clean the oil cooler and oil pipe line. HINT:

C11090 (e) OK NG The Bottom is Damaged Spray compressed air of 196 kPa (2 kgf/cm2, 28 psi) from the inlet hose. If plenty of fine powders are identified in the ATF, add new ATF using a bucket pump and clean it again. (2) If the ATF is cloudy, inspect the oil cooler (radiator). Prevent deformation of the torque converter clutch and damage to the oil pump gear. (1) When any marks due to interference are found on the end of the bolt for the torque converter clutch and on the bottom of the bolt hole, replace the bolt and the torque converter clutch. (2) All of the bolts shall have the same length. (3) No missing spring washer. D25368 2. (a) (b) INSPECT DRIVE PLATE & RING GEAR SUB-ASSY Set up a dial indicator and measure the drive plate runout. Check the damage of the ring gear. Maximum runout: 0.20 mm (0.0079 in.) If the runout is not within the specification or ring gear is damaged, replace the drive plate. C81014 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3216 40-34 AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION WIRE (U241E/U140F) TRANSMISSION WIRE (U241E/U140F) 4005V-06 REPLACEMENT 1. 2. (a) (b) REMOVE ENGINE UNDER COVER NO.1 DRAIN AUTOMATIC TRANSAXLE FLUID Remove the drain plug, gasket and drain ATF. Install a new gasket and drain plug. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) 3. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSY (a) Remove the 18 bolts, oil pan and gasket. NOTICE: Some fluid will remain in the oil pan. Remove all pan bolts, and carefully remove the oil pan assembly. Discard the gasket. (b) Remove the 2 magnets from the oil pan. C83111 (c) Examine particles in pan. (1) Remove the magnets and use them to collect any steel chips. Look carefully at the chips and particles in the pan and the magnet to anticipate what type of wear you will find in the transaxle. Steel (magnetic): bearing, gear and plate wear Brass (non-magnetic): bearing wear 4. (a) (b) SEPARATE TRANSMISSION WIRE Disconnect the 5 connectors. Remove the bolt and lock plate, and remove the ATF temperature sensor. 5. (a) (b) REMOVE TRANSMISSION WIRE Disconnect the transmission wire connector. Remove the bolt and transmission wire. AT0103 D25591 C50009 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3220 40-35 AUTOMATIC TRANSMISSION / TRANS 6. (a) (b) - TRANSMISSION WIRE (U241E/U140F) INSTALL TRANSMISSION WIRE Coat a O-ring of the transmission wire connector with ATF. Install the transmission wire. D03636 (c) Install the bolt. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) 7. (a) (b) CONNECT TRANSMISSION WIRE Coat a O-ring of the ATF temperature sensor with ATF. Install the ATF temperature sensor with the lock plate and bolt. Torque: 6.6 N⋅m (67 kgf⋅cm, 58 in.⋅lbf) Connect the 5 shift solenoid valve connectors. C50009 (c) D25591 8. (a) (b) INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSY Install the 2 magnets in the oil pan. Apply seal packing or equivalent to 18 bolts. Seal packing: THREE BOND 2430 or equivalent D25674 (c) Install a new gasket, oil pan and 18 bolts to the transaxle case. Torque: 7.6 N⋅m (77 kgf⋅cm, 67 in.⋅lbf) NOTICE: Because the bolts should be seal bolts, apply seal packing to bolts and tighten them within 10 minutes after application. C83111 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3221 40-36 AUTOMATIC TRANSMISSION / TRANS 9. 10. - TRANSMISSION WIRE (U241E/U140F) ADD AUTOMATIC TRANSAXLE FLUID INSPECT AUTOMATIC TRANSAXLE FLUID(SEE PAGE 40-2 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3222 40-40 AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION VALVE BODY ASSY (U241E/U140F) TRANSMISSION VALVE BODY ASSY (U241E/U140F) 40064-06 REPLACEMENT 1. 2. (a) (b) REMOVE ENGINE UNDER COVER NO.1 DRAIN AUTOMATIC TRANSAXLE FLUID Remove the drain plug, gasket and drain ATF. Install a new gasket and drain plug. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) 3. REMOVE AUTOMATIC TRANSAXLE OIL PAN SUB-ASSY (a) Remove the 18 bolts, oil pan and gasket. NOTICE: Some fluid will remain in the oil pan. Remove all pan bolts, and carefully remove the oil pan assembly. Discard the gasket. (b) Remove the 2 magnets from the oil pan. C83111 (c) Examine particles in pan. (1) Remove the magnets and use them to collect any steel chips. Look carefully at the chips and particles in the pan and the magnet to anticipate what type of wear you will find in the transaxle. Steel (magnetic): bearing, gear and plate wear Brass (non-magnetic): bearing wear 4. (a) (b) SEPARATE TRANSMISSION WIRE Disconnect the 5 connectors. Remove the bolt and lock plate, and remove the ATF temperature sensor. AT0103 D25591 5. REMOVE VALVE BODY OIL STRAINER ASSY (a) Remove the 3 bolts and oil strainer. NOTICE: Be careful as some fluid will come out with the oil strainer. D09179 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3226 40-41 AUTOMATIC TRANSMISSION / TRANS (b) - TRANSMISSION VALVE BODY ASSY (U241E/U140F) Remove the O-ring from the oil strainer. C69150 6. (a) REMOVE TRANSMISSION VALVE BODY ASSY Support the valve body assy and remove the 17 bolts and the valve body assy. NOTICE: Be careful not to drop the check valve body, spring and accumulator piston. D03553 (b) Remove the check ball body and spring. (c) Remove the 5 bolts and 5 shift solenoid valves. 7. (a) INSTALL TRANSMISSION VALVE BODY ASSY Install the 5 shift solenoid valves with the 5 bolts. Torque: 6.6 N·m (67 kgf·cm, 58 in.⋅lbf) for Bolt A 11 N·m (112 kgf·cm, 8 ft ·lbf) for Bolt B Bolt length: 12 mm (0.47 in.) for Bolt A 45 mm (1.77 in.) for Bolt B C50017 A B B B A D02938 A A B B B D02938 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3227 40-42 AUTOMATIC TRANSMISSION / TRANS (b) - TRANSMISSION VALVE BODY ASSY (U241E/U140F) Install the spring and check ball body. C50017 (c) (d) A C B
A C
B A C B D03553 Align the groove of the manual valve with the pin of lever. Install the 17 bolts. Torque: 11 N⋅m (110 kgf⋅cm, 8 ft⋅lbf) NOTICE:  Push the valve body against the accumulator piston spring and the check ball body to install it.  Tighten those bolts marked by
in the illustration first temporarily because they are positioning bolts. Bolt length: 25 mm (0.984 in.) for Bolt A 41 mm (1.614 in.) for Bolt B 45 mm (1.771 in.) for Bolt C 8. (a) (b) INSTALL VALVE BODY OIL STRAINER ASSY Coat a new O-ring with ATF. Install the O-ring to the oil strainer. (c) Install the oil strainer with the 3 bolts. Torque: 11 N⋅m (110 kgf⋅cm, 8 ft⋅lbf) C69150 D09179 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3228 40-43 AUTOMATIC TRANSMISSION / TRANS 9. (a) (b) (c) - TRANSMISSION VALVE BODY ASSY (U241E/U140F) INSTALL TRANSMISSION WIRE Coat a O-ring with ATF. Install the ATF temperature sensor with the lock plate and bolt. Torque: 6.6 N⋅m (67 kgf⋅cm, 58 in.⋅lbf) Connect the 5 shift solenoid valve connectors. D25591 10. (a) (b) INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB-ASSY Install the 2 magnets in the oil pan. Apply seal packing or equivalent to 18 bolts. Seal packing: THREE BOND 2430 or equivalent D25674 (c) Install a new gasket, oil pan and 18 bolts to the transaxle case. Torque: 7.6 N⋅m (77 kgf⋅cm, 67 in.⋅lbf) NOTICE: Because the bolts should be seal bolts, apply seal packing to bolts and tighten them within 10 minutes after application. C83111 11. 12. ADD AUTOMATIC TRANSAXLE FLUID INSPECT AUTOMATIC TRANSAXLE FLUID (SEE PAGE 40-2 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3229 40-51 AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL OIL SEAL (U241E) FRONT DIFFERENTIAL OIL SEAL (U241E) 40065-09 REPLACEMENT 1. 2. 3. (a) (b) 4. 5. REMOVE FRONT WHEELS REMOVE ENGINE UNDER COVER NO.1 DRAIN AUTOMATIC TRANSAXLE FLUID Remove the drain plug, gasket and drain ATF. Install a new gasket and drain plug. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) REMOVE FRONT DRIVE SHAFT ASSY RH (SEE PAGE 30-21 ) REMOVE FRONT DRIVE SHAFT ASSY LH (SEE PAGE 30-21 ) SST 6. (a) REMOVE TRANSAXLE HOUSING OIL SEAL Using SST, pull out the oil seal. SST 09308-00010 7. REMOVE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL Using SST, pull out the oil seal. SST 09308-00010 D25827 SST (a) D25828 8. (a) SST (b) INSTALL TRANSAXLE HOUSING OIL SEAL Using SST and a hammer, drive in a new oil seal. SST 09316-6001 1 (09316-00011) Oil seal drive in depth: 0
0.5 mm (0
0.020 in.) Coat the lip of the oil seal with MP grease. D25829 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3237 40-52 AUTOMATIC TRANSMISSION / TRANS 9. (a) (b) - FRONT DIFFERENTIAL OIL SEAL (U241E) INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL Using SST and a hammer, drive in a new oil seal. SST 09649-17010, 09950-70010 (09951-07150) Oil seal drive in depth: 0
0.5 mm (0
0.020 in.) Coat the lip of the oil seal with MP grease. SST D25830 10. 11. 12. 13. 14. 15. INSTALL FRONT DRIVE SHAFT ASSY LH (SEE PAGE 30-21 ) INSTALL FRONT DRIVE SHAFT ASSY RH (SEE PAGE 30-21 ) INSTALL FRONT WHEELS Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) ADD AUTOMATIC TRANSAXLE FLUID INSPECT AUTOMATIC TRANSAXLE FLUID (SEE PAGE 40-2 ) CHECK ABS SPEED SENSOR SIGNAL 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3238 40-53 AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL OIL SEAL (U140F) FRONT DIFFERENTIAL OIL SEAL (U140F) 4005W-06 REPLACEMENT HINT: When replacing the front differential oil seal (LH) or (RH), perform step 1 to 11 or 12 to 21 respectively. 1. REMOVE FRONT WHEELS 2. REMOVE ENGINE UNDER COVER NO.1 3. DRAIN AUTOMATIC TRANSAXLE FLUID (a) Remove the drain plug, gasket and drain ATF. (b) Install a new gasket and drain plug. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) 4. REMOVE FRONT DRIVE SHAFT ASSY LH (SEE PAGE 30-21 ) 5. SST (a) REMOVE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL Using SST, pull out the oil seal. SST 09308-00010 D25835 6. (a) (b) INSTALL DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL Using SST and a hammer, drive in a new oil seal. SST 09726- 27012 (09726- 02041), 09950- 70010 (09951-07200) Oil seal drive in depth: 0
0.5 mm (0
0.020 in.) Coat the lip of the oil seal with MP grease. SST D25836 7. 8. 9. 10. 11. 12. 13. 14. INSTALL FRONT DRIVE SHAFT ASSY LH (SEE PAGE 30-21 ) INSTALL FRONT WHEELS Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) ADD AUTOMATIC TRANSAXLE FLUID INSPECT AUTOMATIC TRANSAXLE FLUID (SEE PAGE 40-2 ) REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (SEE PAGE 14-24 ) REMOVE FRONT DRIVE SHAFT ASSY RH (SEE PAGE 30-21 ) REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (SEE PAGE 31-9 ) REMOVE TRANSFER ASSY (SEE PAGE 31-9 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3239 40-54 AUTOMATIC TRANSMISSION / TRANS - FRONT DIFFERENTIAL OIL SEAL (U140F) 15. (a) REMOVE TRANSAXLE HOUSING OIL SEAL Using a screw driver with vinyl tape wound around its tip, remove the oil seal. NOTICE: Be careful not to damage the housing. Vinyl Tape D25618 16. (a) A (b) INSTALL TRANSAXLE HOUSING OIL SEAL Using SST and a hammer, drive in a new oil seal. SST 09309-37010 Oil seal drive in depth: 6.0
0.5 mm (0.236
0.020 in.) Coat the lip of the oil seal with MP grease. SST D25837 17. 18. 19. 20. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (SEE PAGE 31-9 ) INSTALL TRANSFER ASSY (SEE PAGE 31-9 ) INSTALL FRONT DRIVE SHAFT ASSY RH (SEE PAGE 30-21 ) INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (SEE PAGE 14-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3240 40-59 AUTOMATIC TRANSMISSION / TRANS - SHIFT LOCK SYSTEM (ATM) SHIFT LOCK SYSTEM (ATM) 40067-10 ON-VEHICLE INSPECTION 1. (a) (b) (c) (d) 2. (a) (b) 3. (a) (b) (c) (d) CHECK SHIFT LOCK OPERATION Shift the shift lever to P position. Turn the ignition switch to LOCK. Check that the shift lever cannot be shifted to any other positions that P. Turn the ignition switch ON, depress the brake pedal and check that the shift lever can be shifted to any other positions. CHECK SHIFT LOCK RELEASE BUTTON OPERATION Using a small screwdriver, remove the shift lock release cover. When operating the shift lever with the shift lock release button pressed, check that the lever can be shifted to any position other than P. CHECK KEY INTERLOCK OPERATION Turn the ignition switch ON. Depress the brake pedal and shift the shift lever to any other position than P. Check that the ignition key cannot be turned to LOCK. Shift the shift lever to P position, turn the ignition key to LOCK and check that the ignition key can be removed. 4. INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY (a) Using a voltmeter, measure the voltage at each terminal. HINT: Do not disconnect the shift lock control unit assembly connector. ACC IG STP KLS+ E C82814 Terminal Measuring Condition Voltage (V) 1 (ACC) - 3 (E) Ignition switch ACC 10 - 14 1 (ACC) - 3 (E) Ignition switch OFF 0 2 (STP) - 3 (E) Depress brake pedal 10 - 14 2 (STP) - 3 (E) Release brake pedal 0 4 (KLS+) - 3 (E) (1) Ignition switch ACC and P position (2) Ignition switch ACC and except P position (3) Ignition switch ACC and except P position (After approx. 1 second) 0 7.5 - 11 6-9 5 (IG) - 3 (E) Ignition switch ON 10 - 14 5 (IG) - 3 (E) Ignition switch OFF 0 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3245 40-60 AUTOMATIC TRANSMISSION / TRANS (b) - SHIFT LOCK SYSTEM (ATM) Using an ohmmeter, measure the resistance at terminal E (3) and body ground. HINT: Do not disconnect the shift lock control unit assembly connector. ACC IG STP KLS+ E C82814 Terminal 1 (E) - Body ground Measuring Condition Specified Value Always Continuity 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3246 40-73 AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION CONTROL CABLE ASSY (ATM) TRANSMISSION CONTROL CABLE ASSY (ATM) 4005X-06 REPLACEMENT 1. 2. 3. 4. 5. 6. REMOVE REMOVE REMOVE REMOVE REMOVE REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSY CENTER (SEE PAGE 71-10 ) FLOOR CARPET COVER CENTER RH (SEE PAGE 71-10 ) FLOOR CARPET COVER CENTER LH (SEE PAGE 71-10 ) BATTERY AIR CLEANER ASSY AIR CLEANER HOSE NO.1 7. (a) (b) REMOVE TRANSMISSION CONTROL CABLE ASSY Remove the nut from the control shaft lever. Disconnect the control cable from the control shaft lever. (c) Remove the clip and disconnect the control cable from the control cable bracket. (d) Disconnect the control cable from the control cable clamp. D25414 D25415 D25416 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3259 40-74 AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION CONTROL CABLE ASSY (ATM) (e) Disconnect the cable end from the rod of the floor shift assy. (f) Remove the 2 nuts. (g) (h) Remove the 3 bolts. Pull out the control cable from the body. 8. (a) (b) INSTALL TRANSMISSION CONTROL CABLE ASSY Pull in the control cable to the body. Install the 3 bolts. Torque: 4.9 N⋅m (50 kgf⋅cm, 43 in.⋅lbf) D25449 D25450 C83207 C83207 (c) Install the cable end, as shown in the illustration. HINT: Install it with the uneven surface facing up. D25449 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3260 40-75 AUTOMATIC TRANSMISSION / TRANS - TRANSMISSION CONTROL CABLE ASSY (ATM) (d) Install the control cable and 2 nuts. Torque: 11.8 N⋅m (122 kgf⋅cm, 9 ft⋅lbf) (e) Connect the control cable to the control cable clamp. (f) Temporarily install the control cable to the control shaft lever with nuts. (g) Install the control cable and clip to the bracket. D25450 D25416 D25414 D25415 9. 10. 11. INSTALL AIR CLEANER ASSY ADJUST SHIFT LEVER POSITION (SEE PAGE 40-71 ) INSPECT SHIFT LEVER POSITION (SEE PAGE 40-71 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3261 40-72 AUTOMATIC TRANSMISSION / TRANS - KEY INTER LOCK SOLENOID (ATM) KEY INTER LOCK SOLENOID (ATM) 4005S-05 INSPECTION 1. (a) (b) 4 KLS+ 3 KLSD25589 INSPECT KEY INTER LOCK SOLENOID Disconnect the solenoid connector. Connect KLS+ (4) terminal to the batteries’ positive (+) terminal, and KLS- (3) terminal to the battery negative (-) terminal, and apply about 12V between KLS+ - KLS- terminals. (c) Check that operation noise can be heard from the solenoid. If the solenoid does not operate, replace the solenoid. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3258 AUTOMATIC TRANSMISSION / TRANS - PARK/NEUTRAL POSITION SWITCH ASSY (U151E/U151F) 40-1 1 4016X-01 ADJUSTMENT 1. (a) (b) INSPECT SWITCH ASSY, NEUTRAL START Apply the parking brake and turn the ignition switch to the ON position. Depress the brake pedal and check that the engine starts only when the shift lever is set in the N or P position. (c) Check that the back-up light is lit and the reverse warning buzzer sounds only when the shift lever is set in the R position. If a failure is found, check the park/neutral position switch for continuity. Neutral Basic Line 2. (a) (b) (c) (d) Groove ADJUST SWITCH ASSY, NEUTRAL START Loosen the 2 bolts of park/neutral position switch and set the shift lever to the N position. Align the groove and neutral basic line. Hold the switch in position and tighten the 2 bolts. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) After adjustment, perform the inspection described in step 1. C99453 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3197 AUTOMATIC TRANSMISSION / TRANS - PARK/NEUTRAL POSITION SWITCH ASSY (U151E/U151F) 40-7 PARK/NEUTRAL POSITION SWITCH ASSY (U151E/U151F) 4016W-01 REPLACEMENT 1. REMOVE ENGINE UNDER COVER NO.1 2. (a) (b) SEPARATE TRANSMISSION CONTROL CABLE ASSY Remove the nut from the control shaft lever. Disconnect the control cable from the control shaft lever. D30614 (c) Remove the clip and disconnect the control cable from the control cable bracket. NOTICE: Do not hold the resin guide pipe. C89134 3. (a) (b) REMOVE PARK/NEUTRAL POSITION SWITCH ASSY Disconnect the park/neutral position switch connector. Remove the nut, washer and control shaft lever. (c) Pry out the lock plate. C99458 C99457 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3193 40-8 AUTOMATIC TRANSMISSION / TRANS - PARK/NEUTRAL POSITION SWITCH ASSY (U151E/U151F) (d) Remove the lock nut and lock plate. (e) Remove the 2 bolts and pull out the park/neutral position switch. 4. (a) INSTALL PARK/NEUTRAL POSITION SWITCH ASSY Install the park/neutral position switch to the manual valve shaft. Temporarily install the 2 bolts. G25453 C99454 (b) C99454 (c) (d) Place the lock plate and tighten the nut. Torque: 6.9 N⋅m (70 kgf⋅cm, 61 in.⋅lbf) Temporarily install the control shaft lever. G25453 (e) (f) N Turn the lever counterclockwise until it stops, then turn it clockwise 2 notches. Remove the control shaft lever. D30919 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3194 AUTOMATIC TRANSMISSION / TRANS Groove - PARK/NEUTRAL POSITION SWITCH ASSY (U151E/U151F) 40-9 (g) (h) Align the groove with the neutral basic line. Hold the switch in position and tighten the 2 bolts. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) (i) Using a screwdriver, stake the nut with the lock plate. (j) (k) Install the control shaft lever, washer and nut. Torque: 13 N⋅m (130 kgf⋅cm, 9 ft⋅lbf) Connect the park/neutral position switch connector. 5. (a) INSTALL TRANSMISSION CONTROL CABLE ASSY Install the control cable and clip to the bracket. (b) Temporarily install the control cable to the control shaft lever with the nut. Neutral Basic Line C99456 C99457 C99458 C89134 D30614 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3195 40-10 6. 7. 8. AUTOMATIC TRANSMISSION / TRANS - PARK/NEUTRAL POSITION SWITCH ASSY (U151E/U151F) ADJUST SHIFT LEVER POSITION (SEE PAGE 40-71 ) INSPECT SHIFT LEVER POSITION (SEE PAGE 40-71 ) INSPECT PARK/NEUTRAL POSITION SWITCH ASSY (SEE PAGE 40-1 1) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3196 40-6 AUTOMATIC TRANSMISSION / TRANS - PARK/NEUTRAL POSITION SWITCH ASSY (U241E/U140F) 4017L-01 ADJUSTMENT 1. (a) (b) INSPECT PARK/NEUTRAL POSITION SWITCH ASSY Apply the parking brake and turn the ignition switch ON. Depress the brake pedal and check that the engine starts only when the shift lever is set in N or P position and it does not start in other positions. (c) Check that the back-up light is lit and the reverse warning buzzer sounds only when the shift lever is set in R position and these do not function in other positions. If a failure is found, check the park/neutral position switch for continuity. 2. (a) Neutral Basic Line (b) (c) (d) Groove ADJUST PARK/NEUTRAL POSITION SWITCH ASSY Loosen the 2 bolts of park/neutral position switch and set the shift lever to the N position. Align the groove and neutral basic line. Hold the switch in position and tighten the 2 bolts. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) After adjustment, perform the inspection described in step 1. D25514 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3192 AUTOMATIC TRANSMISSION / TRANS - PARK/NEUTRAL POSITION SWITCH ASSY (U241E/U140F) 40-3 PARK/NEUTRAL POSITION SWITCH ASSY (U241E/U140F) 4017K-01 REPLACEMENT 1. REMOVE ENGINE UNDER COVER NO.1 2. (a) (b) SEPARATE TRANSMISSION CONTROL CABLE ASSY Remove the nut from the control shaft lever. Disconnect the control cable from the control shaft lever. (c) Remove the clip and disconnect the control cable from the control cable bracket. 3. (a) (b) REMOVE PARK/NEUTRAL POSITION SWITCH ASSY Remove the nut, washer and control shaft lever. Pry out the lock plate and remove the manual valve shaft nut. Remove the 2 bolts and pull out the park/neutral position switch. D25414 D25415 (c) D09636 4. (a) (b) (c) (d) INSTALL PARK/NEUTRAL POSITION SWITCH ASSY Install the park/neutral position switch to the manual valve shaft. Place a new lock plate and tighten the nut. Torque: 6.9 N⋅m (70 kgf⋅cm, 61 in.⋅lbf) Temporarily install the 2 bolts. Temporarily install the control shaft lever. D09639 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3189 40-4 AUTOMATIC TRANSMISSION / TRANS (e) (f) - PARK/NEUTRAL POSITION SWITCH ASSY (U241E/U140F) Turn the lever counterclockwise until it stops, then turn it clockwise 2 notches. Remove the control shaft lever. D09641 Neutral Basic Line (g) (h) Align the groove with neutral basic line. Hold the switch in position and tighten the 2 bolts. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) (i) Using a screwdriver, stake the nut with the lock plate. (j) Install the control shaft lever, washer and nut. Torque: 12.7 N⋅m (130 kgf⋅cm, 9 ft⋅lbf) 5. (a) INSTALL TRANSMISSION CONTROL CABLE ASSY Temporarily install the control cable to the control shaft lever with nuts. Groove D25513 D09643 D09644 D25414 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3190 AUTOMATIC TRANSMISSION / TRANS (b) - PARK/NEUTRAL POSITION SWITCH ASSY (U241E/U140F) 40-5 Install the control cable and clip to the bracket. D25415 6. 7. 8. ADJUST SHIFT LEVER POSITION (See page 40-71 ) INSPECT SHIFT LEVER POSITION INSPECT PARK/NEUTRAL POSITION SWITCH ASSY (See page 40-6 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3191 40-49 AUTOMATIC TRANSMISSION / TRANS - OIL W/HOSE COOLER ASSY (U241E/U140F) OIL W/HOSE COOLER ASSY (U241E/U140F) 4017J-01 REPLACEMENT 1. 2. 3. (a) 4. (a) REMOVE RADIATOR GRILLE (See page 76-2 ) REMOVE FRONT BUMPER COVER (See page 76-2 ) SEPARATE OIL COOLER OUTLET TUBE NO.1 Loosen the clip and separate the oil cooler hose. SEPARATE TRANSMISSION OIL COOLER HOSE NO.1 Loosen the clip and separate the transmission oil cooler hose No. 1. 5. (a) REMOVE OIL W/HOSE COOLER ASSY Remove the bolt, nut and oil cooler assy. D25421 6. INSTALL OIL W/HOSE COOLER ASSY (a) Install the oil cooler assy, bolt A and nut B. HINT: After temporally tightening bolt A, tighten in order of nut B, bolt A. Torque: 7.0 N⋅m (71 kgf⋅cm, 62 in.⋅lbf) B A D25421 7. (a) 8. (a) 9. 10. INSTALL TRANSMISSION OIL COOLER HOSE NO.1 Install the transmission oil cooler hose No. 1 and clip. INSTALL OIL COOLER OUTLET TUBE NO.1 Install the oil cooler hose and clip. ADD AUTOMATIC TRANSAXLE FLUID INSPECT AUTOMATIC TRANSAXLE FLUID (See page 40-2 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3235 40-12 AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U241E/U140F) AUTOMATIC TRANSAXLE ASSY (U241E/U140F) 40062-07 REPLACEMENT 1. 2. 3. 4. 5. REMOVE ENGINE ASSY W/ TRANSAXLE (SEE PAGE 14-24 ) REMOVE FRONT DRIVE SHAFT ASSY RH (SEE PAGE 30-21 ) REMOVE FRONT DRIVE SHAFT ASSY LH (SEE PAGE 30-21 ) REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (4WD DRIVE TYPE) (SEE PAGE 31-9 ) REMOVE TRANSFER ASSY (4WD DRIVE TYPE) (SEE PAGE 31-9 ) 6. (a) REMOVE TRANSMISSION CONTROL CABLE BRACKET NO.2 Remove the bolt and control cable clamp. 7. (a) (b) REMOVE WIRE HARNESS CLAMP Disconnect the wire harness from the clamp. Remove the 3 bolts and 2 clamps. 8. (a) SEPARATE WIRE HARNESS Remove the wire harness. 9. (a) (b) (c) REMOVE STARTER ASSY Remove the nut and disconnect the starter wire. Disconnect the connector. Remove the 2 bolts and starter. C83203 D25422 C83204 D25404 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3198 40-13 AUTOMATIC TRANSMISSION / TRANS 10. (a) (b) (c) - AUTOMATIC TRANSAXLE ASSY (U241E/U140F) SEPARATE CONNECTOR Disconnect the transmission wire connector. Disconnect the park/neutral position switch connector. Disconnect the speed sensor connector. 11. (a) (b) REMOVE TRANSMISSION CONTROL CABLE BRACKET NO.1 Remove the bolt and oil cooler tube clamp. Remove the 2 bolts and transmission control cable bracket. D25403 12. (a) (b) (c) REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSY Remove the ATF level gauge. Remove the bolt and oil filler tube. Remove the O-ring from the oil filler tube. 13. (a) SST 14. (a) REMOVE OIL COOLER INLET TUBE NO.1 Using SST and spanner, disconnect the oil cooler inlet tube. SST 09023-12701 REMOVE OIL COOLER OUTLET TUBE NO.1 Using SST and spanner, disconnect the oil cooler outlet tube. SST 09023-12701 D25405 15. (a) REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Remove the 2 bolts and engine mounting bracket FR. 16. (a) REMOVE FLYWHEEL HOUSING UNDER COVER Remove the flywheel housing under cover. C83205 D25407 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3199 40-14 AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U241E/U140F) 17. (a) REMOVE AUTOMATIC TRANSAXLE ASSY Turn the crankshaft to gain access and remove the 6 bolts while holding the crankshaft pulley bolt with a wrench. (b) (c) Remove the 9 bolts. Separate and remove the automatic transaxle. D25408 U241E U140F D32109 18. 19. REMOVE TORQUE CONVERTER CLUTCH ASSY INSPECT TORQUE CONVERTER CLUTCH ASSY (SEE PAGE 40-29 ) SST 09350-32014 (09351-32010, 09351-32020) 20. INSTALL TORQUE CONVERTER CLUTCH ASSY (a) Install the torque converter clutch to the automatic transaxle. (b) A Using calipers, measure dimension A between the transaxle and the end surface of the drive plate. C83051 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3200 40-15 AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U241E/U140F) (c) Using calipers and a straight edge, measure the dimension B shown in the illustration and check that B is greater than A measured in (b). Standard: A + 1 mm or more 21. (a) INSTALL AUTOMATIC TRANSAXLE ASSY Install the automatic transaxle and 9 bolts to the engine. Torque: Bolt A: 64 N⋅m (650 kgf⋅cm, 47 ft⋅lbf) Bolt B: 46 N⋅m (470 kgf⋅cm, 34 ft⋅lbf) Bolt C: 37.2 N⋅m (379 kgf⋅cm, 27 ft⋅lbf) Apply a few drops of adhesive to each 2 threads on the tip of the 6 torque converter clutch mounting bolts. Adhesive: Part No. 08833-00070 or equivalent B Dimension B A U241E: C65911 A B A B C U140F: A C C A (b) C B A B C C C C D25617 (c) Install the 6 torque converter clutch mounting bolts. Torque: 41 N⋅m (420 kgf⋅cm, 30 ft⋅lbf) HINT: First install green colored bolt and then the 5 bolts. D25408 22. (a) INSTALL FLYWHEEL HOUSING UNDER COVER Install the flywheel housing under cover. D25407 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3201 40-16 AUTOMATIC TRANSMISSION / TRANS 23. (a) - AUTOMATIC TRANSAXLE ASSY (U241E/U140F) INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Install the engine mounting bracket FR and 2 bolts to the automatic transaxle. Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) C83205 24. (a) (b) (c) INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSY Coat a new O-ring with ATF, and install it to the oil filler tube. Install the oil filler tube and bolt to the automatic transaxle. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) Install the ATF level gauge. 25. INSTALL TRANSMISSION CONTROL CABLE BRACKET NO.1 (a) Install the control cable bracket and 2 bolts. Torque: 11.8 N⋅m (122 kgf⋅cm, 9 ft⋅lbf) 26. (a) (b) INSTALL OIL COOLER INLET TUBE NO.1 Temporarily install the oil cooler outlet tube. Temporarily install the oil cooler inlet tube. (c) Install the oil cooler tube clamp and bolt. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) C83206 HINT: Install them so that the oil cooler tube cushion is positioned as illustrated. D25410 (d) SST Using SST and spanner, tighten the oil cooler inlet tube. SST 09023-12701 Torque: 34.3 N⋅m (350 kgf⋅cm, 25 ft⋅lbf) D25411 27. (a) INSTALL OIL COOLER OUTLET TUBE NO.1 Using SST and spanner, tighten the oil cooler outlet tube. SST 09023-12701 Torque: 34.3 N⋅m (350 kgf⋅cm, 25 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3202 40-17 AUTOMATIC TRANSMISSION / TRANS 28. (a) (b) (c) - AUTOMATIC TRANSAXLE ASSY (U241E/U140F) INSTALL STARTER ASSY Install the starter and 2 bolts. Torque: 39 N⋅m (398 kgf⋅cm, 29 ft⋅lbf) Connect the connecter. Install the starter wire and nut. Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf) D25404 29. (a) INSTALL WIRE HARNESS Install the wire harness and bolt. Torque: 25.5 N⋅m (260 kgf⋅cm, 19 ft⋅lbf) 30. (a) INSTALL WIRE HARNESS CLAMP Install the 2 clamps and 3 bolts. Torque: 8.4 N⋅m (86 kgf⋅cm, 74 in.⋅lbf) Connect the wire harness to the clamp. C83204 (b) D25422 31. (a) INSTALL TRANSMISSION CONTROL CABLE BRACKET NO.2 Install the control cable clamp and bolt. Torque: 11.8 N⋅m (122 kgf⋅cm, 9 ft⋅lbf) C83203 32. 33. 34. 35. 36. INSTALL TRANSFER ASSY (4WD DRIVE TYPE) (SEE PAGE 31-9 ) INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (4WD DRIVE TYPE) (SEE PAGE 31-9 ) INSTALL FRONT DRIVE SHAFT ASSY LH (SEE PAGE 30-21 ) INSTALL FRONT DRIVE SHAFT ASSY RH (SEE PAGE 30-21 ) INSTALL ENGINE ASSY W/ TRANSAXLE (SEE PAGE 14-24 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3203 40-18 AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U151E/U151F) AUTOMATIC TRANSAXLE ASSY (U151E/U151F) 4012C-02 COMPONENTS 8.4 (86, 74 in.⋅lbf)
Bearing Bracket Hole Snap Ring 13 (133, 10) 8.4 (86, 74 in.⋅lbf) Front Drive Shaft Assy RH Wire Harness Clamp 12 (122, 9) Wire Harness Clamp 32 (330, 24) Transmission Control Cable Bracket No.2 46 (470, 34) 64 (650, 47) 41 (418, 30) Torque Converter Clutch Assy Automatic Transaxle Assy x6
Front Drive Shaft LH Hole Snap Ring 37 (377, 27) 7.8 (80, 69 in.⋅lbf) 5.5 (56, 49 in.⋅lbf) Flywheel Housing Under Cover
O-Ring Transmission Oil Level Gauge sub-assy Front Drive Shaft Assy LH Transmission Oil Filler tube sub-assy Automatic transmission oil coole tube clamp Transmission Control Cable Bracket No.1 Starter Assy 5.4 (56, 49 in.⋅lbf) Oil Cooler Outlet Tube No.1 9.8 (100, 87 in.⋅lbf) 12 (122, 9) Oil Cooler Inlet Tube No.1 Engine Mounting Bracket FR 37 (377, 27) 64 (653, 47) 34 (347, 25) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part D31755 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3204 40-19 AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U151E/U151F) 13 (133, 10) Front Drive Shaft Assy RH 8.4 (86, 74 in.⋅lbf)
Front Drive Shaft RH Hole Snap Ring 8.4 (86, 74 in.⋅lbf) Wire Harness Clamp 12 (122, 9) Transmission Control Cable Bracket No.2 34 (350, 25) Wire Harness Clamp Transfer Stiffener Plate RH 69 (700, 51) 46 (470, 34) 64 (650, 47) Transfer Assy 41 (418, 30) x6 Torque Converter Clutch Assy 37 (377, 27) 5.5 (56, 49 in.⋅lbf) 7.8 (80, 69 in.⋅lbf) 69 (700, 51) Transmission Oil Filler tube sub-assy Front Drive Shaft Assy LH Flywheel Housing Under Cover Automatic transmission Oil cooler tube clamp
O-Ring Transmission Oil Level Gauge sub-assy Transmission Control Cable Bracket No.1 5.4 (55, 48 in.⋅lbf)
Front Drive Shaft LH Hole Snap Ring 9.8 (100, 87 in.⋅lbf) 12 (122, 9) Oil Cooler Inlet Tube No.1 34 (347, 25) Oil Cooler Outlet Tube No.1 Engine Mounting Bracket No.1 Starter Assy 64 (653, 47) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque 37 (377, 27)
Non-reusable part D31756 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3205 40-20 AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U151E/U151F) 4016Y-02 REPLACEMENT 1. 2. 3. 4. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (SEE PAGE 14-149 ) REMOVE FRONT DRIVE SHAFT ASSY LH (SEE PAGE 30-21 ) SST 09520-01010, 09520-24010 (09520-32040) REMOVE FRONT DRIVE SHAFT ASSY RH (2WD DRIVE TYPE) (SEE PAGE 30-21 ) REMOVE FRONT DRIVE SHAFT ASSY RH (4WD DRIVE TYPE) (SEE PAGE 30-21 ) SST 09520-01010, 09520-24010 (09520-32040) 5. (a) REMOVE TRANSMISSION CONTROL CABLE BRACKET NO.2 Remove the bolt and transmission control cable bracket No.2. G25454 6. (a) (b) REMOVE WIRE HARNESS CLAMP Disconnect the wire harnesses from the clamps. Remove the 3 bolts and 2 clamps. 7. (a) DISCONNECT WIRE HARNESS Remove the bolt and wire harness. 8. (a) (b) (c) REMOVE STARTER ASSY Remove the nut and disconnect the starter wire. Disconnect the connector. Remove the 2 bolts and starter assy. D25422 G25456 D30464 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3206 40-21 AUTOMATIC TRANSMISSION / TRANS Transmission Wire Connector - AUTOMATIC TRANSAXLE ASSY (U151E/U151F) 9. (a) (b) (c) DISCONNECT CONNECTOR Disconnect the transmission wire connector. Disconnect the park/neutral position switch connector. Disconnect the 2 speed sensor connectors. 10. REMOVE TRANSMISSION CONTROL CABLE BRACKET NO.1 Remove the bolt and automatic transmission oil cooler tube clamp. Remove the 2 bolts and transmission control cable bracket No.1. Park/neutral Position Switch Connector Speed Sensor Connectors D30864 (a) (b) C91736 11. (a) (b) (c) REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSY Remove the transmission oil level gauge sub-assy. Remove the bolt and transmission oil filler tube sub-assy. Remove the O-ring from the transmission oil filler tube sub-assy . C91737 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3207 40-22 AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U151E/U151F) (d) Disconnect the breather hose from the wire harness bracket. 12. (a) REMOVE OIL COOLER INLET TUBE NO.1 Using SST and a spanner, disconnect the oil cooler inlet tube No.1. SST 09023-12701 D31339 SST C88047 13. (a) REMOVE OIL COOLER OUTLET TUBE NO.1 Using SST and a spanner, disconnect the oil cooler outlet tube No.1. SST 09023-12701 14. (a) REMOVE ENGINE MOUNTING BRACKET FR Remove the 3 bolts and engine mounting bracket FR. 15. (a) REMOVE AUTOMATIC TRANSAXLE ASSY Remove the 2 bolts and flywheel housing under cover. D30470 D30471 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3208 40-23 AUTOMATIC TRANSMISSION / TRANS (b) - AUTOMATIC TRANSAXLE ASSY (U151E/U151F) Turn the crankshaft to gain access and remove the 6 bolts while holding the crankshaft pulley bolt with a wrench. HINT: There will be one green colored bolt. D30472 U151E: (c) (d) Remove the 8 bolts. Separate and remove the automatic transaxle. 16. REMOVE TRANSFER STIFFENER PLATE RH (4WD DRIVE TYPE) Remove the 5 bolts and transfer stiffener plate RH. U151F: D32008 (a) G25458 17. 18. 19. REMOVE TRANSFER ASSY (4WD DRIVE TYPE) (SEE PAGE 31-9 ) REMOVE TORQUE CONVERTER CLUTCH ASSY INSPECT TORQUE CONVERTER CLUTCH ASSY (SEE PAGE 40-2 ) SST 09350-32014 (09351-32010, 09351-32020) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3209 40-24 AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U151E/U151F) 20. (a) INSTALL TORQUE CONVERTER CLUTCH ASSY Install the torque converter clutch to the automatic transaxle. (b) Using vernier calipers and a straight edge, measure the dimension ”A” between the transaxle fitting part of the engine and the converter fitting part of the drive plate. A D31087 G26518 (c) Using vernier calipers and a straight edge, measure the dimension ”B” shown in the illustration and check that ”B” is greater than ”A”, previously measured. See step 20 (b). Standard: A + 1 mm or more NOTICE: Remember to minus the thickness of the straight edge. B Dimension B 21. D31341 INSTALL TRANSFER ASSY (4WD DRIVE TYPE) (SEE PAGE 31-9 ) U151E: 22. (a) A A A A A (b) B C A A U151F: C INSTALL AUTOMATIC TRANSMISSION W/TRANSFER Install the automatic transaxle w/ transfer with the 8 bolts to the engine. Torque: Bolts A: 64 N⋅m (650 kgf⋅cm, 47 ft⋅lbf) Bolt B: 46 N⋅m (470 kgf⋅cm, 34 ft⋅lbf) Bolts C: 37 N⋅m (377 kgf⋅cm, 27 ft⋅lbf) Apply a few drops of adhesive to each of 2 threads on the tip of the 6 torque converter clutch mounting bolts. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent A A A B C C D32008 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3210 40-25 AUTOMATIC TRANSMISSION / TRANS (c) - AUTOMATIC TRANSAXLE ASSY (U151E/U151F) Install the 6 torque converter clutch mounting bolts. Torque: 41 N⋅m (418 kgf⋅cm, 30 ft⋅lbf) HINT: First install the green colored bolt and then the remaining 5 bolts. D30472 (d) Install the flywheel housing under cover to the automatic transaxle with the 2 bolts. Torque: 7.8 N⋅m (80 kgf⋅cm, 69 in⋅lbf) 23. INSTALL TRANSFER STIFFENER PLATE RH (4WD DRIVE TYPE) Install the transfer stiffener plate RH with 5 bolts to the transfer and engine mounting bracket RR. Torque: 34 N⋅m (350 kgf⋅cm, 25 ft⋅lbf) D30471 (a) G25458 24. (a) 25. (a) INSTALL ENGINE MOUNTING BRACKET FR Install the engine mounting bracket FR and 3 bolts to the automatic transaxle. Torque: 64 N⋅m (653 kgf⋅cm, 47 ft⋅lbf) INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSY Coat a new O-ring with ATF, and install it to the transmission oil filler tube sub-assy. D30470 (b) Install the transmission oil filler tube sub-assy and bolt to the automatic transaxle. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) C88135 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3211 40-26 AUTOMATIC TRANSMISSION / TRANS - AUTOMATIC TRANSAXLE ASSY (U151E/U151F) (c) Install the transmission oil level gauge sub-assy. NOTICE:
The breather hose should be on the left side of the vehicle. (d) Connect the breather hose to the wire harness bracket. D31339 26. (a) 27. (a) (b) INSTALL TRANSMISSION CONTROL CABLE BRACKET NO.1 Install the transmission control cable bracket No.1 and 2 bolts. Torque: 12 N⋅m (122 kgf⋅cm, 9 ft⋅lbf) INSTALL OIL COOLER INLET TUBE NO.1 Temporarily install the oil cooler outlet tube No.1. Temporarily install the oil cooler inlet tube No.1. C88278 (c) Install the automatic transmission oil cooler tube clamp and bolt. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) HINT: Install the automatic transmission oil cooler tube clamp and bolt so that the oil cooler tube cushion is positioned as illustrated. C91745 (d) Using SST and a spanner, tighten the oil cooler inlet tube No.1. SST 09023-12701 Torque: 34 N⋅m (347 kgf⋅cm, 25 ft⋅lbf) SST C92540 28. (a) INSTALL OIL COOLER OUTLET TUBE NO.1 Using SST and a spanner, tighten the oil cooler outlet tube No.1. Torque: 34 N⋅m (347 kgf⋅cm, 25 ft⋅lbf) SST 09023-12701 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3212 40-27 AUTOMATIC TRANSMISSION / TRANS Transmission Wire Connector - AUTOMATIC TRANSAXLE ASSY (U151E/U151F) 29. (a) (b) (c) CONNECT CONNECTOR Connect the transmission wire connector. Connect the park/neutral position switch connector. Connect the 2 speed sensor connectors. 30. (a) INSTALL STARTER ASSY Install the starter assy and 2 bolts. Torque: 37 N⋅m (377 kgf⋅cm, 27 ft⋅lbf) Connect the connector. Install the starter wire and nut. Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf) Park/neutral Position Switch Connector Speed Sensor Connectors D30864 (b) (c) D30464 31. (a) INSTALL WIRE HARNESS Install the wire harness and bolt. Torque: 13 N⋅m (130 kgf⋅cm, 9 ft⋅lbf) 32. (a) INSTALL WIRE HARNESS CLAMP Install the 2 clamps and 3 bolts. Torque: 8.4 N⋅m (86 kgf⋅cm, 74 in.⋅lbf) Connect the wire harnesses to the clamps. G25456 (b) D25422 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3213 40-28 AUTOMATIC TRANSMISSION / TRANS 33. (a) - AUTOMATIC TRANSAXLE ASSY (U151E/U151F) INSTALL TRANSMISSION CONTROL CABLE BRACKET NO.2 Install the transmission control cable bracket No.2 with the bolt. Torque: 12 N⋅m (122 kgf⋅cm, 9 ft⋅lbf) G25454 34. 35. 36. 37. 38. 39. INSTALL FRONT DRIVE SHAFT ASSY LH (SEE PAGE 30-21 ) INSTALL FRONT DRIVE SHAFT ASSY RH (2WD DRIVE TYPE) (SEE PAGE 30-21 ) INSTALL FRONT DRIVE SHAFT ASSY RH (4WD DRIVE TYPE) (SEE PAGE 30-21 ) INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (SEE PAGE 14-149 ) RESET MEMORY (SEE PAGE 05-1005 ) PERFORM INITIALIZATION (SEE PAGE 01-4 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3214 50-3 STEERING COLUMN - STEERING SYSTEM 5004Y-02 ON-VEHICLE INSPECTION Maximum Freeplay 1. (a) (b) CHECK STEERING WHEEL FREEPLAY Stop the vehicle and align the tires straight ahead. Turn the steering wheel gently right and left, and check the steering wheel free play. Maximum freeplay: 30 mm (1.18 in.) If the free play exceeds the maximum, replace the steering intermediate shaft sub-assy or steering gear. 30 mm (1.18 in.) F46831 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3264 50-1 STEERING COLUMN - STEERING SYSTEM STEERING SYSTEM 5004W-02 PRECAUTION 1. (a) 2. (a) HANDLING PRECAUTIONS FOR STEERING SYSTEM Care must be taken when replacing parts. Incorrect replacement may affect the performance of the steering system and result in a driving hazard. HANDLING PRECAUTIONS FOR SRS AIRBAG SYSTEM The HIGH LANDER is equipped with SRS (Supplemental Restraint System) such as the driver airbag and front passenger airbag. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notice for the supplemental restraint system (see page 60-1 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3262 50-2 STEERING COLUMN - STEERING SYSTEM 5004X-03 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in the order shown. If necessary, repair or replace these parts. Symptom Suspect Area See page 1. Tires (Improperly inflated) 2. Power steering fluid level (Low) 3. Drive belt (Loose) 9. Power steering link assy 28-1 51-3 14-5 14-125 26-7 26-20 51-8 51-17 51-28 Poor return 1. 2. 3. 4. Tires (Improperly inflated) Front wheel alignment (Incorrect) Steering column (Binding) Power steering link assy 28-1 26-7 51-28 Excessive play 1. 2. 3. 4. 5. Steering system joints (Worn) Suspension arm ball joints (Worn) Intermediate shaft, Sliding yoke (Worn) Front wheel bearing (Worn) Power steering link assy 26-20 30-38 51-28 Hard steering Abnormal noise 4. 5. 6. 7. 8. Front wheel alignment (Incorrect) Steering system joints (Worn) Suspension arm ball joints (Worn) Steering column (Binding) Power steering vane pump 1. Power steering fluid level (Low) 2. Steering system joints (Worn) 3. Power steering vane pump 51-3 51-8 51-17 51-28 4. Power steering link assy 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3263 50-4 STEERING COLUMN - STEERING SYSTEM 5004Z-02 REPAIR 1. (a) Steering Wheel Masking Tape Steering Column Upper Cover STEERING OFF CENTER REPAIR PROCEDURE Inspect steering wheel off center. (1) Apply masking tape on the top center of the steering wheel and steering column upper cover. (2) Drive the vehicle in a straight line for 100 meters at a constant speed of 35 mph (56 km/h), and hold the steering wheel to maintain the course. F16015 (3) Steering Column Upper Cover Draw a line on the masking tape as shown in the illustration. Marked Line Steering Wheel Masking Tape F16016 (4) Turn the steering wheel to the center position. HINT: Look at the upper surface of the steering wheel, steering spoke and SRS airbag line to find the center position. (5) Draw a new line on the masking tape on the steering wheel as shown in the illustration. (6) Measure the distance between the 2 lines on the masking tape on the steering wheel. Steering Column Upper Cover Marked Line Steering Wheel F16017 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3265 50-5 STEERING COLUMN - STEERING SYSTEM (7) Convert the measured distance to steering angle. Measured distance 1 mm (0.04 in.) = Steering angle of approximately 1 degree. HINT: Make a note of the steering angle. (b) Adjust steering angle. (1) (2) Draw a line on the RH and LH tie rod ends and rack ends respectively where it can be easily seen. Using a paper gauge, measure the distance from the RH and LH tie rod ends to the rack end screws. HINT:

Marked Line Measure both the RH and LH sides. Make a note of the measured values. R00429 (3) F16018 Remove the RH and LH boot clips from the rack boots. (4) Loosen the RH and LH lock nuts. (5) Turn the RH and LH rack ends by the same amount (but in different directions) according to the steering angle. One 360 degree turn of rack end (1.5 mm (0.059 in.) horizontal movement) eguals to 12 degrees of steering angle. (6) Tighten the RH and LH lock nuts by the specified torque. Torque: 74 N·m (750 kgf·cm, 54 ft⋅lbf) NOTICE: Make sure that the difference in length between the RH and LH tie rod ends and rack end screws are within 1.5 mm (0.059 in.). (7) Install the RH and LH boot clips. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3266 50-6 STEERING COLUMN - STEERING COLUMN ASSY STEERING COLUMN ASSY 5009G-01 COMPONENTS Horn Button Assy 8.8 (90, 78 in.⋅lbf) 50 (510, 37) Steering Wheel Cover Lower No.2 Steering Column Cover UPR Spiral Cable Sub-assy Steering Wheel Assy Steering Wheel Cover Lower No.2 8.8 (90, 78 in.⋅lbf) Windshield Wiper Switch Assy Head Lamp Dimmer Switch Assy Steering Column Assy Steering Column Cover LWR 35 (360, 26) 21 (210, 15) Steering Intermediate Shaft Sub-assy 21 (210, 15) 35 (360, 26) Clamp Instrument Panel Finish Panel Sub-assy Lower Instrument Panel Insert Sub-assy LWR LH N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque F46486 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3267 50-7 STEERING COLUMN - STEERING COLUMN ASSY Key Cylinder Lamp Assy (w/ Illuminated Entry System) Transponder Key Amplifier (w/ Engine Immobiliser System) Ignition Switch Lock Cylinder Assy Key Inter Lock Solenoid  Tapered-Head Bolt Steering Column Clamp Upper Steering Column Upper w/ Switch Bracket Assy Steering Column Tube Un-lock Warning Switch Assy Ignition or Starter Switch  Steering Main Shaft Snap Ring (Outer Side)  Steering Main Shaft Bushing  Steering Main Shaft Snap Ring (Inner Side) Steering Main Shaft Assy  Non-reusable part F46487 F46487 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3268 50-8 STEERING COLUMN - STEERING COLUMN ASSY 5009H-01 OVERHAUL 1. 2. 3. 4. 5. PRECAUTION (SEE PAGE 60-1 ) DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60-1 ) PLACE FRONT WHEELS FACING STRAIGHT AHEAD REMOVE STEERING WHEEL COVER LOWER NO.2 (SEE PAGE 60-17 ) REMOVE HORN BUTTON ASSY (SEE PAGE 60-17 ) 6. (a) (b) Matchmarks (c) SST REMOVE STEERING WHEEL ASSY Remove the steering wheel assy set nut. Place matchmarks on the steering wheel assy and main shaft assy. Using SST, remove the steering wheel assy. SST 09950- 50013 (09951- 05010, 09952- 05010, 09953-05020, 09954-05021) F40348 7. (a) REMOVE STEERING COLUMN COVER LWR Remove the 3 screws and steering column cover LWR. H40197 8. 9. 10. 11. 12. 13. REMOVE REMOVE REMOVE REMOVE REMOVE REMOVE STEERING COLUMN COVER UPR SPIRAL CABLE SUB-ASSY (SEE PAGE 60-26 ) HEADLAMP DIMMER SWITCH ASSY (SEE PAGE 65-25 ) WINDSHIELD WIPER SWITCH ASSY (SEE PAGE 66-16 ) INSTRUMENT PANEL FINISH PANEL SUB-ASSY LOWER (SEE PAGE 71-10 ) INSTRUMENT PNL INSERT SUB-ASSY LWR LH (SEE PAGE 71-10 ) 14. B (a) (b) SEPARATE STEERING INTERMEDIATE SHAFT SUB-ASSY Loosen the bolt A and remove the clamp from the steering intermediate shaft sub-assy. Loosen the bolt B. A F46489 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3269 50-9 STEERING COLUMN (c) Matchmarks (d) - STEERING COLUMN ASSY Place matchmarks on the steering intermediate shaft sub-assy and steering gear assy. Remove the bolt and separate the steering intermediate shaft sub-assy. F40352 15. (a) (b) REMOVE STEERING COLUMN ASSY Separate the connectors and wire harness clamps. Remove the 2 bolts, 2 nuts and steering column assy from the instrument panel reinforcement assy. 16. REMOVE STEERING INTERMEDIATE SHAFT SUB-ASSY Place matchmarks on the steering intermediate shaft sub-assy and steering shaft. Remove the bolt and steering intermediate shaft subassy. F46490 (a) (b) Matchmarks 17. F46491 REMOVE KEY CYLINDER LAMP ASSY (W/ ILLUMINATED ENTRY SYSTEM) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3270 50-10 STEERING COLUMN - STEERING COLUMN ASSY 18. F46482 REMOVE TRANSPONDER KEY AMPLIFIER (W/ ENGINE IMMOBILISER SYSTEM) (a) Widen the claw hung on the upper bracket by approx. 1.0 mm (0.039 in.) using a screwdriver. (b) Pull the transponder key amplifier toward the rear of the vehicle with the claw open. NOTICE: Take care not to use excessive force to prevent the case from being damaged. 19. (a) INSPECT STEERING MAIN SHAFT ASSY Measure the steering main shaft length. Standard length: 504.5
1 mm (19.862
0.039 in.) If the length is out of specification, replace the steering column assy with a new one. F46495 20. Screw Extractor (a) (b) (c) F46492 21. 22. (a) REMOVE STEERING COLUMN UPPER W/SWITCH BRACKET ASSY Using a centering punch, mark the center of the 2 tapered-head bolts. Using a 3 to 4 mm (0.12 to 0.16 in.) drill, drill in to the 2 bolts. Using a screw extractor, remove the 2 bolts and steering column upper w/ switch bracket assy. REMOVE STEERING COLUMN CLAMP UPPER REMOVE STEERING MAIN SHAFT ASSY Using a snap ring expander, remove the steering main shaft snap ring (outer side). F46493 (b) Using a brass bar and a hammer, remove the steering main shaft assy and steering main shaft bushing. NOTICE: Be careful not to drop the steering main shaft assy. F46494 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3271 50-1 1 STEERING COLUMN - STEERING COLUMN ASSY (c) Using a snap ring expander, remove the steering main shaft snap ring (inner side). 23. (a) REMOVE IGNITION SWITCH LOCK CYLINDER ASSY Place the ignition switch lock cylinder assy at the ACC position. Push down the stop pin with a screwdriver, and pull out the cylinder assy. F40490 (b) F46483 24. (a) (b) Claws REMOVE UN-LOCK WARNING SWITCH ASSY Separate the un-lock warning switch assy connector from the ignition or starter switch assy. Remove the un-lock warning switch assy by pushing up the center part and releasing the 2 claws. F46484 (c) (d) Disengage the secondary locking device. Using a small screwdriver, disengage the locking lug of the terminals 2 and 4, and pull the terminals out from the un-lock warning switch assy rear side. F46322 25. (a) 26. (a) 27. (a) 28. (a) REMOVE KEY INTER LOCK SOLENOID Remove the 2 screws and solenoid from the steering column bracket assy. REMOVE IGNITION OR STARTER SWITCH ASSY Remove the 2 screws and ignition or starter switch assy from the steering column bracket assy UPR. INSTALL IGNITION OR STARTER SWITCH ASSY Install the ignition or starter switch assy to the steering column bracket assy UPR with the 2 screws. INSTALL KEY INTER LOCK SOLENOID Install the solenoid to the steering column bracket assy with the 2 screws. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3272 50-12 STEERING COLUMN 29. (a) (b) (c) - STEERING COLUMN ASSY INSTALL UN-LOCK WARNING SWITCH ASSY Install the un-lock warning switch assy. Connect the terminals 2 and 4 of the un-lock warning switch assy connector. Connect the un-lock warning switch assy connector to the ignition or starter switch assy. F46323 30. (a) (b) 31. (a) (b) INSTALL IGNITION SWITCH LOCK CYLINDER ASSY Make sure the ignition switch lock cylinder assy at the ACC position. Install the ignition switch lock cylinder assy. INSPECT STEERING LOCK OPERATION Check that the steering lock mechanism is activated when removing the key. Check that the steering lock mechanism is deactivated when inserting the key and turning it to ACC position. HINT: If there is any abnormality, replace the ignition switch lock cylinder assy. 32. (a) (b) INSTALL STEERING MAIN SHAFT ASSY Using a snap ring expander, install a new steering main shaft snap ring (inner side) to the steering main shaft assy. Install the steering main shaft assy to the steering column tube. F46498 (c) Using a snap ring expander, install a new steering main shaft snap ring (outer side) to the steering main shaft assy. F46493 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3273 50-13 STEERING COLUMN - STEERING COLUMN ASSY 33. (a) INSTALL STEERING MAIN SHAFT BUSH Using SST and a hammer, install a new steering main shaft bushing. SST 09608-06041 34. INSTALL STEERING COLUMN UPPER W/SWITCH BRACKET ASSY Temporarily install the steering column upper w/ switch bracket assy and steering column upper clamp with 2 new tapered-head bolts. Tighten the 2 tapered-head bolts until the bolt heads break off. SST F46499 (a) (b) F46500 35. INSTALL KEY CYLINDER LAMP ASSY (W/ ILLUMINATED ENTRY SYSTEM) 36. F46485 INSTALL TRANSPONDER KEY AMPLIFIER (W/ ENGINE IMMOBILISER SYSTEM) (a) Align the transponder key amplifier with the installation position of the upper bracket with the amplifier inclined. (b) Push the transponder key amplifier up and connect it to the upper bracket. NOTICE: Take care not to push the amplifier up with excessive force to prevent it from being damaged. 37. Matchmarks (a) (b) TEMPORARILY TIGHTEN STEERING INTERMEDIATE SHAFT SUB-ASSY Align the matchmarks on the steering intermediate shaft sub-assy and steering main shaft assy. Temporarily install the steering intermediate shaft subassy with the bolt. F46491 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3274 50-14 STEERING COLUMN 38. (a) (b) (c) - STEERING COLUMN ASSY INSTALL STEERING COLUMN ASSY Install the steering column assy with the 2 bolts and nuts. Torque: 21 N⋅m (210 kgf⋅cm, 15 ft⋅lbf) Connect the connectors. Connect the wire harness clamps to the steering column tube. F46490 39. Matchmarks (a) (b) CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSY Align the matchmarks on the intermediate shaft sub-assy and steering gear assy. Install the bolt. Torque: 35 N⋅m (360 kgf⋅cm, 26 ft⋅lbf) F40352 (c) A (d) Tighten the bolt A. Torque: 35 N⋅m (360 kgf⋅cm, 26 ft⋅lbf) Connect the clamp to the steering intermediate shaft sub-assy and tighten the bolt B. B F46489 40. 41. 42. 43. 44. 45. (a) PLACE FRONT WHEELS FACING STRAIGHT AHEAD INSPECT SPIRAL CABLE SUB-ASSY (SEE PAGE 60-26 ) INSTALL SPIRAL CABLE SUB-ASSY (SEE PAGE 60-26 ) CENTER SPIRAL CABLE (SEE PAGE 60-26 ) INSTALL STEERING COLUMN COVER UPR INSTALL STEERING COLUMN COVER LWR Install the steering column cover LWR with the 3 screws. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3275 50-15 STEERING COLUMN 46. (a) (b) (c) 47. 48. 49. - STEERING COLUMN ASSY INSTALL STEERING WHEEL ASSY Align the matchmarks on the steering wheel assy and steering main shaft assy. Install the steering wheel assy set nut. Torque: 50 N·m (510 kgf·cm, 37 ft·lbf) Connect the connector. INSTALL HORN BUTTON ASSY (SEE PAGE 60-17 ) CONNECT BATTERY NEGATIVE TERMINAL INSPECT SRS WARNING LIGHT (SEE PAGE 05-1207 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3276 51-7 POWER STEERING - VANE PUMP ASSY (2AZ-FE) VANE PUMP ASSY (2AZ-FE) 510H6-01 COMPONENTS Pressure Port Union 69 (704, 51)
O-Ring Flow Control Valve Power Steering Oil Pressure Switch 21 (214, 15) Flow Control Valve Compression Spring Vane Pump Housing Front
O-Ring Power Steering Suction Port Union 12 (122, 9)
Vane Pump Housing Oil Seal Vane Pump Housing Rear W/Pulley Shaft Sub-assy
Vane Pump Shaft Snap Ring
O-Ring Vane Pump Side Plate Front
O-Ring X10 Vane Pump Rotor 22 (224, 16) Vane Pump Plate N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque Vane Pump Cam Ring
Non-reusable part Power steering fluid G30662 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3283 51-8 POWER STEERING - VANE PUMP ASSY (2AZ-FE) 510H7-01 OVERHAUL NOTICE:
Do not overtighten when using a vise.
When installing, coat the parts indicated by the arrows with power steering fluid (see page 51-7 ). 1. REMOVE FRONT WHEEL RH 2. DRAIN POWER STEERING FLUID 3. REMOVE FRONT FENDER APRON SEAL RH 4. REMOVE FAN AND GENERATOR V BELT (SEE PAGE 14-5 ) SST 09249-63010 5. DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.1 (a) Remove the clip and disconnect the oil reservoir to pump hose No.1. NOTICE: Take care not to spill fluid on the V belt. Turn Hold 6. (a) DISCONNECT PRESSURE FEED TUBE ASSY Using a wrench (27 mm) to hold the pressure port union, remove the union bolt and the gasket. 7. (a) (b) REMOVE VANE PUMP ASSY Disconnect the connector from the oil pressure switch. Using SST and a deep socket wrench (14 mm), loosen bolt A. SST 09249-63010 Remove bolt B and the vane pump assy. F40529 A (c) SST B F40342 8. (a) FIX VANE PUMP ASSY Using SST, hold the vane pump assy in a vise. SST 09630-00014 (09631-00132) SST F41481 9. (a) (b) REMOVE POWER STEERING SUCTION PORT UNION Remove the bolt and the suction port union. Remove the O-ring from the suction port union. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3284 51-9 POWER STEERING 10. (a) (b) (c) - VANE PUMP ASSY (2AZ-FE) REMOVE FLOW CONTROL VALVE Remove the pressure port union. Remove the O-ring from the pressure port union. Remove the flow control valve and the compression spring. C84485 11. REMOVE POWER STEERING OIL PRESSURE SWITCH NOTICE: If the oil pressure switch is dropped or damaged, replace it with a new one. 12. (a) (b) REMOVE VANE PUMP HOUSING REAR Remove the 4 bolts and the housing rear from the housing front. Remove the O-ring from the housing rear. C84483 13. (a) (b) REMOVE W/PULLEY SHAFT SUB-ASSY Using 2 screwdrivers, remove the snap ring from the w/ pulley shaft sub-assy. Remove the w/pulley shaft sub-assy. 16. (a) (b) REMOVE VANE PUMP SIDE PLATE FRONT Remove the side plate front from the housing front. Remove the O-ring from the side plate front. C57767 14. (a) (b) 15. REMOVE VANE PUMP ROTOR Remove the 10 vane pump plates. Remove the vane pump rotor. REMOVE VANE PUMP CAM RING C65368 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3285 51-10 POWER STEERING (c) - VANE PUMP ASSY (2AZ-FE) Remove the O-ring from the housing front. C65369 17. REMOVE VANE PUMP HOUSING OIL SEAL (a) Using a screwdriver, remove the housing oil seal. NOTICE: Be careful not to damage the housing front. Cloth D30331 18. INSPECT VANE PUMP SHAFT AND BUSH IN HOUSING FRONT (a) Using a micrometer and a caliper gauge, measure the oil clearance. Maximum clearance: 0.07 mm (0.0028 in.) If it is more than the maximum, replace the vane pump assy. F09875 19. Thickness (a) INSPECT VANE PUMP ROTOR AND VANE PUMP PLATES Using a micrometer, measure the thickness of the vane pump plates. Minimum thickness: 1.405 to 1.411 mm (0.05531 to 0.05555 in.) D30648 (b) Using a feeler gauge, measure the clearance between a side face of the vane pump rotor groove and the vane plates. Maximum clearance: 0.03 mm (0.0012 in.) If clearance exceeds maximum, replace the vane pump assy. Feeler Gauge R10282 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3286 51-1 1 POWER STEERING - VANE PUMP ASSY (2AZ-FE) 20. (a) INSPECT FLOW CONTROL VALVE Coat the flow control valve with power steering fluid and check that it falls smoothly into the flow control valve hole under its own weight. If it lacks smoothness, replace the vane pump assy. G30668 (b) Check the flow control valve for leakage. Close one of the holes and apply compressed air, 392 to 490 kPa (4 to 5 kgf/cm2, 57 to 71 psi), into the opposite side hole, and confirm that air does not come out from the both end holes. If air leaks, replace the vane pump assy. Compressed Air Close R07591 21. Vernier Calipers INSPECT FLOW CONTROL VALVE COMPRESSION SPRING (a) Using vernier calipers, measure the free length of the compression spring. Minimum free length: 30.3 mm (1.193 in.) If it is less than the minimum, replace the vane pump assy. R08702 22. INSPECT PRESSURE PORT UNION If the union seat in the pressure port union is severely damaged, it may cause fluid leakage. In that case, replace the vane pump assy. 23. (a) (b) INSTALL VANE PUMP HOUSING OIL SEAL Coat a new housing oil seal lip with power steering fluid. Using SST and a press, install a new housing oil seal. SST 09950- 60010 (09951- 00280), 09950- 70010 (09951-07100) NOTICE: Make sure that the housing oil seal is installed in the correct direction. SST Oil Seal F08480 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3287 51-12 POWER STEERING VANE PUMP ASSY (2AZ-FE) 24. (a) Vinyl Tape C70122 - D30334 INSTALL W/PULLEY SHAFT SUB-ASSY Coat bushing surface of the housing front with power steering fluid. (b) Gradually insert the w/pulley shaft sub-assy from the pulley side. NOTICE:
Do not damage the housing oil seal lip in the housing front.
After inserting the w/pulley shaft sub-assy, check that the oil seal lip faces in the correct direction. 25. INSTALL VANE PUMP SIDE PLATE FRONT (a) Coat a new O-ring with power steering fluid and install it into the housing front. C65369 (b) Coat a new O-ring with power steering fluid and install it onto the side plate front. C65368 (c) Align the dent of the side plate front with that of the housing front, and install the side plate front. NOTICE: Make sure that the side plate front is installed in the correct direction. Side Plate Front Housing Front F46198 26. (a) Housing Front Cam Ring Inscribed Mark INSTALL VANE PUMP CAM RING Align the dent of the cam ring with that of the side plate front, and install the cam ring with the inscribed mark facing upward. NOTICE: Make sure that the cam ring is installed in the correct direction. F46199 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3288 51-13 POWER STEERING - VANE PUMP ASSY (2AZ-FE) 27. INSTALL VANE PUMP ROTOR (a) Install the vane pump rotor. HINT: Vane pump rotor has no specific direction. C95038 Inward (b) (c) Coat 10 vane pump plates with power steering fluid. Install the vane pump plates with the round end facing outward. 28. (a) INSTALL VANE PUMP SHAFT SNAP RING Using a screwdriver and a snap ring expander, install a new snap ring to the w/pulley shaft sub-assy. 29. (a) INSTALL VANE PUMP HOUSING REAR Coat a new O-ring with power steering fluid and install it onto the housing rear. Align the straight pin of the housing rear with the dents of the cam ring, side plate front and the housing front, and install the housing rear with the 4 bolts. Torque: 22 N⋅m (224 kgf⋅cm, 16 ft⋅lbf) Outward C95777 D30335 C57770 D30336 (b) Housing Rear Housing Front Cam Ring F46200 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3289 51-14 POWER STEERING VANE PUMP ASSY (2AZ-FE) 30. (a) INSPECT PRELOAD Check that the pump rotates smoothly without abnormal noise. (b) Temporarily install the service bolt. Recommended service bolt: Thread diameter: 10 mm (0.39 in.) Thread pitch: 1.25 mm (0.0492 in.) Bolt length: 50 mm (1.97 in.) (c) Using a torque wrench, check the pulley rotating torque. C53369 Rotating torque: 0.27 N⋅m (2.8 kgf⋅cm, 2.4 in.⋅lbf) or less If the rotating torque is not as specified, check the housing oil seal. INSTALL POWER STEERING OIL PRESSURE SWITCH Coat a new O-ring with power steering fluid and install it to the oil pressure switch. Install the oil pressure switch onto the vane pump assy. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) Service Bolt 31. (a) (b) - 32. (a) (b) (c) (d) INSTALL FLOW CONTROL VALVE Coat the compression spring and the flow control valve with power steering fluid. Install the compression spring and the flow control valve. Coat a new O-ring with power steering fluid and install it onto the pressure port union. Install the pressure port union. Torque: 69 N⋅m (704 kgf⋅cm, 51 ft⋅lbf) C84485 33. (a) (b) INSTALL POWER STEERING SUCTION PORT UNION Coat a new O-ring with power steering fluid, and install it to the suction port union. Install the suction port union with the bolt. Torque: 12 N⋅m (122 kgf⋅cm, 9 ft⋅lbf) 34. (a) (b) A (c) SST B Fulcrum Length F40330 INSTALL VANE PUMP ASSY Temporarily tighten bolt A to the vane pump assy. Install the vane pump assy and bolt B. Torque: 37 N⋅m (377 kgf⋅cm, 27 ft⋅lbf) Using SST and a deep socket wrench (14 mm), tighten bolt A. SST 09249-63010 Torque: 26 N⋅m (264 kgf⋅cm, 19 ft⋅lbf) HINT:

(d) Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). This torque value is effective when SST is parallel to a torque wrench. Connect the connector to the oil pressure switch. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3290 51-15 POWER STEERING Gasket Pressure Feed Tube Assy Stopper F41596 35. (a) - VANE PUMP ASSY (2AZ-FE) CONNECT PRESSURE FEED TUBE ASSY Install the pressure feed tube assy and a new gasket to the vane pump assy with the union bolt. HINT: Make sure the stopper of the pressure feed tube assy touches the housing front as shown in the illustration. (b) Using a wrench (27 mm) to hold the pressure port union, torque the union bolt. Torque: 52 N⋅m (525 kgf⋅cm, 38 ft⋅lbf) 36. CONNECT OIL RESERVOIR TO PUMP HOSE NO.1 (a) Connect the oil reservoir to pump hose No.1 with the clip. NOTICE: Take care not to spill fluid on the V belt. 37. INSTALL FAN AND GENERATOR V BELT (SEE PAGE 14-5 ) SST 09249-63010 38. INSTALL FRONT FENDER APRON SEAL RH 39. INSTALL FRONT WHEEL RH Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) 40. BLEED POWER STEERING FLUID (SEE PAGE 51-3 ) 41. INSPECT FLUID LEAK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3291 51-3 POWER STEERING - POWER STEERING SYSTEM 51018-17 ON-VEHICLE INSPECTION 1. (a) INSPECT DRIVE BELT Visually check the belt for excessive wear, frayed cords, etc. If any defect is found, replace the drive belt. HINT: Cracks on the rib side of a belt are considered acceptable. Replace the belt if there are any missing ribs. F40449 2. (a) (b) F13530 Normal Abnormal CHECK FLUID LEVEL Keep the vehicle level. With the engine stopped, check the fluid level in the oil reservoir. If necessary, add fluid. Fluid: ATF DEXRON II or III HINT: When hot, check that the fluid level is within the HOT LEVEL range on the reservoir. If the fluid is cold, check that it is within the COLD LEVEL range. (c) Start the engine and run at idle. (d) Turn the steering wheel from lock to lock several times to raise fluid temperature. Fluid temperature: 75 to 80C (167 to 176F) (e) Check for foaming or emulsification. If foaming or emulsification is identified, bleed air in the power steering system (see step 3). F40897 (f) 5 mm (0.20 in.) or less Engine Idling Engine Stopped R11786 With the engine idling, measure the fluid level in the reservoir. (g) Stop the engine. (h) Wait a few minutes and measure the fluid level in the reservoir again. Maximum fluid level rise: 5 mm (0.20 in.) or less If the fluid level rise exceeds the maximum, bleed air in the power steering system (see step 3). (i) Check the fluid level. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3279 51-4 POWER STEERING Normal Abnormal F40897 - POWER STEERING SYSTEM 3. BLEED AIR IN POWER STEERING SYSTEM NOTICE: If you replace or separate the components for power steering oil pressure line, bleed air in the power steering system after the operation. (a) Idle the engine at 1,000 rpm or less until bubbles in the fluid disappear. (Be sure not to turn the steering wheel.) (b) When the bubbles disappear, slowly turn the steering wheel from lock to lock 2 or 3 times. (c) Repeat procedures (a) and (b) until the fluid level in the reservoir becomes stable and bubbles disappear. If the fluid level goes below the MAX line, add fluid. (d) When the fluid level becomes stable, increase and decrease oil pressure 2 or 3 times for both left and right by turning the steering wheel to the full lock positions and jiggling it there. (e) Make sure that no bubbles exist in the reservoir. When turning the steering wheel quickly or turning it from lock to lock position, check that the steering wheel is not heavy to turn and there is no abnormal noise or vibration. (f) When there are fluid leaks or abnormalities after bleeding air, repair them and repeat procedures (a) to (e). If the abnormalities still exist, replace the related parts. 4. CHECK STEERING FLUID PRESSURE (a) Disconnect the pressure feed tube assy (see page 30-3 ). (b) Connect SST, as shown in the illustration on the next page. SST 09640-10010 (09641-01010, 09641-01020, 09641-01030) NOTICE: Check that the valve of the SST is in the open position. (c) Bleed the power steering system. (d) Start the engine and run at idle. (e) Turn the steering wheel from lock to lock several times to raise fluid temperature. Fluid temperature: 75 to 80°C (167 to 176°F) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3280 51-5 POWER STEERING Attachment - POWER STEERING SYSTEM Attachment SST IN OUT F40336 (f) Oil Reservoir PS Gear Closed PS Vane Pump SST Z15498 Oil Reservoir PS Gear Open PS Vane Pump SST With the engine idling, close the valve of the SST and observe the reading on the SST. Fluid pressure: 7,800 to 8,300 kPa (80 to 85 kgf/cm2, 1,131 to 1,204 psi) NOTICE:
Do not keep the valve closed for more than 10 seconds.
Do not allow the fluid temperature to become too high. (g) (h) With the engine idling, open the valve fully. Measure the fluid pressure at engine speeds of 1,000 rpm and 3,000 rpm. Difference in fluid pressure: 490 kPa (5 kgf/cm2, 71 psi) or less NOTICE: Do not turn the steering wheel. Z15499 (i) Oil Reservoir Lock Position PS Gear Open PS Vane Pump SST Z15500 With the engine idling and the valve fully opened, turn the steering wheel to the left or right full lock position. Fluid pressure: 7,800 to 8,300 kPa (80 to 85 kgf/cm2, 1,131 to 1,204 psi) NOTICE:
Do not keep the steering wheel in the full lock position for more than 10 seconds.
Do not allow the fluid temperature to become too high. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3281 51-6 POWER STEERING (j) (k) (l) 5. (a) (b) (c) (d) F08858 - POWER STEERING SYSTEM Disconnect the SST. SST 09640- 10010 (09641- 01010, 09641- 01020, 09641-01030) Connect the pressure feed tube assy (see page 30-3 ). Bleed the power steering system (see step 3). CHECK STEERING EFFORT Center the steering wheel. Remove the steering wheel pad (see page 60-17 ). Start the engine and run it at idle. Measure the steering effort in both directions. Steering effort (Reference): 6.0 N·m (60 kgf·cm, 53 in.·lbf) or less HINT: Check tire type, pressure and road surface before making your diagnosis. (e) Tighten the steering wheel set nut. Torque: 51 N·m (520 kgf·cm, 38 ft·lbf) (f) Install the steering wheel pad (see page 60-17 ). (g) Clear the DTCs (see page 05-1215 ). (h) Inspect the airbag warning light (see page 05-1207 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3282 51-1 POWER STEERING - POWER STEERING SYSTEM POWER STEERING SYSTEM 51016-08 PRECAUTION 1. (a) 2. (a) HANDLING PRECAUTIONS FOR STEERING SYSTEM Care must be taken when replacing parts. Incorrect replacement could affect the performance of the steering system and result in a driving hazard. HANDLING PRECAUTIONS FOR SRS AIRBAG SYSTEM The vehicle is equipped with SRS (Supplemental Restraint System) such as the airbags. If service operation is not carried out properly, in a step by step fashion, sudden deployment of the airbags may result in serious injury. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notice for the supplemental restraint system (see page 60-1 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3277 51-2 POWER STEERING - POWER STEERING SYSTEM 51017-14 PROBLEM SYMPTOMS TABLE HINT: Use the table below to help determine the cause of the problem. The numbers indicate likely causes of the problem in descending order. Check each part in order. Repair or replace parts as necessary. Symptom Suspected Area 1. Tires (Improperly inflated) 2. Power steering fluid level (Low) 3. Drive belt (Loose) Hard steering 4. 5. 6. 7. 8. Front wheel alignment (Incorrect) Steering system joints (Worn) Suspension arm ball joints (Worn) Steering column (Binding) Power steering vane pump See page 2AZ-FE: 3MZ-FE: 2AZ-FE: 3MZ-FE: 9. Power steering gear 28-1 51-3 14-1 14-121 26-7 26-20 50-8 51-8 51-17 30-3 Poor return 1. 2. 3. 4. Tires (Improperly inflated) Front wheel alignment (Incorrect) Steering column (Binding) Power steering gear 28-1 26-7 50-8 30-3 Excessive freeplay 1. 2. 3. 4. 5. Steering system joints (Worn) Suspension arm ball joints (Worn) Intermediate shaft, Sliding yoke (Worn) Front wheel bearing (Worn) Power steering gear 26-20 50-8 30-3 30-3 Abnormal noise 1. Power steering fluid level (Low) 2. Steering system joints (Worn) 3. Power steering vane pump 2AZ-FE: 3MZ-FE: 4. Power steering gear 51-3 51-8 51-17 30-3 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3278 51-16 POWER STEERING - VANE PUMP ASSY (3MZ-FE) VANE PUMP ASSY (3MZ-FE) 510C9-07 COMPONENTS Pressure Port Union 83 (846, 61) Vane Pump Housing Rear
O-Ring Power Steering Suction Port Union Flow Control Valve Vane Pump Bracket Rear Flow Control Valve Compression Spring
O-Ring 24 (245, 18)
Gasket 13 (133, 10)
O-Ring Vane Pump Housing Front 43 (438, 32) 43 (438, 32) 24 (245, 18) Pump Bracket Front
Vane Pump Housing Oil Seal Vane Pump Pulley Wave Washer Vane Pump Shaft X10 Vane Pump Cam Ring Vane Pump Rotor Vane Pump Plate
Vane Pump Shaft Snap Ring 44 (449, 32) N⋅m (kgf⋅cm, ft⋅lbf) Vane Pump Side Plate Rear : Specified torque
Non-reusable part Power steering fluid D31109 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3292 51-17 POWER STEERING - VANE PUMP ASSY (3MZ-FE) 510DV-05 OVERHAUL NOTICE:
Do not overtighten when using a vise.
When installing, coat the parts indicated by the arrows with power steering fluid (see page 51-16 ). 1. REMOVE FRONT WHEEL RH 2. DRAIN POWER STEERING FLUID 3. REMOVE FRONT FENDER APRON SEAL RH 4. DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.1 (a) Remove the clip and disconnect the oil reservoir to pump hose No.1. NOTICE: Take care not to spill fluid on the V belt. 5. REMOVE POWER STEERING OIL PRESSURE SWITCH (a) Disconnect the connector. (b) Remove the oil pressure switch from the union bolt. NOTICE: Be careful not to drop the oil pressure switch. If the oil pressure switch is dropped or severely damaged, replace it with a new one. 6. (a) Turn (b) DISCONNECT PRESSURE FEED TUBE ASSY Using a wrench (24 mm) to keep the pressure port union, remove the union bolt and the gasket. Disconnect the pressure feed tube assy. 7. (a) REMOVE VANE PUMP V BELT Loosen the 2 bolts and remove the vane pump V belt. Keep F41598 G25718 8. (a) REMOVE VANE PUMP ASSY Remove the 2 bolts and the vane pump assy. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3293 51-18 POWER STEERING 9. (a) SST (b) - VANE PUMP ASSY (3MZ-FE) REMOVE VANE PUMP PULLEY Using SST, keep the vane pump pulley from rotating and loosen the nut. SST 09960-10010 (09962-01000, 09963-01000) Remove the nut and the vane pump pulley from the vane pump shaft. F41600 10. REMOVE POWER STEERING SUCTION PORT UNION (a) Remove the bolt and the suction port union. (b) Remove the O-ring from the suction port union. 11. REMOVE FLOW CONTROL VALVE (a) Remove the pressure port union. (b) Remove the O-ring from the pressure port union. (c) Remove the flow control valve and the compression spring. 12. REMOVE VANE PUMP BRACKET REAR (a) Remove the 2 bolts and the vane pump bracket rear from the vane pump assy. 13. REMOVE VANE PUMP HOUSING REAR (a) Remove the 4 bolts and the vane pump housing rear from the vane pump housing front. (b) Remove the gasket. (c) Remove the 2 O-rings from the vane pump housing rear. 14. REMOVE VANE PUMP SIDE PLATE REAR (a) Remove the wave washer from the vane pump side plate rear. HINT: Make sure direction of the part. (b) Remove the vane pump side plate rear. HINT: Make sure direction of the part. 15. REMOVE VANE PUMP CAM RING HINT: Make sure direction of the part. 16. (a) REMOVE VANE PUMP SHAFT SNAP RING Using a screwdriver, remove the vane pump shaft snap ring from the vane pump shaft. C65312 17. (a) (b) 18. REMOVE VANE PUMP ROTOR Remove the 10 vane pump plates from the vane pump rotor. Remove the vane pump rotor. REMOVE VANE PUMP SHAFT 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3294 51-19 POWER STEERING 19. (a) - VANE PUMP ASSY (3MZ-FE) REMOVE PUMP BRACKET FRONT Remove the bolt and the pump bracket front from the vane pump housing front. 20. (a) REMOVE VANE PUMP HOUSING OIL SEAL Using a screwdriver, remove the vane pump housing oil seal from the vane pump housing front. NOTICE: Be careful not to damage the bushing of the vane pump housing front. Shop Rag D30653 21. INSPECT VANE PUMP SHAFT AND BUSH IN HOUSING FRONT (a) Using a micrometer and a caliper gauge, measure the oil clearance. Standard clearance: 0.027 to 0.054 mm (0.00106 to 0.00213 in.) Maximum clearance: 0.07 mm (0.0028 in.) If clearance exceeds maximum, replace the vane pump assy. (b) Check that there is no severe damage or wear on the bushing of the vane pump housing front and the vane pump shaft. If necessary, replace the vane pump assy. Caliper Gauge Micrometer Vane Pump Shaft Bushing Vane Pump Housing Front D30759 22. Thickness (a) INSPECT VANE PUMP ROTOR AND VANE PUMP PLATES Using a micrometer, measure the thickness of the vane pump plates. Minimum thickness: 1.397 to 1.403 mm ( 0.0550 to 0.0552 in.) D30648 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3295 51-20 POWER STEERING - VANE PUMP ASSY (3MZ-FE) (b) Using a feeler gauge, measure the clearance between the vane pump rotor groove and the vane pump plate. Maximum clearance: 0.03 mm (0.0012 in.) If clearance exceeds maximum, replace the vane pump assy. Feeler Gauge R10282 23. (a) INSPECT FLOW CONTROL VALVE Coat the flow control valve with power steering fluid and check that it falls smoothly into the flow control valve hole under its own weight. If it lacks smoothness, replace the vane pump assy. R11288 (b) Check the flow control valve for leakage. Close one of the holes and apply compressed air, 392 to 490 kPa (4 to 5 kgf/cm2, 57 to 71 psi), into the opposite side hole, and confirm that air does not come out from the both end holes. If air leaks, replace the vane pump assy. Compressed Air R07591 24. Vernier Calipers INSPECT FLOW CONTROL VALVE COMPRESSION SPRING (a) Using vernier calipers, measure the free length of the compression spring. Minimum free length: 32.24 mm (1.2693 in.) If it is less than the minimum, replace the vane pump assy. R08702 25. INSPECT PRESSURE PORT UNION If the union seat in the pressure port union is severely damaged, it may cause fluid leakage. In that case, replace the vane pump assy. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3296 51-21 POWER STEERING SST 27. (a) VANE PUMP ASSY (3MZ-FE) 26. (a) Press Oil Seal W03541 - F41624 INSTALL VANE PUMP HOUSING OIL SEAL Coat a new vane pump housing oil seal lip with power steering fluid. (b) Using SST and a press, install the vane pump housing oil seal. SST 09950-60010 (09951-00330), 09950-70010 (09951-07100) NOTICE: Make sure that the vane pump housing oil seal is installed in the correct direction. INSTALL PUMP BRACKET FRONT Install the pump bracket front with the bolt. Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) 28. (a) Bushing F40339 Inscribed Mark INSTALL VANE PUMP SHAFT Coat bushing surface of the vane pump housing front with power steering fluid. (b) Gradually insert the vane pump shaft from the pulley side. NOTICE:
Do not damage the vane pump housing oil seal lip in the vane pump housing front.
After installation, check the vane pump housing oil seal lip. 29. (a) INSTALL VANE PUMP CAM RING Align the holes of the vane pump cam ring with the 2 straight pins, and install the vane pump cam ring with the inscribed mark facing upward. Straight Pin D30649 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3297 51-22 POWER STEERING - VANE PUMP ASSY (3MZ-FE) 30. (a) INSTALL VANE PUMP ROTOR Install the vane pump rotor with the inscribed mark facing downward. NOTICE: Make sure that the vane pump rotor is installed in the correct direction. Inscribed Mark Inscribed Mark D30650 Inward (b) (c) Coat all 10 vane pump plates with power steering fluid. Install the vane pump plates with the round end facing outward. NOTICE: Make sure that the vane pump plates are installed in the correct direction. Outward C95777 D30335 31. (a) INSTALL VANE PUMP SHAFT SNAP RING Using a snap ring expander, install a new vane pump shaft snap ring onto the vane pump shaft. 32. (a) INSTALL VANE PUMP SIDE PLATE REAR Align the groove of the vane pump cam ring with that of the vane pump side plate rear to install. D30651 Set F41480 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3298 51-23 POWER STEERING (b) (c) - VANE PUMP ASSY (3MZ-FE) Install the wave washer so that its protrusions fit into the slots in the vane pump side plate rear. Coat 2 new O-rings with power steering fluid and install them onto the vane pump side plate rear. R11292 Gasket 33. INSTALL VANE PUMP HOUSING REAR (a) Install a new gasket to the vane pump housing front. NOTICE: Make sure that the gasket is installed with the cutout in the correct position. (b) Install the vane pump housing rear with the 4 bolts. Torque: 24 N⋅m (245 kgf⋅cm, 18 ft⋅lbf) Cutout Part D30652 34. (a) (b) (c) MEASURE VANE PUMP ROTATION TORQUE Check that the vane pump rotates smoothly without abnormal noise. Temporarily install the nut to the vane pump shaft. Using a torque wrench, check the vane pump rotating torque. Rotating torque: 0.27 N⋅m (2.8 kgf⋅cm, 2.4 in.⋅lbf) or less F41573 35. (a) INSTALL VANE PUMP BRACKET REAR Install the vane pump bracket rear with the 2 bolts. Torque: 43 N⋅m (438 kgf⋅cm, 32 ft⋅lbf) 36. INSTALL FLOW CONTROL VALVE (a) Coat the compression spring with power steering fluid and install it to the vane pump housing front. (b) Coat the flow control valve with power steering fluid. (c) Install the flow control valve to the vane pump housing front. NOTICE: Make sure that the flow control valve is installed in the correct direction. (d) Coat a new O-ring with power steering fluid and install it to the pressure port union. (e) Install the pressure port union to the vane pump housing front. Torque: 83 N⋅m (846 kgf⋅cm, 61 ft⋅lbf) 37. INSTALL POWER STEERING SUCTION PORT UNION (a) Coat a new O-ring with power steering fluid and install it to the suction port union. (b) Install the suction port union with the bolt to the vane pump housing front. Torque: 13 N⋅m (133 kgf⋅cm, 10 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3299 51-24 POWER STEERING 38. (a) (b) SST - VANE PUMP ASSY (3MZ-FE) INSTALL VANE PUMP PULLEY Install the vane pump pulley to the vane pump shaft. Using SST, keep the vane pump pulley from rotating and install the nut. SST 09960-10010 (09962-01000, 09963-01000) Torque: 44 N⋅m (449 kgf⋅cm, 32 ft⋅lbf) F41600 39. (a) INSTALL VANE PUMP ASSY Temporarily install the vane pump assy with the 2 bolts. 40. (a) A (b) B (c) INSTALL VANE PUMP V BELT Install the vane pump V belt and adjust the V belt tension (see page 14-121 ). Torque the bolt A. Torque: 43 N⋅m (440 kgf⋅cm, 32 ft⋅lbf) Torque the bolt B. Torque: 43 N⋅m (440 kgf⋅cm, 32 ft⋅lbf) G25718 Pressure Feed Tube Assy Stopper W03441 F41567 41. (a) CONNECT PRESSURE FEED TUBE ASSY Using a wrench (24 mm) to keep the pressure port union, connect the pressure feed tube assy with the union bolt and a new gasket. Torque: 52 N⋅m (525 kgf⋅cm, 38 ft⋅lbf) NOTICE: Make sure that the stopper of the pressure feed tube assy touches the pump bracket front as shown in the illustration, then tighten the union bolt. 42. (a) INSTALL POWER STEERING OIL PRESSURE SWITCH Install the oil pressure switch to the union bolt. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) NOTICE: Be careful to keep oil away from the connector. (b) Connect the connector. 43. CONNECT OIL RESERVOIR TO PUMP HOSE NO.1 (a) Connect the oil reservoir to pump hose No.1. (b) Install the clip. 44. INSTALL FRONT FENDER APRON SEAL RH 45. INSTALL FRONT WHEEL RH Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) 46. BLEED POWER STEERING FLUID (SEE PAGE 51-3 ) 47. INSPECT FLUID LEAK 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3300 51-25 POWER STEERING - POWER STEERING LINK ASSY POWER STEERING LINK ASSY 510DW-03 COMPONENTS Pressure Feed Tube Assy 9.8 (100, 87 in.⋅lbf) Return Tube Assy 25 (250, 18) *22 (230, 16) 25 (250, 18) *22 (230, 16) Steering Intermediate Shaft Sub-assy Return Tube Assy 49 (500, 36) 35 (360, 26) 9.8 (100, 87 in.⋅lbf) Tube Clamp 70 (714, 52)  Cotter Pin 74 (755, 55) Power Steering Link Assy Front Stabilizer Bar Front Stabilizer Link Assy RH 49 (500, 36)  Cotter Pin 16 (163, 12) 16 (163, 12) Front Stabilizer Link Assy LH Front Stabilizer Bracket No.1 RH Front Stabilizer Bracket No.1 LH Front Stabilizer Bar Bush No.1 Front Stabilizer Bar Bush No.1 Front Stabilizer Bracket No.2 N⋅m (kgf⋅cm, ft⋅lbf) 74 (755, 55) : Specified torque  Non-reusable part * For use with SST G30786 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3301 51-26 POWER STEERING Steering Right Turn Pressure Tube - POWER STEERING LINK ASSY Tube Clamp 21 (214, 15) 13 (127, 9) *11 (116, 8)  O-Ring  O-Ring Dust Cover  O-Ring  O-Ring Control Valve Housing  Power Steering Control Valve Upper Oil Seal Steering Left Turn Pressure Tube  Control Valve Upper Bearing 13 (127, 9) *11 (116, 8)  Control Valve Spacer Power Steering Control Valve  Oil Seal Rack Housing  Gasket Compression Spring
Rack Guide Spring Cap Lock Nut 69 (699, 51) *51 (515, 38)
Rack Guide Spring Cap Rack Guide  25 (250, 18)
Rack Housing Cap 59 (597, 43) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque  Non-reusable part
Precoated part MP grease Molybdenum disulfide lithium base grease Power steering fluid * For use with SST D30948 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3302 51-27 POWER STEERING - POWER STEERING LINK ASSY  Steering Rack Boot No.2 Clamp Steering Rack Boot No.2 Lock Nut ÇÇ ÇÇ 74 (750, 54) Steering Rack Boot Clip Tie Rod Assy LH Rack Housing Steering Rack End Sub-assy 84 (851, 62) *60 (616, 45)  Claw Washer Power Steering Rack  O-Ring  Power Piston Oil Seal  Power Steering Cylinder Tube Oil Seal  Claw Washer Cylinder End Stopper Steering Rack End Sub-assy 84 (851, 62) *60 (616, 45)  Wire Tie Rod Assy RH Lock Nut 74 (750, 54) Steering Rack Boot No.1 ÇÇ ÇÇ  Rack Bush Oil Seal  O-Ring Power Steering Rack Bush Steering Rack Boot Clip N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque  Non-reusable part Silicon grease Molybdenum disulfide lithium base grease Power steering fluid * For use with SST Å  Steering Rack Boot No.1 Clamp D30805 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3303 51-28 POWER STEERING - POWER STEERING LINK ASSY 510DX-05 OVERHAUL NOTICE: When installing ,coat the parts indicated by arrows with power steering fluid or molybdenum disulfide lithium base grease (see page 51-25 ). 1. INSPECT CENTER FRONT WHEEL 2. REMOVE FRONT WHEEL 3. SEPARATE TIE ROD ASSY LH (SEE PAGE 30-21 ) SST 09628-6201 1 4. SEPARATE TIE ROD ASSY RH SST 09628-6201 1 HINT: Perform the same procedure as for the LH. 5. (a) SEPARATE STEERING INTERMEDIATE SHAFT SUB-ASSY Fix the steering wheel with the seat belt in order to prevent rotation. HINT: This operation is useful to prevent damage to the spiral cable. F47048 (b) B (c) (d) A Loosen bolt A and remove the clamp from the steering column hole cover No.1. Separate the steering column hole cover No.2 from the steering column hole cover No.1. Loosen bolt B. F46489 (e) Matchmarks (f) Put matchmarks on the steering intermediate shaft subassy and the steering link assy. Remove the bolt and disengage the steering intermediate shaft sub-assy. F40352 6. SEPARATE FRONT STABILIZER LINK ASSY LH (SEE PAGE 30-21 ) 7. SEPARATE FRONT STABILIZER LINK ASSY RH HINT: Perform the same procedure as for the LH. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3304 51-29 POWER STEERING 8. (a) (b) - POWER STEERING LINK ASSY REMOVE FRONT STABILIZER BRACKET NO.1 LH Remove the 2 bolts, the stabilizer bracket No.1 LH and the stabilizer bracket No.2. Remove the stabilizer bar bush No.1 from the stabilizer bar. D30771 9. REMOVE FRONT STABILIZER BRACKET NO.1 RH HINT: Perform the same procedure as for the LH. 10. (a) (b) DISCONNECT RETURN TUBE ASSY Remove the tube clamp from the pressure feed tube assy. Using SST, disconnect the return tube assy from the steering link assy. SST 09023-12701 (c) Remove the nut and the return tube clamp. 11. (a) DISCONNECT PRESSURE FEED TUBE ASSY Using SST, disconnect the pressure feed tube assy from the steering link assy. SST 09023-12701 SST D30607 F40331 SST D30608 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3305 51-30 POWER STEERING - POWER STEERING LINK ASSY (b) Remove the bolt and the pressure feed tube clamp. 12. (a) REMOVE POWER STEERING LINK ASSY Remove the 2 bolts, the nuts and the steering link assy. 13. (a) (b) REMOVE STEERING LEFT TURN PRESSURE TUBE Remove the tube clamp from the turn pressure tubes. Using SST, disconnect the left turn pressure tube. SST 09023-38201 Remove the 2 O-rings from the left turn pressure tube. F40334 LH: RH: D29979 SST (c) O-ring F40532 14. REMOVE STEERING RIGHT TURN PRESSURE TUBE SST 09023-38201 HINT: Perform the same procedure as for the left turn pressure tube. 15. (a) SST FIX POWER STEERING LINK ASSY Using SST, secure the steering link assy. SST 09612-00012 HINT: Wrap the SST with tape before use, in order to prevent damaging the steering link assy. F40533 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3306 51-31 POWER STEERING 16. (a) (b) - POWER STEERING LINK ASSY REMOVE TIE ROD ASSY LH Put matchmarks on the tie rod assy LH and the rack end. Loosen the lock nut and remove the tie rod assy LH and the lock nut. Matchmarks F40050 17. REMOVE TIE ROD ASSY RH HINT: Perform the same procedure as for the LH. 18. REMOVE STEERING RACK BOOT CLIP (a) Remove the 2 boot clips. 19. REMOVE STEERING RACK BOOT NO.2 CLAMP (a) Using pliers, remove the rack boot No.2 clamp. NOTICE: Be careful not to damage the boot. 20. REMOVE STEERING RACK BOOT NO.1 CLAMP HINT: Perform the same procedure as for the No.2 clamp. NOTICE: Be careful not to damage the boot. 21. REMOVE STEERING RACK BOOT NO.2 22. REMOVE STEERING RACK BOOT NO.1 23. (a) REMOVE STEERING RACK END SUB-ASSY Using a screwdriver and a hammer, unstake the claw washer. NOTICE: Avoid any impact to the steering rack. Claw Washer C83166 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3307 51-32 POWER STEERING - POWER STEERING LINK ASSY (b) Using 2 SST, remove the rack end RH and the claw washer. SST 09922-10010 NOTICE: Use SST 09922-10010, following the direction shown in the illustration. (c) Using 2 SST, hold the steering rack and remove the rack end LH and the claw washer. SST 09922-10010 NOTICE: Use SST 09922-10010, following the direction shown in the illustration. RH: SST LH: SST F40558 24. (a) REMOVE RACK GUIDE Using SST, remove the spring cap lock nut. SST 09922-10010 NOTICE: Use SST 09922-10010, following the direction shown in the illustration. SST F40534 Rack Guide Spring Cap (b) (c) Using SST, remove the rack guide spring cap. SST 09631-10021 Remove the compression spring and the rack guide. SST F40535 25. (a) Socket Wrench (27 mm) REMOVE POWER STEERING CONTROL VALVE Using a socket wrench (27 mm), remove the rack housing cap. F40536 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3308 51-33 POWER STEERING SST POWER STEERING LINK ASSY (b) Using SST, keep the control valve shaft and remove the nut. SST 09616-0001 1 (c) Wrap vinyl tape around the spline of the control valve in order to prevent damaging the oil seal. Remove the dust cover from the control valve housing. Keep Turn - F40537 Vinyl Tape (d) F40538 (e) (f) Remove the 2 bolts and the control valve housing with the control valve. Remove the gasket. (g) (h) Using a plastic hammer, remove the control valve. Remove the oil seal from the control valve. F40539 Vinyl Tape F40540 F45959 (i) Using a screwdriver, remove the 4 control valve spacers. NOTICE: Be careful not to damage the spacer grooves. Control Valve Spacer R11572 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3309 51-34 POWER STEERING 26. SST (a) - POWER STEERING LINK ASSY REMOVE POWER STEERING CONTROL VALVE UPPER OIL SEAL Using SST and a press, remove the control valve upper bearing and the upper oil seal from the control valve housing. SST 09950- 70010 (09951- 07150), 09950- 60010 (09951-00250) F40911 27. (a) (b) REMOVE CYLINDER END STOPPER Using a screwdriver and a hammer, turn the cylinder end stopper clockwise until the wire end is visible through the service hole. Using a screwdriver and a hammer, turn the cylinder end stopper counterclockwise, and remove the wire and the cylinder end stopper. Cylinder End Stopper Wire C83179 28. REMOVE POWER STEERING RACK 29. (a) SST F40542 REMOVE POWER STEERING RACK BUSH Remove the rack bush with the rack bush oil seal from the power steering rack. (b) Using SST, remove the rack bush oil seal from the rack bush. SST 09527-2101 1, 09612-24014 (09613-22011) NOTICE: Be careful not to drop the rack bush. (c) Using a screwdriver, remove the O-ring from the rack bush. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3310 51-35 POWER STEERING - POWER STEERING LINK ASSY 30. (a) Dial Gauge ZX9355 INSPECT POWER STEERING RACK Using a dial gauge, check for runout of the steering rack and teeth wear. Maximum runout: 0.3 mm (0.0118 in.) NOTICE: Make sure that the steering rack is placed holizontally. (b) Check the rack surface for wear and damage. If runout exceeds maximum, replace the power steering link assy. 31. REMOVE POWER STEERING CYLINDER TUBE OIL SEAL (a) Using SST and a press, remove the cylinder tube oil seal. SST 09950- 70010 (09951- 07360), 09950- 60010 (09951-00290) NOTICE: Be careful not to damage the inside surface of the rack housing. SST F40544 32. REMOVE POWER PISTON OIL SEAL (a) Using a screwdriver, remove the oil seal and the O-ring. NOTICE: Be careful not to damage the oil seal groove. R10955 33. (a) INSTALL POWER PISTON OIL SEAL Coat a new O-ring with power steering fluid and install it to the steering rack. (b) Expand the new oil seal with your fingers. NOTICE: Be careful not to overly expand the oil seal. (c) Coat the oil seal with power steering fluid. C03629 (d) Install the oil seal to the steering rack, and adjust with your fingers. N00401 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3311 51-36 POWER STEERING POWER STEERING LINK ASSY 34. SST Oil Seal - SST F40545 INSTALL POWER STEERING CYLINDER TUBE OIL SEAL (a) Coat a new oil seal lip with power steering fluid. (b) Using SST and a press, install the oil seal. SST 09950- 60010 (09951- 00450, 09951- 00250, 09952-06010), 09950-70010 (09951-07360) NOTICE: Make sure that the oil seal is installed in the correct direction. 35. (a) (b) (c) (d) ZK8184 INSPECT TIE ROD ASSY LH Secure the tie rod assy LH in a vise. Install the nut to the stud bolt. Flip the ball joint stud back and forth 5 times. Using a torx wrench, turn the nut continuously at a rate of 2 to 4 seconds per turn and take the torque reading on the 5th turn. Turning torque: 0.49 to 3.43 N⋅m (5.0 to 35.0 kgf⋅cm, 4.3 to 30.4 in.⋅lbf) If not within the specified torque, replace the tie rod assy LH. 36. INSPECT TIE ROD ASSY RH HINT: Perform the same procedure as for the LH. 37. (a) (b) Rack Teeth End INSTALL POWER STEERING RACK Apply grease to the rack teeth ends. Affix SST to the steering rack. SST 09631-33010 HINT: If necessary, scrape the burrs off the rack teeth ends and burnish. (c) Coat SST with power steering fluid. (d) Install the steering rack to the rack housing. (e) Remove SST. SST W02101 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3312 51-37 POWER STEERING - POWER STEERING LINK ASSY 38. (a) (b) SST Oil Seal F40543 INSTALL POWER STEERING RACK BUSH Coat a new rack bush oil seal lip with power steering fluid. Using SST and a press, install the rack bush oil seal to the rack bush. SST 09950- 60010 (09951- 00400), 09950- 70010 (09951-07100) NOTICE: Make sure that the oil seal is installed in the correct direction. (c) Coat a new O-ring with power steering fluid and install it to the rack bush. (d) Coat the rack bush oil seal lip with power steering fluid. (e) Install the rack bush to the rack housing. HINT: Wrap vinyl tape around the end of the steering rack in order to prevent damaging the rack bush oil seal. Vinyl Tape Bush F05730 39. (a) Wire (b) (c) INSTALL CYLINDER END STOPPER Align the installation hole for the wire of the cylinder end stopper with the slot of the rack housing. Install a new wire into the cylinder end stopper. Using a screwdriver, turn the cylinder end stopper counterclockwise by 450
50. Cylinder End Stopper F40546 40. (a) AIR TIGHTNESS TEST Install SST to the rack housing. SST 09631-12071 (09633-00010) (b) Apply a vacuum of 53 kPa (398 mmHg, 15.65 in.Hg) for about 30 seconds. (c) Check that there is no change in the vacuum pressure. If there is a change in the vacuum pressure, check the installation of the oil seals. SST F40547 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3313 51-38 POWER STEERING - POWER STEERING LINK ASSY 41. SST Oil Seal SST F40912 INSTALL POWER STEERING CONTROL VALVE UPPER OIL SEAL (a) Coat the control valve upper bearing with grease, and a new control valve upper oil seal lip with power steering fluid. (b) Using SST and a press, install a new control valve upper oil seal. SST 09950- 70010 (09951- 07150), 09950- 60010 (09951-00180, 09952-06010, 09951-00320) NOTICE: Make sure that the oil seal is installed in the correct direction. (c) SST SST Using SST and a press, install the control valve upper bearing. SST 09950- 70010 (09951- 07150), 09950- 60010 (09951-00180, 09952-06010, 09951-00340) F40913 42. INSTALL POWER STEERING CONTROL VALVE (a) Expand 4 new valve spacers with your fingers. NOTICE: Be careful not to overly expand the valve spacers. (b) Coat the 4 valve spacers with power steering fluid. (c) Install the 4 valve spacers to the control valve, and adjust with your fingers. C03629 (d) Carefully slide the tapered end of SST over the valve spacers until they fit to the control valve. SST 09631-20081 NOTICE: Be careful not to damage the valve spacers. SST Control Valve Spacer R11573 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3314 51-39 POWER STEERING - POWER STEERING LINK ASSY (e) Coat the oil seal lip with power steering fluid. (f) Install the control valve into the valve housing. NOTICE: Be careful not to damage the valve spacer and oil seal lip. HINT: Wrap vinyl tape around the end of the steering rack in order to prevent damaging the oil seal. Vinyl Tape F40548 (g) (h) SST F40549 Oil Seal F45958 Coat a new oil seal lip with power steering fluid. Using SST and a press, install the oil seal. SST 09612-2201 1 NOTICE: Make sure that the oil seal is installed in the correct direction. (i) Apply grease to the needle roller bearing of the rack housing and the serrated part of the control valve. (j) Install a new gasket to the valve housing. (k) Install the control valve housing with the control valve to the rack housing with the 2 bolts. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) HINT: Wrap vinyl tape around the lower spline of the control valve in order to prevent damaging the oil seal. F40539 Keep SST (l) (m) Turn Using SST, keep the control valve from rotating and install a new lock nut. SST 09616-0001 1 Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) Apply sealant to 2 or 3 threads of the rack housing cap. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent F40550 (n) Socket Wrench (27 mm) Using a socket wrench (27 mm), install the rack housing cap. Torque: 59 N⋅m (597 kgf⋅cm, 43 ft⋅lbf) F40536 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3315 51-40 POWER STEERING (o) - POWER STEERING LINK ASSY Using a punch and a hammer, stake the rack housing cap and the rack housing. F41608 43. (a) (b) (c) (d) INSTALL RACK GUIDE Apply grease to the compression spring and the contact surface of the rack guide. Install the rack guide and the compression spring. Apply sealant to 2 or 3 threads of the rack guide spring cap. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Temporarily install the rack guide spring cap. 44. (a) (b) ADJUST TOTAL PRELOAD Temporarily install the RH and LH rack ends sub-assy, in order to prevent the oil seal from being damaged by the rack teeth. Using SST, torque the rack guide spring cap. SST 09631-10021 Torque: 25 N⋅m (250 kgf⋅cm, 18 ft⋅lbf) SST F40724 (c) Using SST, loosen the rack guide spring cap. SST 09631-10021 (d) Using SST, turn the control valve to right and left 1 or 2 times. SST 09616-0001 1 Using SST, loosen the rack guide spring cap until the compression spring stops functioning. SST 09631-10021 SST F40725 SST (e) F40726 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3316 51-41 POWER STEERING (f) SST SST (g) F40553 (h) - POWER STEERING LINK ASSY Using SST and a torque wrench, tighten the rack guide spring cap until the preload falls within specifications. SST 09616-0001 1, 09631-10021 Preload (turning): 1.2 to 1.5 N⋅m (12.2 to 15.3 kgf⋅cm, 10.6 to 13.3 in.⋅lbf) Apply sealant to 2 or 3 threads of the rack guide spring cap lock nut. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Temporarily install the rack guide spring cap lock nut. (i) Rack Guide Spring Cap Nut SST Fulcrum Length SST F40554 Using SST, hold the rack guide spring cap and using another SST, torque the spring cap lock nut. SST 09616-0001 1, 09922-10010 Torque: 51 N⋅m (515 kgf⋅cm, 38 ft⋅lbf) NOTICE: Use SST 09922-10010, following the direction shown in the illustration. HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). (j) Precheck the total preload. Preload (turning): 1.2 to 1.5 N⋅m (12.2 to 15.3 kgf⋅cm, 10.6 to 13.3 in.⋅lbf) (k) Remove the RH and LH rack ends sub-assy. (l) Apply MP grease around the control valve shaft, as shown in the illustration. (m) (n) Wrap vinyl tape around the spline of the control valve. Install the dust cover to the control valve housing. MP Grease F40555 Vinyl Tape F40538 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3317 51-42 POWER STEERING 45. (a) RH: SST - POWER STEERING LINK ASSY INSTALL STEERING RACK END SUB-ASSY Install 2 new claw washers, and temporarily install the 2 rack ends sub-assy. HINT: Align the claws of the claw washer with the steering rack grooves. (b) Using SST, install the 2 rack end sub-assy. SST 09922-10010 Torque: 60 N⋅m (616 kgf⋅cm, 45 ft⋅lbf) NOTICE: Use SST 09922-10010, following the direction shown in the illustration. HINT:
Using SST, hold the rack and install the rack end subassy.
Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). Fulcrum Length LH: SST Fulcrum Length F47052 (c) Using a brass bar and a hammer, stake the 2 claw washers. NOTICE: Avoid any impact to the steering rack. C35928 46. (a) INSPECT STEERING RACK END SUB-ASSY Ensure that the holes of the rack ends are not clogged with grease. HINT: If the hole is clogged, the pressure inside the boot will change after it is assembled and steering wheel is turned. ZX9390 47. 48. F41951 INSTALL STEERING RACK BOOT NO.2 INSTALL STEERING RACK BOOT NO.1 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3318 51-43 POWER STEERING - POWER STEERING LINK ASSY 49. (a) INSTALL STEERING RACK BOOT NO.2 CLAMP Using SST, tighten the rack boot No.2 clamp, as shown in the illustration. SST 09521-24010 Clearance: 3.0 mm (0.118 in.) or less NOTICE: Be careful not to damage the boot. SST F40556 50. INSTALL STEERING RACK BOOT NO.1 CLAMP SST 09521-24010 HINT: Perform the same procedure as for the No.2 clamp. 51. INSTALL STEERING RACK BOOT CLIP (a) Using pliers, install the 2 boot clips. 52. (a) INSTALL TIE ROD ASSY LH Screw the lock nut and tie rod assy LH on the rack end until the matchmarks are aligned. Torque: 74 N⋅m (750 kgf⋅cm, 54 ft⋅lbf) HINT: After adjusting toe-in, torque the lock nut (see page 26-7 ). Matchmarks F40050 53. INSTALL TIE ROD ASSY RH HINT: Perform the same procedure as for the LH. 54. (a) Fulcrum Length (b) O-ring INSTALL STEERING LEFT TURN PRESSURE TUBE Coat 2 new O-rings with power steering fluid and install them to the left turn pressure tube. Using SST, install the left turn pressure tube to the steering link assy. SST 09023-38201 Torque: 11 N⋅m (116 kgf⋅cm, 8 ft⋅lbf) HINT: SST F40557

Use a torque wrench with a fulcrum length of 300 mm (9.84 in.). This torque value is effective when SST is parallel to a torque wrench. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3319 51-44 POWER STEERING 55. (a) (b) - POWER STEERING LINK ASSY INSTALL STEERING RIGHT TURN PRESSURE TUBE Perform the same procedure as for the left turn pressure tube. SST 09023-38201 Install the tube clamp to the turn pressure tubes. LH: RH: 56. (a) INSTALL POWER STEERING LINK ASSY Install the power steering link assy with the 2 bolts and the nuts. Torque: 70 N⋅m (714 kgf⋅cm, 52 ft⋅lbf) 57. (a) CONNECT PRESSURE FEED TUBE ASSY Using SST, connect the pressure feed tube assy to the steering link assy. SST 09023-12701 Torque: 22 N⋅m (230 kgf⋅cm, 16 ft⋅lbf) D29979 HINT:
Fulcrum Length SST D30610
(b) Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). This torque value is effective when SST is parallel to a torque wrench. Install the pressure feed tube assy clamp with the bolt. Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf) F40334 58. (a) CONNECT RETURN TUBE ASSY Using SST, connect the return tube assy to the steering link assy. SST 09023-12701 Torque: 22 N⋅m (230 kgf⋅cm, 16 ft⋅lbf) HINT:
Fulcrum Length SST D30609
(b) Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). This torque value is effective when SST is parallel to a torque wrench. Install the tube clamp to the pressure feed tube assy. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3320 51-45 POWER STEERING - POWER STEERING LINK ASSY (c) Install the return tube clamp with the nut. Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf) 59. (a) (b) INSTALL FRONT STABILIZER BRACKET NO.1 LH Install the stabilizer bar bush No.1 to the stabilizer bar. Install the stabilizer bracket No.1 LH and the stabilizer bracket No.2 with the 2 bolts. Torque: 16 N⋅m (163 kgf⋅cm, 12 ft⋅lbf) F40331 D30771 60. INSTALL FRONT STABILIZER BRACKET NO.1 RH HINT: Perform the same procedure as for the LH. 61. CONNECT FRONT STABILIZER LINK ASSY LH (SEE PAGE 30-21 ) 62. CONNECT FRONT STABILIZER LINK ASSY RH HINT: Perform the same procedure as for the LH. 63. Matchmarks (a) (b) CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSY Align the matchmarks on the intermediate shaft sub-assy and the steering link assy. Install the bolt. Torque: 35 N⋅m (360 kgf⋅cm, 26 ft⋅lbf) F40352 (c) B (d) (e) A Tighten bolt A. Torque: 35 N⋅m (360 kgf⋅cm, 26 ft⋅lbf) Install the steering column hole cover No.2 to the steering hole cover No.1. Install the clamp to the steering column hole cover No.1 and tighten bolt B. F46489 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3321 51-46 POWER STEERING - POWER STEERING LINK ASSY 64. CONNECT TIE ROD ASSY LH (SEE PAGE 30-21 ) 65. CONNECT TIE ROD ASSY RH HINT: Perform the same procedure as for the LH. 66. INSTALL FRONT WHEEL Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) 67. BLEED POWER STEERING FLUID (SEE PAGE 51-3 ) 68. CHECK POWER STEERING FLUID LEAKAGE 69. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (SEE PAGE 26-7 ) 70. PERFORM STEERING ANGLE SENSOR ZERO POINT CALIBRATION (SEE PAGE 05-765 ) 71. INSPECT STEERING WHEEL CENTER POINT 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3322 55-1 1 HEATER & AIR CONDITIONER - REFRIGERANT REFRIGERANT 5502F-03 ON-VEHICLE INSPECTION 1. (a) INSPECT REFRIGERANT VOLUME Check the sight glass on the cooler refrigerant liquid pipe A. Test conditions:
Engine is running at 1,500 rpm
Blower speed control switch is at ”HI”
A/C switch is ON
Temperature control dial is at ”MAX. COOL”
Doors are fully open Sight Glass I30576 Item Symptom Amount of refrigerant Corrective Actions 1 Bubbles exist Insufficient* (1) Check for gas leakage and repair if necessary (2) Add refrigerant until bubbles disappear 2 No bubbles exist Empty, insufficient or excessive Refer to 3 and 4 3 No temperature difference between compressor inlet and outlet Empty or nearly empty (1) Check for gas leakage with gas leak detector and repair if necessary (2) Add refrigerant until bubbles disappear 4 Considerable temperature difference between compressor inlet and outlet Proper or excessive Refer to 5 and 6 5 Immediately after air conditioning is turned off, refrigerant clears Excessive (1) Discharge refrigerant (2) Remove air and supply proper amount of purified refrigerant 6 Immediately after air conditioning is turned off, refrigerant foams and then becomes clear Proper - *: Bubbles in the sight glass with ambient temperatures higher than usual can be considered normal if cooling is sufficient. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3333 55-12 HEATER & AIR CONDITIONER 2. (a) - REFRIGERANT INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET This is a method in which the trouble is located by using a manifold gauge set. Read the manifold gauge pressure when these conditions are established. Test conditions:
Temperature at the air inlet with the switch set at RECIRC is 30 to 35°C (86 to 95°F)
Engine is running at 1,500 rpm
Blower speed control switch is at ”HI”
Temperature control dial is at ”COOL”
A/C switch is ON
Doors are fully open (1) Normally functioning refrigeration system Gauge reading: Low pressure side: 0.15 to 0.25 MPa (1.5 to 2.5 kgf/cm2) High pressure side: 1.37 to 1.57 MPa (14 to 16 kgf/cm2) E50573 (2) Moisture is present in refrigeration system Condition : Periodically cools and then fails to cool. I22117 Symptom Probable cause During operation, pressure on low pressure side cycles between normal and vacuum Moisture in refrigeration system freezes at expansion valve orifice, causing a temporary stop of cycle. However, when it melts, normal state is restored. Diagnosis
Drier in oversaturated state
Moisture in refrigeration system freezes at expansion valve orifice and blocks circulation of refrigerant Corrective Actions (1) Replace condenser (2) Remove moisture in cycle by repeatedly evacuating air (3) Supply proper amount of new refrigerant 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3334 55-13 HEATER & AIR CONDITIONER - (3) REFRIGERANT Insufficient cooling Condition: Cooling system does not function effectively. I22118 Symptom
Pressure is low on both low and high pressure sides
Bubbles are seen through sight glass continuously
Insufficient cooling performance Probable cause Diagnosis Gas leakage in refrigeration system (4)
Insufficient refrigerant
Refrigerant leaking Corrective Actions (1) Check for gas leakage and repair if necessary (2) Supply proper amount of new refrigerant (3) If the indicated pressure value is close to 0 when connected to the gauge, create a vacuum after inspecting and repairing the location of leakage. Poor circulation of refrigerant Condition: Cooling system does not function effectively. I22119 Symptom
Pressure is low on both low and high pressure sides
Frost exists on pipe from condenser to unit Probable cause Refrigerant flow is obstructed by dirt in the receiver Diagnosis Receiver is clogged Corrective Action Replace condenser 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3335 55-14 HEATER & AIR CONDITIONER (5) - REFRIGERANT Refrigerant does not circulate Condition: Cooling system does not function (sometimes it may function). I22120 Symptom
Vacuum is indicated on low pressure side and very low pressure is indicated on high pressure side
Frost or dew is seen on piping on both sides of receiver/drier or expansion valve Probable cause Diagnosis
Refrigerant flow is obstructed by moisture or dirt in refrigeration system Refrigerant does not circulate
Refrigerant flow is obstructed by a gas leak from expansion valve (6) Corrective Actions (1) Check the expansion valve (2) Clean out dirt in expansion valve by blowing air (3) Replace condenser (4) Evaporate air and supply proper amount of new refrigerant (5) For gas leakage from expansion valve, replace expansion valve Refrigerant is overcharged or cooling effectiveness of condenser is insufficient Condition: Cooling system does not function. I22121 Symptom Probable cause Diagnosis Corrective Actions
Pressure is too high on both low and high pressure sides
No air bubbles are seen through sight glass even when engine rpm lowers
Unable to develop sufficient performance due to excessive use of refrigeration system
Cooling effectiveness of condenser is insufficient
Excessive refrigerant in cycle → excessive refrigerant is supplied
Condenser cooling effectiveness is insufficient → condenser fins are clogged at cooling fan (1) Clean condenser (2) Check cooling fan with cooling fan motor operation (3) If (1) and (2) are normal check the amount of refrigerant and supply proper amount of refrigerant 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3336 55-15 HEATER & AIR CONDITIONER - (7) REFRIGERANT Air present in refrigeration system Condition: Cooling system does not function. NOTE: These gauge indications occur when the refrigeration system opens and the refrigerant is charged without vacuum purging. Symptom
Pressure is too high on both low and high pressure sides
The low pressure piping is too hot to touch
Bubbles can be seen through sight glass Probable cause Diagnosis
Air present in refrigeration system
Insufficient vacuum purging Air in system (8) I22122 Corrective Actions (1) Check compressor oil to see if it is dirty or insufficient (2) Evacuate air and supply new refrigerant Expansion valve malfunction Condition: Insufficient cooling I22123 Symptom
Pressure is too high on both low and high pressure sides
Frost or large amount of dew on piping on low pressure side Probable cause Trouble in expansion valve Diagnosis
Excessive refrigerant in low pressure piping
Expansion valve opened too wide Corrective Actions Check expansion valve 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3337 55-16 HEATER & AIR CONDITIONER - REFRIGERANT (9) Defective compressor Condition : Insufficient cooling I22124 Symptom Probable cause
Pressure is too high both on low and high pressure sides
Pressure is too low on high pressure side Diagnosis Corrective Actions
Compression failure
Leakage from damaged valve or broken sliding parts Internal leak in compressor Repair or replace compressor Gauge readings (Reference) Pressure on low pressure side MPa (kgf/cm2) 0.5 (5.0) Blower HI Zone 0.4 (4.0) 1.06 (10.8) 0.3 (3.0) 0.27 (2.75) 0.2 (2.0) 1.2 (12.2) 0.22 (2.24) 0.2 (2.03) Blower LO Zone 1.25 (12.7) 0.14 (1.42) 0.5 (5.0) 1.32 (13.4) 1.0 (10.0) 1.5 (15.0) Pressure on high pressure side 2.0 (20.0) MPa (kgf/cm2) I30081 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3338 55-17 HEATER & AIR CONDITIONER - REFRIGERANT 5519P-01 REPLACEMENT 1. (a) (b) DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM Turn the A/C switch on. Operate the cooler compressor at an engine rpm of approximately 1,000 for 5 to 6 minutes to circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible. (c) Stop the engine. (d) Using SST, let the refrigerant gas out. SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080) 2. CHARGE REFRIGERANT (a) Using a vacuum pump, perform vacuum purging. (b) Using SST charge refrigerant, HFC-134a (R134a). Standard: 650
50 g (22.93
1.76 oz.) SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080) NOTICE: Do not start the engine before charging with refrigerant as the cooler compressor doesn’t work properly without any refrigerant, which causes the compressor to overheat. Amount to be charged Add. 100g Mean value in proper range
50 g (
1.76 oz.) High Pressure Overcharged Point where bubbles disappear Refrigerant Amount Sub-cool system I37365 3. WARM UP ENGINE NOTICE: Warm up the engine at less than 2000 rpm for 2 minutes or more after charging with refrigerant. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3339 55-18 HEATER & AIR CONDITIONER - REFRIGERANT 4. (a) INSPECT LEAKAGE OF REFRIGERANT Perform in these conditions:
Stop the engine.
Secure good ventilation (the gas leak detector may not react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas).
Repeat the test 2 or 3 times.
Make sure that there is some refrigerant remaining in the refrigeration system. When compressor is off: approx. 392 to 588 kPa (4 to 6 kgf/cm2, 57 to 85 psi) (b) Bring the gas leak detector close to the drain hose before performing the test. Drain Hose HINT:
Gas Leak Detector N14519 After the blower motor has stopped, leave the cooling unit for more than 15 minutes.
Expose the gas leak detector sensor under the drain hose.
When bringing the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to the volatile gases. If such reaction is unavoidable, the vehicle must be lifted up. (c) If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test. (d) Disconnect the connector and leave the pressure switch for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test. (e) Bring the gas leak detector close to the refrigerant lines and perform the test. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3340 55-24 HEATER & AIR CONDITIONER - V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 5519R-01 ADJUSTMENT 1. Bolt C Bolt A (a) (b) (c) Bolt B Measuring Position I38885 Boroughs TO HINT:
DENSO ADJUST V (COOLER COMPRESSOR CRANKSHAFT PULLEY) BELT NO.1 Loosen bolt A. Loosen bolt B. Apply drive belt tension by turning bolt C. Drive belt tension: New belt: 160 to 180 lbf Used belt: 115 to 135 lbf
”New V belt” refers to a belt which has been used for less than 5 minutes on a running engine. ”Used V belt” refers to a belt which has been used for 5 minutes or more on a running engine. N01881 (d) Bolt A (e) Tighten bolt A. Torque: 58 N⋅m (591 kgf⋅cm, 43 ft⋅lbf) Tighten bolt B. Torque: 18 N⋅m (183 kgf⋅cm, 13 ft⋅lbf) Bolt B I30370 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3346 HEATER & AIR CONDITIONER - 55-21 V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 5519Q-01 INSPECTION 1. (a) Measuring Position I38885 DENSO Boroughs N01881 Correct INSPECT V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 Belt tension: Using a belt tension gauge, check the V belt tension. V belt New belt N (kg, lb) Used belt N (kg, lb) 160 to 180 115 to 135 NOTICE:
Check the V belt deflection at the specified point.
When installing a new belt, set its tension value as specified.
When checking a belt used for over 5 minutes, confirm the deflection value is within the specified range.
When reinstalling a belt used for over 5 minutes, perform the check based on the used deflection value.
V belt tension and deflection values should be checked after 2 revolutions of engine cranking.
When using a belt tension gauge, confirm the accuracy first by using a master gauge.
Check that the drive belt fits properly in the ribbed grooves. Wrong CH0086 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3343 55-22 HEATER & AIR CONDITIONER - V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 5519S-01 REPLACEMENT Bolt C Bolt A 1. (a) (b) (c) REMOVE V (COOLER COMPRESSOR CRANKSHAFT PULLEY) BELT NO.1 Loosen bolt A. Loosen bolt B. Loosen bolt C and remove the V belt. TO INSTALL V (COOLER COMPRESSOR CRANKSHAFT PULLEY) BELT NO.1 Temporarily install the V belt as illustrated. TO Bolt B I30370 2. (a) Correct Wrong I30370 I36012 I39353 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3344 HEATER & AIR CONDITIONER V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 55-23 3. Bolt C Measuring Position I38885 Correct - ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (a) Apply drive belt tension by turning bolt C. Drive belt tension: New belt: 160 to 180 lbf Used belt: 115 to 135 lbf NOTICE:
”New V belt” refers to a belt which has been used for less than 5 minutes on a running engine.
”Used V belt” refers to a belt which has been used for 5 minutes or more on a running engine.
After installing the V belt, check that it fits properly in the ribbed grooves. Wrong I36012 4. Bolt A (a) (b) Bolt B FULLY TIGHTEN V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 Tighten bolt A. Torque: 58 N⋅m (591 kgf⋅cm, 43 ft⋅lbf) Tighten bolt B. Torque: 18 N⋅m (183 kgf⋅cm, 13 ft⋅lbf) I30370 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3345 55-25 HEATER & AIR CONDITIONER - INTEGRATION CONTROL & PANEL ASSY INTEGRATION CONTROL & PANEL ASSY 5519T-01 COMPONENTS Manual Air Conditioning: Heater Control Name Sheet No. 2 Air Conditioning Amplifier Assy Integration Control & Panel Bulb x5 Heater Control Housing Sub-assy Heater Control Housing Heater Blower Switch Heater Control Name Sheet No.1 Control Knob Sub-assy AUTO Air Conditioning: Heater Control Housing Sub-assy Control Knob Sub-assy Integration Control & Panel Bulb I40413 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3347 55-26 HEATER & AIR CONDITIONER - INTEGRATION CONTROL & PANEL ASSY 5519U-01 OVERHAUL HINT: COMPONENTS: see page 55-25 1. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY CENTER (SEE PAGE 71-10 ) 2. REMOVE INTEGRATION CONTROL & PANEL ASSY (SEE PAGE 71-10 ) 3. REMOVE RADIO RECEIVER ASSY (SEE PAGE 71-10 ) 4. REMOVE CONTROL KNOB SUB-ASSY 5. REMOVE HEATER CONTROL NAME SHEET NO.1 (MANUAL AIR CONDITIONING) 6. (a) REMOVE HEATER CONTROL NAME SHEET NO.2 Using a screwdriver protected by taping, remove the heater control name sheet No. 2. 7. (a) (b) REMOVE HEATER CONTROL HOUSING SUB-ASSY Release the lock of connector and disconnect the cable. Remove the 8 screws and heater control housing. 8. (a) REMOVE AIRCONDITIONER AMPLIFIER ASSY Remove the 3 screws and air conditioner amplifier assy from the heater control housing. E51992 E51993 E51994 9. REMOVE HEATER BLOWER SWITCH (MANUAL AIR CONDITIONING) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3348 55-27 HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY AIR CONDITIONING RADIATOR ASSY 5519V-01 COMPONENTS Instrument Panel Reinforcement 29 (300, 21) 29 (300, 21) 29 (300, 21) 29 (300, 21) 29 (300, 21) 29 (300, 21) Instrument Panel Brace Sub-assy No.1 29 (300, 21) 12 (122, 9) 29 (300, 21) 29 (300, 21) Floor Shift Assy 20 (200, 14) Heater to Register Duct Center Air Conditioning Radiator Assy 29 (300, 21) Instrument Panel Brace Sub-assy No.2 Air Duct No.1 Water Hose Air Duct No.2 Piping Clamp
O-ring Blower Assy 9.8 (100, 87 in.⋅lbf) Bracket N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque 9.8 (100, 87 in.⋅lbf) Compressor Oil ND-OIL 8 or equivalent
Non-reusable parts I39666 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3349 55-28 HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY Cooler Expansion Valve Cooler Evaporator Sub-assy No.1
O-ring
O-ring 5.4 (55, 48 in.⋅lbf) Wiring Air Conditioning Harness Sub-assy AUTO AIR CONDITIONER: Blower Resistor Blower Motor Control Clamp Cooler Thermistor No.1 Plate Heater Radiator Unit Sub-assy Wiring Air Conditioning Harness Sub-assy No.2 Air Mix Damper Servo Sub-assy Mode Damper Servo Sub-Assy Air Duct No.2 Air Duct No.1 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-resuable parts I30858 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3350 55-29 HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY 5519W-02 OVERHAUL HINT: COMPONENTS: see page 55-27 ,71-6 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (SEE PAGE 55-17 ) SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080) 2. (a) DISCONNECT COOLER REFRIGERANT SUCTION PIPE NO.1 Install SST on piping clamp. SST 09870-00015 HINT: Make sure the direction of the piping clamp claw and SST by seeing the illustration shown on the caution label. SST I03838 (b) Push down the SST and release the clamp lock. NOTICE: Be careful not to deform the tube when pushing SST. (c) Pull SST slightly and push the release lever, and then remove the piping clamp with SST. Pull Push SST Release Lever Disconnect the tube using hand I03839 (d) Disconnect the cooler refrigerant suction hose No.1. NOTICE:
Do not use tools like screwdriver to remove the tube.
Cap the open fittings immediately to keep moisture or dirt out of the system. (e) Remove the 2 O-rings from the cooler refrigerant suction hose No.1. Screw Driver I06919 3. DISCONNECT COOLER REFRIGERANT LIQUID PIPE A SST 09870-00025 HINT: Disconnect of the cooler refrigerant liquid pipe A is same as the cooler refrigerant suction pipe No.1. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3351 55-30 HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY 4. (a) DISCONNECT HEATER OUTLET WATER HOSE Using pliers, grip the claws of the clip and slide the clip, and then disconnect the heater outlet water hose. NOTICE:
Do not apply any excessive force to the heater outlet water hose.
Prepare a drain pan or cloth for when the cooling water leaks. I30392 5. (a) 6. DISCONNECT HEATER INLET WATER HOSE Disconnection of the heater inlet water hose is same as the heater outlet water hose. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY (SEE PAGE 71-10 ) SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021) HINT: Refer to the instructions for removal of the instrument panel safety pad sub-assy. 7. (a) SEPARATE STEERING COLUMN ASSY Remove the 2 bolts and 2 nuts, disconnect the steering column assy from the instrument panel reinforcement assy. 8. (a) SEPARATE FLOOR SHIFT ASSY Remove the 2 nuts and disconnect the shift cable. (b) Remove the 4 nuts and disconnect transmission floor shift assy. I30537 I30538 I30390 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3352 55-31 HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY 9. REMOVE AIR DUCT REAR NO.2 (a) Remove the side scuff plate. (b) Take up the floor carpet. HINT: Take up the floor carpet so that the air duct rear No.2 can be removed. (c) Remove the air duct rear No.2. I30378 10. REMOVE AIR DUCT REAR NO.1 HINT: Remove it in the same way with the air duct rear No.2. 11. (a) (b) REMOVE INSTRUMENT PANEL BRACE SUB-ASSY NO.1 Disconnect the connector clamp. Remove the 3 bolts, 2 nuts and instrument panel brace sub-assy No.1. I30377 12. (a) REMOVE INSTRUMENT PANEL BRACE SUB-ASSY NO.2 Remove the 2 bolts, 2 nuts and instrument panel brace sub-assy No.2. I30375 13. REMOVE AIRCONDITIONER AMPLIFIER ASSY (W/ LEXUS NAVIGATION SYSTEM) (SEE PAGE 55-68 ) 14. (a) (b) REMOVE ECM Disconnect the connector. Remove the 2 nuts, and ECU. I30545 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3353 55-32 HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY 15. (a) (b) REMOVE MULTIPLEX NETWORK BODY ECU Disconnect the connector. Remove the 2 nuts and multiplex network body ECU. 16. DISCONNECT INSTRUMENT PANEL JUNCTION BLOCK ASSY Remove the bolt and 2 nuts, disconnect the instrument panel junction block assy. I30544 (a) I30540 17. (a) (b) REMOVE SKID CONTROL ECU ASSY Disconnect the connector. Remove the 2 nuts and skid control ECU assy. 18. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSY Remove the 5 bolts, 4 nuts and instrument panel reinforcement assy. I30546 (a) I30539 19. (a) : Clamp REMOVE AIR CONDITIONER UNIT ASSY Disconnect the connector and clamp. I30386 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3354 55-33 HEATER & AIR CONDITIONER (b) (c) 20. (a) - AIR CONDITIONING RADIATOR ASSY Disconnect the connectors connecting the wiring air indicator harness sub-assy and vehicle harness. Remove the 2 bolts, 2 nuts and air conditioner unit assy. REMOVE AIR CONDITIONING RADIATOR ASSY Remove the screw, disconnect the connected part of the duct and take off the air duct No.2. I30383 :3 Claws : 3 Claws (b) (c) Remove the 4 screws and bracket. Disconnect the connection between the blower assy and the air conditioner radiator assy and remove the air conditioning radiator assy. 21. (a) REMOVE AIR DUCT NO.1 Release the 3 claw fittings, remove the air duct No.1. 22. (a) REMOVE HEATER TO REGISTER DUCT CENTER Release the 4 claw fittings, remove the heater to register duct center. 23. (a) REMOVE MODE DAMPER SERVO SUB-ASSY Remove the 3 screws and mode damper servo sub-assy. I30380 I30385 : 4 Claws I30381 I30389 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3355 55-34 HEATER & AIR CONDITIONER 24. (a) - AIR CONDITIONING RADIATOR ASSY REMOVE WIRING AIR CONDITIONING HARNESS SUB-ASSY Remove the wiring air conditioning harness sub-assy from the air conditioner radiator assy. I30388 25. (a) REMOVE AIRMIX DAMPER SERVO SUB-ASSY Remove the 3 screws and airmix damper servo sub-assy. 26. (a) (b) REMOVE HEATER RADIATOR UNIT SUB-ASSY Remove the screw and clamp. Remove the heater radiator unit sub-assy from the air conditioner radiator assy. I30387 I30391 27. REMOVE COOLER THERMISTOR NO.1 28. (a) REMOVE BLOWER MOTOR CONTROL (AUTO AIR CONDITIONING) Remove the 2 screws and blower motor control. I30382 29. (a) 30. (a) REMOVE BLOWER RESISTOR (MANUAL AIR CONDITIONING) Remove the 2 screws and blower resistor. REMOVE WIRING AIR INDICATOR HARNESS SUB-ASSY NO.2 Remove the wiring air indicator harness sub-assy No.2 from the blower motor control. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3356 55-35 HEATER & AIR CONDITIONER 31. (a) (b) - AIR CONDITIONING RADIATOR ASSY REMOVE COOLER EXPANSION VALVE Using a hexagon wrench 4 mm (0.16 in.), remove the 2 hexagon bolts and cooler expansion valve. Remove the 2 O-rings from the air conditioner tube assy. I30379 32. (a) (b) REMOVE COOLER EVAPORATOR SUB-ASSY NO.1 Remove the 11 screws and radiator case. Remove the cooler evaporator sub-assy No.1 from the air conditioner radiator assy. (c) Remove the 2 O-rings from the cooler evaporator subassy No.1. 33. (a) INSTALL COOLER EVAPORATOR SUB-ASSY NO.1 Sufficiently apply compressor oil to the 2 new O-rings and fitting surface of the coder evaporator sub-assy No.1. Compressor oil: ND-OIL 8 or equivalent Install the 2 O-rings on the coder evaporator sub-assy No.1. I30541 E69079 (b) E69079 (c) (d) Install the cooler evaporator No.1 to the air conditioner radiator assy. Install the evaporator cover with the 11 screws. I30541 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3357 55-36 HEATER & AIR CONDITIONER 34. (a) (b) (c) I30379 35. (a) (b) - AIR CONDITIONING RADIATOR ASSY INSTALL COOLER EXPANSION VALVE Sufficiently apply compressor oil to the 2 new O-rings and fitting surface of the air conditioning tube assy. Compressor oil: ND-OIL 8 or equivalent Install the 2 O-rings on the air conditioning tube assy. Using a hexagon wrench 4mm (0.15 in.), install the cooler expansion valve and 2 hexagon bolts to the cooler evaporator No.1. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) INSTALL AIR CONDITIONER UNIT ASSY Install the air conditioner unit assy with the 2 bolts and 2 nuts. Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf) Connect the connectors connecting the wiring air indicator No.2 harness and vehicle harness. I40415 : Clamp (c) Install the connector and clamp. 36. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSY Install the instrument panel reinforcement assy with the 5 bolts and 4 nuts. Torque: 29 N⋅m (300 kgf⋅cm, 21 ft⋅lbf) I30386 (a) I30539 37. (a) INSTALL SKID CONTROL ECU ASSY Install the skid control ECU assy with the 2 nuts. Torque: 5.0 N⋅m (50 kgf⋅cm, 43 in.⋅lbf) I30546 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3358 55-37 HEATER & AIR CONDITIONER 38. (a) - AIR CONDITIONING RADIATOR ASSY INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSY Install the instrument panel junction block assy with the bolt and 2 nuts. Torque: 8.4 N⋅m (86 kgf⋅cm, 74 in.⋅lbf) I30540 39. (a) INSTALL ECM Install the ECM with the 2 nuts. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) 40. INSTALL INSTRUMENT PANEL BRACE SUB-ASSY NO.2 Install the instrument panel brace sub-assy No.2 with the 2 bolts and 2 nuts. Torque: 29 N⋅m (300 kgf⋅cm, 21 ft⋅lbf) I30545 (a) I30375 41. (a) INSTALL INSTRUMENT PANEL BRACE SUB-ASSY NO.1 Install the instrument panel brace sub-assy No.1 with the 3 bolts and 2 nuts. Torque: 29 N⋅m (300 kgf⋅cm, 21 ft⋅lbf) I30377 42. (a) (2) (3) (1) INSTALL FLOOR SHIFT ASSY Install the floor shift assy with the 4 nuts. Torque: 12 N⋅m (122 kgf⋅cm, 9 ft⋅lbf) NOTICE: Tighten the nuts in numerical order shown in the illustration to install the floor shift assy. (4) I30390 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3359 55-38 HEATER & AIR CONDITIONER - AIR CONDITIONING RADIATOR ASSY (b) Install the shift cable with the 2 nuts. Torque: 20 N⋅m (200 kgf⋅cm, 14 ft⋅lbf) 43. (a) INSTALL STEERING COLUMN ASSY Install the steering column assy with the 2 bolts and 2 nuts. Torque: 21 N⋅m (210 kgf⋅cm, 15 ft⋅lbf) I30538 I30537 44. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY (SEE PAGE 71-10 ) 45. Wrong Correct (a) (b) Gap (c) I06878 HINT:

46. (a) (b) (c) 47. 48. INSTALL COOLER REFRIGERANT SUCTION PIPE NO.1 Remove the attached vinyl tape from the pipe. Coat a new O-ring with compressor oil and install them to the hose. Compressor oil: ND-OIL 8 or equivalent Install the cooler refrigerant suction pipe No.1 and piping clamp. Be sure to connect the pipe securely. After connection, check the fitting for claw of the piping clamp. INSTALL COOLER REFRIGERANT LIQUID PIPE A Remove the attached vinyl tape from the pipe. Coat a new O-ring with compressor oil and install it to the pipe. Compressor oil: ND-OIL 8 or equivalent Install the cooler refrigerant liquid pipe A and piping clamp. ADD COOLANT 2AZ-FE: (SEE PAGE 16-6 ) 3MZ-FE: (SEE PAGE 16-26 ) CHECK FOR ENGINE COOLANT LEAKS 2AZ-FE: (SEE PAGE 16-1 ) 3MZ-FE: (SEE PAGE 16-20 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3360 55-39 HEATER & AIR CONDITIONER 49. 50. 51. - AIR CONDITIONING RADIATOR ASSY CHARGE REFRIGERANT (SEE PAGE 55-17 ) SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080) Specified amount: 650
50 g (22.93
1.76 oz.) WARM UP ENGINE INSPECT LEAKAGE OF REFRIGERANT (SEE PAGE 55-17 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3361 55-40 HEATER & AIR CONDITIONER - BLOWER ASSY BLOWER ASSY 5519X-01 COMPONENTS Blower Assy Air Duct No. 2 9.8 (100, 87 in.⋅lbf) Recirculation Damper Servo Sub-assy Air Filter Sub-assy Air Refiner Element Air Filter Cover Plate Cooling Unit Motor Sub-assy w/ fan Cooler Cover No.1 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque I39665 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3362 55-41 HEATER & AIR CONDITIONER - BLOWER ASSY 5519Y-02 OVERHAUL HINT: COMPONENTS: see page 55-40 1. REMOVE GLOVE COMPARTMENT DOOR ASSY(SEE PAGE 71-10 ) Claw 2. (a) (b) REMOVE AIR DUCT NO.2 Remove the screw. Release the 3 claw fittings and remove the air duct No.2. 3. (a) (b) REMOVE ECM Disconnect the connectors. Remove the 2 nuts and ECM. I30384 I30545 4. (a) REMOVE CLEAN AIR FILTER SUB-ASSY Release the 2 claw fittings and remove the air filter sub-assy. I37367 5. (a) REMOVE CLEAN AIR FILTER Remove the air refiner element from the air filter cover plate. 6. (a) REMOVE BLOWER ASSY Disconnect the connector and clamp of the cooling unit motor w/ fan sub-assy. Disconnect the connector of the recirculation damper servo. Remove the 2 screws and bracket. (b) (c) I30535 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3363 55-42 HEATER & AIR CONDITIONER Claw - BLOWER ASSY (d) (e) Remove the bolt, nut and 2 screws. Disconnect the part fitted to the air conditioner radiator assy and remove the blower assy. 7. REMOVE RECIRCULATION DAMPER SERVO SUB-ASSY Remove the 3 screws and air inlet servo motor (recirculation damper servo sub-assy). I30536 (a) I30577 8. (a) REMOVE COOLING UNIT MOTOR SUB-ASSY W/FAN Remove the 3 screws and cooling unit motor servo subassy w/ fan. 9. (a) INSTALL BLOWER ASSY Aligning the part to be fitted with that of the air conditioner radiator assy, install the blower assy. Install the blower assy with the bolt, nut and 2 screws. Torque: 9.8 N⋅m (100kgf⋅cm, 87 in.⋅lbf) I30376 (b) Claw I30536 (c) (d) Install the bracket with the 2 screws. Install the connector and clamp. I30535 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3364 55-43 HEATER & AIR CONDITIONER 10. (a) - BLOWER ASSY INSTALL ECM Install the ECM with the 2 nuts. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) I30545 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3365 55-59 HEATER & AIR CONDITIONER - COOLER CONDENSER ASSY 551A3-02 COMPONENTS Radiator Upper Support 9.8 (100, 87 in.⋅lbf) 9.8 (100, 87 in.⋅lbf) 9.8 (100, 87 in.⋅lbf) Radiator Upper Support 9.8 (100, 87 in.⋅lbf)
O-ring 5.4 (55, 47 in.⋅lbf) 5.4 (55, 47 in.⋅lbf)
O-ring Cooler Condensor Assy Cooler Dryer Filter
O-ring Cap
Non-reusable parts Compressor oil ND-OIL 8 or equivalent N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque I39650 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3381 55-58 HEATER & AIR CONDITIONER - COOLER CONDENSER ASSY COOLER CONDENSER ASSY 5502P-03 ON-VEHICLE INSPECTION 1. INSPECT COOLER CONDENSER ASSY (a) If a fin of the cooler condenser assy is dirty, clean it with water and dry it with compressor air. NOTICE: Do not damage the fin of the condenser assy. (b) If a fin of the condenser assy is bent, make it straight using a screwdriver or pliers. 2. INSPECT CONDENSER FOR LEAKAGE OF REFRIGERANT (a) Using a halogen leak detector, check pipe joints for gas leakage. (b) If gas leakage is detected in a joint, check the torque of the joint. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3380 55-60 HEATER & AIR CONDITIONER - COOLER CONDENSER ASSY 551A4-01 REPLACEMENT HINT: COMPONENTS: see page 55-59 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (SEE PAGE 55-17 ) SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080) 2. REMOVE BATTERY 3. REMOVE RADIATOR GRILLE (SEE PAGE 76-2 ) 4. I30395 DISCONNECT COOLER REFRIGERANT DISCHARGE PIPE A (a) Remove the bolt and disconnect the cooler refrigerant discharge pipe from the condenser assy. (b) Remove the O-ring from the cooler refrigerant discharge pipe. NOTICE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering. 5. I30394 DISCONNECT COOLER REFRIGERANT LIQUID PIPE A (a) Remove the bolt and disconnect the cooler refrigerant liquid pipe A from the condenser assy. (b) Remove the O-ring from the cooler refrigerant liquid A pipe. NOTICE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering. 6. (a) REMOVE COOLER CONDENSER ASSY Remove the 2 bolts and 2 radiator upper supports. (b) Remove the 2 bolts and slide the upper part of the radiator rearward to remove the cooler condenser assy. I30393 I30396 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3382 55-61 HEATER & AIR CONDITIONER 7. (a) (b) - COOLER CONDENSER ASSY INSTALL COOLER CONDENSER ASSY Insert the bush on the lower side of the cooler condenser assy into the cross member. Install the cooler condenser assy and 2 bolts. Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf) I30397 (c) Install the radiator upper support and 2 bolts to the upper part of the radiator. Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf) I30393 8. (a) 10. 11. 12. INSTALL COOLER REFRIGERANT LIQUID PIPE A Remove the attached vinyl tape from the pipe and connecting part of the cooler condenser assy. (b) Sufficiently apply compressor oil to the O-ring and pipe joint. Compressor oil: ND-OIL 8 or equivalent (c) Install a new O-ring to the cooler refrigerant liquid pipe A. (d) Connect the cooler refrigerant liquid pipe A to the condenser assy with the bolt. I30394 Torque: 5.4 N⋅m (55 kgf⋅cm, 47 in.⋅lbf) 9. INSTALL COOLER REFRIGERANT DISCHARGE PIPE A (a) Remove the attached vinyl tape from the tube and connecting part of the condenser assy. (b) Sufficiently apply compressor oil to the O-ring and tube joint. Compressor oil: ND-OIL 8 or equivalent (c) Install a new O-ring to the cooler refrigerant discharge tube. I30395 (d) Connect the cooler refrigerant liquid pipe A to the condenser assy with the bolt. Torque: 5.4 N⋅m (55 kgf⋅cm, 47 in.⋅lbf) CHARGE REFRIGERANT (SEE PAGE 55-17 ) SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080) Specified amount: 650
50 g (22.93
1.76 oz.) WARM UP ENGINE INSPECT LEAKAGE OF REFRIGERANT (SEE PAGE 55-17 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3383 55-19 HEATER & AIR CONDITIONER - REFRIGERANT LINE REFRIGERANT LINE 5502H-03 COMPONENTS 3MZ-FE: Cooler Refrigerant Liquid Pipe A Piping Clamp (Quick joint) 9.8 (100, 87 in.⋅lbf) Cooler Refrigerant Suction Hose No.1 9.8 (100, 87 in.⋅lbf) 9.8 (100, 87 in.⋅lbf) Cooler Refrigerant Discharge Pipe A 9.8 (100, 87 in.⋅lbf) 5.4 (55, 47 in.⋅lbf) Cooler Refrigerant Discharge Hose No.1 9.8 (100, 87 in.⋅lbf) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque I41129 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3341 55-20 HEATER & AIR CONDITIONER - REFRIGERANT LINE 2AZ-FE: Piping Clamp (Quick joint) Cooler Refrigerant Liquid Tube Pipe A Cooler Refrigerant Suction Hose No.1 9.8 (100, 87 in.⋅lbf) Cooler Refrigerant Discharge Pipe A 9.8 (100, 87 in.⋅lbf) 9.8 (100, 87 in.⋅lbf) 5.4 (55, 47 in.⋅lbf) Cooler Refrigerant Discharge Hose No.1 9.8 (100, 87 in.⋅lbf) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque I41130 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3342 55-44 HEATER & AIR CONDITIONER - COOLER COMPRESSOR ASSY (2AZ-FE) COOLER COMPRESSOR ASSY (2AZ-FE) 551A1-01 COMPONENTS Magnet Clutch Assy Cooler Compressor Assy
Snap Ring
Snap Ring Magnet Clutch Washer 18 (184, 13) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part I31629 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3366 55-45 HEATER & AIR CONDITIONER - COOLER COMPRESSOR ASSY (2AZ-FE) 551J3-01 REPLACEMENT HINT: COMPONENTS: see page 55-44 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (SEE PAGE 55-17 ) 2. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (SEE PAGE 14-5 ) 3. REMOVE GENERATOR ASSY (SEE PAGE 19-16 ) 4. E52000 DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE NO.1 (a) Remove the nut and disconnect the cooler refrigerant discharge hose No.1. (b) Remove the O-ring from the cooler refrigerant discharge hose No.1. NOTICE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering. 5. E52001 DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO.1 (a) Remove the nut and disconnect the cooler refrigerant suction hose No.1. (b) Remove the O-ring from the cooler refrigerant suction hose No.1. NOTICE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering. 6. (a) (b) REMOVE COMPRESSOR AND MAGNETIC CLUTCH Disconnect the connector. Remove the nut. (c) Using a E8 torque socket wrench, remove the stud bolt. E52002 E52003 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3367 55-46 HEATER & AIR CONDITIONER (d) - COOLER COMPRESSOR ASSY (2AZ-FE) Remove the 3 bolts and compressor and magnetic clutch. E52004 7. REMOVE MAGNET CLUTCH ASSY (a) Remove the bolt and the bracket. (b) Place the compressor and magnetic clutch in a vise. NOTICE: Do not get the bracket and harness caught in the vise. I30371 (c) SST (d) Using SST, hold the magnet clutch hub. SST 95047-10400 Remove the bolt, magnet clutch hub and magnet clutch washer. HINT: There is no set number of magnet clutch washers since they are used for adjusting. E66758 (e) Using a snap ring expander, remove the snap ring and magnet clutch rotor. NOTICE: Do not damage the seal cover of the bearing when removing the snap ring. (f) Remove the screw and disconnect the connector. E37091 (g) Using a snap ring expander, remove the snap ring and magnet clutch stator. I30400 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3368 55-47 HEATER & AIR CONDITIONER 8. (a) - COOLER COMPRESSOR ASSY (2AZ-FE) INSTALL MAGNET CLUTCH ASSY Fit the parts as shown in the illustration and install the magnet clutch stator. I30365 (b) Using a snap ring expander, install a new snap ring with the chamfered side facing up. NOTICE: Do not damage the seal cover of the bearing when removing the snap ring. (c) Install the screw and connect the connector. I32461 (d) I31582 Using a snap ring expander, install the magnet clutch rotor and a new snap ring with the chamfered side facing up. NOTICE:
Do not expand the snap ring by more than 30.5 mm (1.2 in) when installing it.
Do not damage the seal cover of the bearing when removing the snap ring. (e) Install the magnet clutch washer and magnet clutch hub. NOTICE: Do not change the combination of the magnet clutch washers used before disassembly. (f) Using SST, hold the magnet clutch hub and install the bolt. SST 95047-10400 Torque: 18 N⋅m (183 kgf⋅cm, 13 ft⋅lbf) NOTICE: Make sure that there is no foreign matter or oil on the compressor shaft, bolt, and clutch hub. SST E66759 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3369 55-48 HEATER & AIR CONDITIONER - COOLER COMPRESSOR ASSY (2AZ-FE) 9. (a) (b) I30372 INSPECT MAGNETIC CLUTCH CLEARANCE Set the dial gage to the magnet clutch hub. Connect the positive battery lead to terminal 3 of the magnet clutch connector and the negative lead to the earth wire. Turn on and off the magnet clutch and measure the clearance. Standard clearance: 0.35 to 0.60 mm (0.013 to 0.023 in.) If the measured value is not within the standard range, remove the magnet clutch hub and adjust it with magnet clutch washers. NOTICE: Adjustment shall be performed with 3 or less magnet clutch washers. (c) Remove the compressor and magnetic clutch from the vise. (d) Install bracket with the bolt. I30371 10. (a) INSPECT COMPRESSOR OIL When replacing the compressor and magnetic clutch with new one, after gradually removing the refrigerant gas from the service valve, drain the following amount of oil from the new compressor and magnetic clutch before installation. Standard: (Oil capacity inside new cooler compressor assy: 120 + 15 cc (4.06 + 0.5 fl.oz.)) - (Remaining oil amount in the removed cooler compressor assy) = (Oil amount to be removed when replacing) NOTICE:
When checking the compressor oil level, observe the precautions on the cooler removal/installation.
Because compressor oil remains in the pipes of the vehicle, if a new cooler compressor assy is installed without removing some oil inside, the oil amount becomes too much, preventing heat exchange in the refrigerant cycle and causing refrigerant failure.
If the remaining oil in the removed cooler compressor assy is too small in volume, check for oil leakage.
Be sure to use ND-OIL8 for compressor oil. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3370 55-49 HEATER & AIR CONDITIONER 11. (a) - COOLER COMPRESSOR ASSY (2AZ-FE) TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH Install the compressor and magnetic clutch with the stud bolt, 3 bolts and nut. E52005 12. Bolt A Nut Bolt C Bolt B I39669 Nut Bolt C Bolt A FULLY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH Temporarily tighten nut. (a) HINT: Do not over tighten the bolt until the compressor no longer moves. (b) Push down on the rear side of the compressor and fully tighten bolt B, bolt C, bolt A and nut in order. (c) Connect the connector. Push Bolt B I45795 13. (a) (b) (c) INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 Remove the attached vinyl tape from the hose. Sufficiently apply compressor oil to the O-ring and fit surface of the compressor and magnetic clutch. Install a new O-ring to the cooler refrigerant suction hose No.1. Compressor oil: ND-OIL 8 or equivalent I30634 (d) Install the cooler refrigerant suction hose No.1 to the compressor and magnetic clutch with the nut. Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf) E52001 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3371 55-50 HEATER & AIR CONDITIONER 14. (a) (b) (c) - COOLER COMPRESSOR ASSY (2AZ-FE) INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO.1 Remove the attached vinyl tape from the hose. Sufficiently apply compressor oil to the O-ring and fit surface of the compressor and magnetic clutch. Install a new O-ring to the cooler refrigerant discharge hose No.1. Compressor oil: ND-OIL 8 or equivalent I30633 (d) Install the cooler refrigerant discharge hose No.1 to the compressor and magnetic clutch with the nut. Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf) E52000 15. 16. 17. 18. 19. INSTALL BELT, V-RIBBED (SEE PAGE 14-5 ) INSTALL GENERATOR ASSY (SEE PAGE 19-16 ) CHARGE REFRIGERANT (SEE PAGE 55-17 ) WARM UP ENGINE (SEE PAGE 55-17 ) INSPECT LEAKAGE OF REFRIGERANT (SEE PAGE 55-17 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3372 55-62 HEATER & AIR CONDITIONER - REAR HEATER BLOWER SWITCH REAR HEATER BLOWER SWITCH 551A5-02 REPLACEMENT HINT: Installation is in the reverse order of removal. 2 Claws 2 Claws 2 Clips 1. (a) REMOVE DECK SIDE TRIM COVER FRONT LH Using a thin flat-head screwdriver with the tip taped up with protective tape, disengage the 2 claw fittings and remove the deck side trim cover front. 2. (a) (b) (c) REMOVE DECK SIDE TRIM COVER RH Remove the bolt. Release the 2 clip fittings and 2 claw fittings. Remove the connector and deck side trim cover RH. 3. (a) REMOVE REAR HEATER BLOWER SWITCH Remove the 2 screws and rear heater blower switch. I38984 I38985 I40098 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3384 55-63 HEATER & AIR CONDITIONER - REAR HEATER ASSY REAR HEATER ASSY 551A6-01 COMPONENTS Foot Air Duct Rear No.5 Rear Heater Assy Plate 9.8 (100, 87 in.⋅lbf) Foot Air Duct Rear 9.8 (100, 87 in.⋅lbf) 9.8 (100, 87 in.⋅lbf) Rear Heater Blower Resistor Rear Heater Blower Motor Sub-assy Clip Clip Rear Heater Unit Sub-assy Rear Heater Blower Fan Sub-assy 4.0 (41, 35 in.⋅lbf) Water Pipe & Hose Sub-assy N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque I39532 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3385 55-64 HEATER & AIR CONDITIONER - REAR HEATER ASSY 551A7-02 REPLACEMENT HINT:

1. 2. 3. Installation is in the reverse order of removal. COMPONENTS: see page 55-63 REMOVE DECK SIDE TRIM COVER FRONT LH (SEE PAGE 55-62 ) REMOVE DECK SIDE TRIM COVER RH (SEE PAGE 55-62 ) REMOVE DECK TRIM SIDE PANEL ASSY RH (SEE PAGE 76-21 ) 4. (a) Heater Water Inlet Hose Water pipe Heater Water Outlet Hose I39530 DISCONNECT HEATER WATER OUTLET HOSE Using pliers, grip the claws of the clip and slide the clip, and disconnect the heater water outlet hose. NOTICE:
When installing or removing the hoses, hold heater water pipes to prevent deformation.
Do not apply any excessive force to the heater water outlet hose.
Prepare a drain pan or cloth in case the cooling water leaks. 5. DISCONNECT HEATER WATER INLET HOSE HINT: Disconnect the heater water inlet hose in the same way as the heater water outlet hose. 6. (a) REMOVE FOOT AIR DUCT REAR Remove the 2 clips and foot air duct rear. 7. (a) (b) REMOVE AIR DUCT REAR NO.5 Disconnect the wire harness clamp. Remove the 2 clips and air duct rear No.5. I38988 Clamp I38986 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3386 55-65 HEATER & AIR CONDITIONER Clamp Clamp - REAR HEATER ASSY 8. (a) (b) REMOVE REAR HEATER ASSY Disconnect the washer hose clamp. Remove the 4 bolts and plate. (c) (d) Disconnect the heater relay No.1 clamp. Disconnect the heater blower resistor connector. (e) Remove the 4 bolts and rear heater assy. I38990 I38991 I38992 9. (a) REMOVE WATER PIPE & HOSE SUB-ASSY Using pliers, grip the claws of the 2 clips and slide the 2 clips, and disconnect the heater water hose. NOTICE: Do not apply any excessive force to the heater water hose. I39531 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3387 55-66 HEATER & AIR CONDITIONER 2 Clamps - REAR HEATER ASSY 10. (a) (b) REMOVE REAR HEATER BLOWER RESISTOR Disconnect the 2 clamps and connector. Remove the 2 screws and rear heater blower resistor. 11. (a) REMOVE REAR HEATER UNIT SUB-ASSY Remove the 9 screws and clamp. (b) Remove the rear heater unit sub-assy from the heater case. 12. (a) (b) REMOVE REAR HEATER BLOWER FAN SUB-ASSY Remove the nut and heater blower fan sub-assy. Remove the washer. 13. REMOVE REAR HEATER BLOWER MOTOR SUB-ASSY Disconnect the connector clamp. Remove the 3 screws and heater blower motor sub-assy. I38993 I38994 I38995 I38996 (a) (b) Clamp I38997 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3388 55-67 HEATER & AIR CONDITIONER 14. (a) (b) - REAR HEATER ASSY INSTALL REAR HEATER BLOWER FAN SUB-ASSY Install the washer. Install the heater blower fan sub-assy with the nut. Torque: 4.0 N⋅m (41 kgf⋅cm, 35 in.⋅lbf) I38996 15. (a) INSTALL REAR HEATER ASSY Install the rear heater assy with the 4 bolts. Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf) NOTICE: Tighten the bolts in the numerical order shown in the illustration to install the rear heater assy. (2) (3) (1) (4) Clamp I38992 (b) (c) Install the heater blower resistor connector. Install the heater relay No.1. (d) (e) Install the waher hose. Install the plate with the 4 bolts. Torque: Bolt A: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf) I38991 (A) Clamp I38990 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3389 55-51 HEATER & AIR CONDITIONER - COOLER COMPRESSOR ASSY (3MZ-FE) COOLER COMPRESSOR ASSY (3MZ-FE) 5519Z-01 COMPONENTS Cooler Compressor Bracket Magnet Clutch Assy Cooler Compressor Assy
Snap Ring
Snap Ring 18 (184, 13) Magnet Clutch Washer N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part I31774 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3373 55-52 HEATER & AIR CONDITIONER - COOLER COMPRESSOR ASSY (3MZ-FE) 551A0-01 REPLACEMENT HINT: COMPONENTS: see page 55-51 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (SEE PAGE 55-17 ) SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080) 2. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (SEE PAGE 55-22 ) 3. 5. DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO.1 (a) Remove the bolt and disconnect the cooler refrigerant suction hose No.1 from the compressor and magnetic clutch. (b) Remove the O-ring from the cooler refrigerant suction hose No.1. NOTICE: Seal the opening of the disconnected parts using vinyl tape I30579 to prevent moisture and foreign matter from entering. 4. DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE NO.1 (a) Remove the nut and disconnect the cooler refrigerant discharge hose No.1 from the compressor and magnetic clutch. (b) Remove the O-ring from the cooler refrigerant discharge hose No.1. NOTICE: Seal the opening of the disconnected parts using vinyl tape I30578 to prevent moisture and foreign matter from entering. REMOVE ENGINE UNDER COVER NO.1 6. (a) (b) REMOVE COMPRESSOR AND MAGNETIC CLUTCH Disconnect the connector and clamp. Remove the 2 bolts, nut and the cooler compressor bracket. I30361 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3374 55-53 HEATER & AIR CONDITIONER (c) - COOLER COMPRESSOR ASSY (3MZ-FE) Remove the 3 bolts and the compressor and magnetic clutch. I30362 7. REMOVE MAGNET CLUTCH ASSY (a) Remove the 2 bolts and the bracket. (b) Place the compressor and magnetic clutch in a vise. NOTICE: Do not get the bracket and harness caught in the vise. I30363 (c) SST (d) Using SST, hold the magnet clutch hub. SST 95047-10400 Remove the bolt, magnet clutch hub and magnet clutch washer. HINT: There is no set number of magnet clutch washers since they are used for adjusting. E66758 (e) Using a snap ring expander, remove the snap ring and magnet clutch rotor. NOTICE: Do not damage the seal cover of the bearing when removing the snap ring. (f) Remove the screw and disconnect the connector. E37091 (g) Using a snap ring expander, remove the snap ring and magnet clutch stator. I30400 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3375 55-54 HEATER & AIR CONDITIONER 8. (a) - COOLER COMPRESSOR ASSY (3MZ-FE) INSTALL MAGNET CLUTCH ASSY Fit the magnet clutch stator convex to the compressor groove as shown in the illustration and install the magnet clutch stator. I30365 I40641 (b) Using a snap ring expander, install a new snap ring with the chamfered side facing up. NOTICE: Do not damage the seal cover of the bearing when removing the snap ring. (c) Install the screw and connect the connector. I32461 (d) I31582 Using a snap ring expander, install the magnet clutch rotor and a new snap ring with the chamfered side facing up. NOTICE:
Do not expand the snap ring by more than 30.5 mm when installing it.
Do not damage the seal cover of the bearing when removing the snap ring. (e) Install the magnet clutch washer and magnet clutch hub. NOTICE: Do not change the combination of the magnet clutch washers used before disassembly. (f) Using SST, hold the magnet clutch hub and install the bolt. SST 95047-10400 Torque: 18 N⋅m (183 kgf⋅cm, 13 ft⋅lbf) NOTICE: Make sure that there is no foreign matter or oil on the compressor shaft, bolt, and clutch hub. SST E66759 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3376 55-55 HEATER & AIR CONDITIONER - COOLER COMPRESSOR ASSY (3MZ-FE) 9. (a) (b) I37852 INSPECT MAGNETIC CLUTCH CLEARANCE Set the dial gage to the magnet clutch hub. Connect the positive battery lead to terminal 3 of the magnet clutch connector and the negative lead to the earth wire. Turn on and off the magnet clutch and measure the clearance. Standard clearance: 0.35 to 0.60 mm (0.013 to 0.023 in.) If the measured value is not within the standard range, remove the magnet clutch hub and adjust it with magnet clutch washers. NOTICE: Adjustment should be performed with 3 or less magnet clutch washers. (c) Remove the compressor and magnetic clutch from the vise. (d) Install bracket with the 2 bolts. I30363 10. (a) INSPECT COMPRESSOR OIL When replacing the compressor and magnetic clutch with a new one, after gradually removing the refrigerant gas from the service valve, drain the following amount of oil from the new compressor and magnetic clutch before installation. Standard: (Oil capacity inside new compressor and magnetic clutch: 120 + 15 cc (4.0 + 0.5 fl. oz.) ) - (Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed when replacing) NOTICE:
When checking the compressor oil level, observe the precautions on the cooler removal/installation.
When a new compressor and magnetic clutch is installed without removing the oil remaining in the pipes (of the vehicle), the oil amount will become excessive, which prevents heat exchange in the refrigerant and causes refrigerant failure.
If the remaining oil in the removed compressor and magnetic clutch is too small in volume, check for oil leakage.
Be sure to use ND-OIL8 or equivalent for compressor oil. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3377 55-56 HEATER & AIR CONDITIONER 11. (a) - COOLER COMPRESSOR ASSY (3MZ-FE) TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH Temporarily tighten the compressor and magnetic clutch with the 3 bolts. I30362 12. FULLY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH (a) Fully tighten the compressor and magnetic clutch with the 3 bolts. Torque: 25 N⋅m (250 kgf⋅cm, 18 in.⋅lbf) NOTICE: Tighten the bolts in the numerical order shown in the illustration to install the compressor and magnetic clutch. (3) (2) (1) E52158 I39849 (b) (B) (A) (c) I30361 13. (a) (b) (c) (d) 14. (a) (b) I30578 Install the cooler compressor bracket with the 2 bolts and nut. Torque: Bolt (A): 25 N⋅m (250 kgf⋅cm, 18 in.⋅lbf) Bolt (B): 18 N⋅m (184 kgf⋅cm, 13 in.⋅lbf) Nut : 25 N⋅m (250 kgf⋅cm, 18 in.⋅lbf) Connect the connector and clamp on the cooler compressor bracket. INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO.1 Remove the attached vinyl tape from the hose. Sufficiently apply compressor oil to the new O-ring and fitting surface of the compressor and magnetic clutch. Compressor oil: ND-OIL8 or equivalent Install the O-ring to the cooler refrigerant discharge hose No.1. Install the cooler refrigerant discharge hose No.1 to the compressor and magnetic clutch with the nut. Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf) INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 Remove the attached vinyl tape from the hose. Sufficiently apply compressor oil to the new O-ring and fitting surface of the compressor and magnetic clutch. Compressor oil: ND-OIL8 or equivalent 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3378 55-57 HEATER & AIR CONDITIONER - COOLER COMPRESSOR ASSY (3MZ-FE) (c) Install the O-ring to the cooler refrigerant suction hose No.1. (d) Install the cooler refrigerant suction hose No.1 to the compressor and magnetic clutch with the bolt. Torque: 9.8 N⋅m (100 kgf⋅cm, 87 in.⋅lbf) I30579 15. 16. 17. 18. 19. 20. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (SEE PAGE 55-22 ) ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (SEE PAGE 55-24 ) FULLY TIGHTEN V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (SEE PAGE 55-24 ) CHARGE REFRIGERANT (SEE PAGE 55-17 ) SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080) Specified amount: 650
50 g (22.93
1.76 oz.) WARM UP ENGINE (SEE PAGE 55-17 ) INSPECT LEAKAGE OF REFRIGERANT (SEE PAGE 55-17 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3379 55-68 HEATER & AIR CONDITIONER - AIRCONDITIONER AMPLIFIER ASSY AIRCONDITIONER AMPLIFIER ASSY 551A8-01 REPLACEMENT 1. 2. 3. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY CENTER (SEE PAGE 71-10 ) REMOVE MULTI-DISPLA Y (CRT DISPLAY) DISPLAY (SEE PAGE 71-10 ) REMOVE FRONT SEAT ARMREST ASSY CENTER (SEE PAGE 71-10 ) 4. (a) (b) REMOVE AIRCONDITIONER AMPLIFIER ASSY Disconnect the connector. Remove the 3 screws and air conditioner amplifier assy. I39670 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3390 55-7 HEATER & AIR CONDITIONER - AIR CONDITIONING SYSTEM 551AB-01 INSPECTION Cooler Thermistor No.1 Connector Front View: 1. COOLER THERMISTOR CONDITIONER) NO.1(MANUAL AIR (a) (b) Remove cooler thermistor No. 1. Check resistance between terminals 1 and 2 of cooler thermistor No. 1 at each temperature, as shown in the chart. Standard: - E12 + E50650 Tester connection Condition Specified condition E12-1 - E12-2 -10 °C (14°F) 8.00 to 10.00 kΩ E12-1 - E12-2 -5 °C (23°F) 6.15 to 7.65 kΩ E12-1 - E12-2 0°C (32°F) 4.75 to 5.85 kΩ E12-1 - E12-2 5°C (41°F) 3.70 to 4.55 kΩ E12-1 - E12-2 10°C (50°F) 3.00 to 3.73 kΩ E12-1 - E12-2 15°C (59°F) 2.45 to 2.88 kΩ E12-1 - E12-2 20°F (68°F) 1.95 to 2.30 kΩ E12-1 - E12-2 25°C (77°F) 1.60 to 1.80 kΩ E12-1 - E12-2 30°C (86°F) 1.28 to 1.47 kΩ NOTICE:
Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor.
When measuring the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decrease (see the graph below). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3329 55-8 HEATER & AIR CONDITIONER Resistance (kΩ) 12.0 11.0 10.0 9.0 8.0 7.0 6.0 5.0 4.0 3.0 2.0 1.0 0.0 -20 -4 - AIR CONDITIONING SYSTEM Maximum permissible value line Minimum permissible value line 0 32 40 (°C) 104 (°F) 20 68 Temperature I38768 I40629 2. HEATER BLOWER CONDITIONER) (a) Inspect blower switch continuity. E37726 SWITCH(MANUAL AIR Condition / Circuit Tester connection Specified condition OFF - No continuity LO 1-8 Continuity M1 1-6-8 Continuity M2 1-5-8 Continuity HI 1-4-8 Continuity If continuity is not as specified, replace the air conditioner control assy. (b) Inspect illumination operation. Connect the positive (+) lead from the battery to terminal 2 and negative (-) lead to terminal 3 then check that the illuminations light up. If there is bulb not light up, replace the bulb. E32877 3. BLOWER RESISTOR(MANUAL AIR CONDITIONER) (a) Measure resistance between terminals, as shown in the chart below. Tester connection Specified condition 1-2 0.642 - 0.738 Ω 1-3 0.205 - 0.235 Ω 1-4 1.572 - 1.803 Ω If resistance is not as specified, replace the blower resistor. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3330 55-9 HEATER & AIR CONDITIONER 1 2 4. - AIR CONDITIONING SYSTEM COOLING UNIT MOTOR SUB-ASSY W/FAN(MANUAL AIR CONDITIONER) (a) Connect the positive (+) lead from the battery to terminal 2 and negative (-) to terminal 1, then check that the motor operation smoothly. If operation is not as specified, replace the blower motor. I07858 3 4 5 3 1 HEATER BLOWER MOTOR RELAY ASSY(MANUAL AIR CONDITIONER) (a) Check that the continuity exists between each pair of terminals of heater blower motor relay assy, as shown in the chart. 5 4 1 5. 2 2 Z19533 (b) (c) Tester connection Specified condition 1-4 No continuity 2-4 Continuity 3-5 62.5 - 90.9 Ω Apply battery voltage between terminals 3 and 5. Check continuity each pair of terminals, as shown the chart. Tester connection 6. Specified condition 1-2 Continuity 2-4 No continuity If continuity is not as specified, replace the heater blower motor relay. MAGNET CLUTCH ASSY(MANUAL AIR CONDITIONER) (a) Connect the positive (+) lead from the battery to terminal and the negative (-) lead to the body ground. (b) Check that the magnetic clutch energized. If operation is not as specified, replace the magnet clutch assy. 7. COOLER COMPRESSOR ASSY(MANUAL AIR CONDITIONER) (a) (b) le-3-2 E05280 Disconnect the cooler compressor assy connector. Measure resistance between terminals 1 and 2 of cooler compressor assy connector. Resistance: 165 - 205 Ω at 20 C (68 F) If resistance is not as specified, replace the cooler compressor assy. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3331 55-10 HEATER & AIR CONDITIONER 8. - AIR CONDITIONING SYSTEM MAGNET- CLUTCH CONDITIONER) RELAY(MANUAL AIR Condition tester connection Specified condition constant 1-2 Continuity Apply B+ between terminals 1 and 2. 3-5 Continuity If continuity is not as specified, replace the magnet-clutch relay. I30152 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3332 55-4 HEATER & AIR CONDITIONER - AIR CONDITIONING SYSTEM 551AC-01 ON-VEHICLE INSPECTION 1. (a) 1 3 2 4 Low pressure side High pressure side ON (Continuity) INSPECT PRESSURE SWITCH NO.1. Magnetic clutch control: Inspect pressure switch operation. (1) Set on the manifold gauge set. (2) Connect the positive (+) lead from the ohmmeter to terminal 4 and the negative (-) lead to terminal 1. (3) Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. 196 kpa 3,140 kpa 2 (2.0 kgf/cm2 28 psi) (132.0 kgf/cm 455 psi) OFF (No continuity) OFF (No continuity) I30146 (b) 1 2 3 4 1,370 kpa (14.0 kgf/cm2 199 psi) ON OFF (Continuity) 1,770 kpa (No continuity) (18.0 kgf/cm2 256 psi) Cooling fan control: Inspect pressure switch operation. (1) Connect the positive (+) lead from the ohmmeter to terminal 2 and the negative (-) lead to terminal 3. (2) Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. I30291 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3326 55-5 HEATER & AIR CONDITIONER Wire Harness Side: 1 8 1 2. 11 A11 (a) A10 9 16 12 - AIR CONDITIONING SYSTEM INSPECT AIR CONDITIONER AMPLIFIER ASSY CIRCUIT Disconnect the connectors from the A/C amplifier assy and inspect the connector on the wire harness side, as shown the chart. 22 I30906 Symbols (Terminals No.) Wiring Color Condition Specified condition A10-11 (GND) Body Ground W-B - Body Ground Constant Continuity A11-5 (TE) A11-12 (SG-1) LG - P Evaporator temp.: 25C (77F) 1.5 kΩ A10-2 (IG) Body Ground BR - Body Ground Turn ignition switch: ON Battery positive voltage A10-2 (IG) Body Ground BR - Body Ground Turn ignition switch: LOCK or ACC No voltage A10-12 (+B) Body Ground W - Body Ground Constant Battery positive voltage A10-13 (ACC) Body Ground GR - Body Ground Turn ignition switch: ACC Battery positive voltage A10-13 (ACC) Body Ground GR - Body Ground Turn ignition switch: except ACC No voltage If the circuit is as specified, try to replace the A/C amplifier assy with a new one. If the circuit is as specified, inspect the circuits connected to other parts. From Back Side: 8 1 11 (b) 1 A11 Connect the connector to A/C amplifier assy and inspect the wire harness side connector from the back side, as shown in the chart. A10 16 9 22 12 I30906 Symbols (Terminals No.) Wiring Color Condition Specified condition A10-4 (MR/F) Body Ground Y - Body Ground Turn ignition switch ON Battery positive voltage A10-4 (MR/F) Body Ground Y - Body Ground Turn ignition switch OFF Below 1 V A10-5 (AIR) Body Ground B - Body Ground Turn ignition switch ON and air flow selector at DEF position Below 1 V A10-5 (AIR) Body Ground B - Body Ground Turn ignition switch ON and air flow selector at except DEF position Battery positive voltage 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3327 55-6 HEATER & AIR CONDITIONER - AIR CONDITIONING SYSTEM Symbols (Terminals No.) Wiring Color Condition Specified condition A10-6 (AIF) Body Ground W - Body Ground Turn ignition switch ON and air inlet control selector at FRESH 10 - 14 V A10-6 (AIF) Body Ground W - Body Ground Turn ignition switch ON and air inlet control selector at RECIRCULATION Below 1 V A10-7 (HR) Body Ground O - Body Ground Turn ignition switch ON and operate the blower motor Below 1 V A10-7 (HR) Body Ground O - Body Ground Turn ignition switch ON and does not operate the blower motor Battery positive voltage


A10-9 (MPX-) G Multiplex communication circuit - A10-15 - A10-21 V (*1) Ignition switch ON and light control rheostat volume DARK No voltage A10-15 - A10-21 V (*1) Ignition switch ON and light control rheostat volume LIGHT Battery voltage A11-2 (MPX+) V (*2) G (*3) Multiplex communication circuit - A11-6 (TPO) A11-1 (SG-4) R-B Turn ignition switch ON and air flow selector at DEF position 0.5 - 1.5 V A11-6 (TPO) A11-1 (SG-4) R-B Turn ignition switch ON and air flow selector at FACE position 4.5 - 5.5 V A11-7 (AOD) Body Ground G - Body Ground Turn ignition switch ON and air flow selector at DEF position Battery positive voltage A11-7 (AOD) Body Ground G - Body Ground Turn ignition switch ON and air flow selector at except FACE position Below 1 V A11-8 (AOF) Body Ground V - Body Ground Turn ignition switch ON and air flow selector at except FACE position Below 1 V A11-8 (AOF) Body Ground V - Body Ground Turn ignition switch ON and air flow selector at FACE position Battery positive voltage A11-9 (S5-4) A11-1 (SG-4) BR - B Turn ignition switch ON 4.5 - 5.5 V A11-10 (TP) A11-12 (SG-1) SB - P Turn ignition switch ON and set temp.: MAX. COOL position 4.5 - 5.5 V A11-10 (TP) A11-12 (SG-1) SB - P Turn ignition switch ON and set temp.: MAX. WARM position 0.5 - 1.5 V A11-1 1 (S5-1) A11-12 (SG-1) O-P Turn ignition switch ON 4.5 - 5.5 V A11-13 (AMC) A11-1 (SG-4) GR - B Turn ignition switch ON and set temp.: MAX. COOL position Battery positive voltage A11-13 (AMC) A11-1 (SG-4) GR - B Turn ignition switch ON and set temp.: MAX. WARM position Below 1 V A11-14 (AMH) A11-1 (SG-4) B-B Turn ignition switch ON and set temp.: MAX. COOL position Below 1 V A11-14 (AMH) A11-1 (SG-4) B-B Turn ignition switch ON and set temp.: MAX. WARM position Battery positive voltage *1:If the circuit is as specified, try to replace the A/C amplifier assy with a new one. If the circuit is as specified, inspect the circuits connected to other parts. *2: w/ Navigation System. *3: w/o Navigation System. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3328 55-2 HEATER & AIR CONDITIONER - AIR CONDITIONING SYSTEM 551AA-01 LOCATION Manual A/C Models: Engine Room J/B
Magnetic Clutch Relay
ECU-B Fuse
50 A HEATER Fuse Condenser Pressure Switch Compressor and Magnetic Clutch I30305 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3324 55-3 HEATER & AIR CONDITIONER - AIR CONDITIONING SYSTEM Manual A/C Models: w/o Navigation System: w/ Navigation System: Instrument Panel J/B
15 A HEATER Fuse
RADIO No. 2 Fuse
AM1 Fuse Multi Display Assy Heater Control Assembly
A/C Amplifier Assy Evaporator Air Outlet Damper Control Servomotor Evaporator Temperature Sensor Expansion Valve Recirculation Damper Servomotor Heater Radiator Blower Motor Blower Motor Resistor Air Mix Damper Control Servomotor I41029 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3325 55-1 HEATER & AIR CONDITIONER - AIR CONDITIONING SYSTEM AIR CONDITIONING SYSTEM 551A9-01 PRECAUTION 1. 2. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME ALWAYS WEAR EYE PROTECTION AC2810 3. AC2811 Wrong LO HI 6. Okay LO BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin. (a) Wash the area with lots of cool water. CAUTION: Do not rub your eyes or skin. (b) Apply clean petroleum jelly to the skin. (c) Go immediately to a physician or hospital for professional treatment. 4. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED FLAME 5. BE CAREFUL NOT TO DROP CONTAINER AND NOT TO APPLY PHYSICAL SHOCKS TO IT HI N11084 DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM If there is not enough refrigerant in the refrigerant system oil lubrication will be insufficient and compressor burnout may occur, so take care to avoid this, necessary care should be taken. 7. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING If the high pressure valves opened, refrigerant flows in the reverse direction and could cause the charging cylinder to rupture, so open and close the only low pressure valve. 8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine overheating etc. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3323 60-16 SUPPLEMENTAL RESTRAINT SYSTEM - HORN BUTTON ASSY HORN BUTTON ASSY 600KC-08 COMPONENTS Torx Screw 8.8 (90, 78 in.⋅lbf) Steering Wheel Assy Steering Column Cover UPR Spiral Cable Sub-assy Steering Wheel Cover Lower No. 2 50 (510, 37) Steering Wheel Cover Lower No. 3 Torx Screw 8.8 (90, 78 in.⋅lbf) Steering Column Cover LWR Horn Button Assy N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque H44248 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3406 60-19 SUPPLEMENTAL RESTRAINT SYSTEM - HORN BUTTON ASSY 600OB-02 DISPOSAL HINT: When scrapping a vehicle equipped with the SRS or disposing of the horn button assy, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION:
Never dispose of a horn button assy that has an undeployed airbag.
The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents.

SST
H40004


1. When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. When deploying the airbag, perform the operation at least 10 m (33 ft) away from the horn button assy. The horn button assy becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a horn button assy with a deployed airbag. Do not apply water, etc. to a horn button assy with a deployed airbag. Always wash your hands with water after completing the operation. DISPOSE OF HORN BUTTON ASSY (WHEN INSTALLED IN VEHICLE) HINT: Prepare a battery as the power source to deploy the airbag. (a) Check the function of the SST. SST 09082-00700 CAUTION: When deploying the airbag, always use the specified SST: SRS Airbag Deployment Tool. SST H40004 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3409 60-20 SUPPLEMENTAL RESTRAINT SYSTEM (1) Battery - HORN BUTTON ASSY Connect the SST to the battery. Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the battery negative (-) terminal. HINT: Do not connect the yellow connector of the SST which is to be connected with the supplemental restraint system. SST H40005 (2) SST H40006 Check the function of the SST. Press the SST activation switch, and check that the LED of the SST activation switch comes on. CAUTION: If the LED comes on when the activation switch is not being pressed, SST malfunction is possible, so be sure not to use the SST. (3) Disconnect the SST from the battery. (b) Precaution (see page 60-1 ). (c) Disconnect the battery negative terminal (see page 60-1 ). (d) Remove the steering column cover LWR. (1) While turning the steering wheel assy to the right and left, remove the 3 screws and steering column cover LWR. H44251 SST H44343 (e) Install the SST. CAUTION: Check that there is no looseness in the steering wheel assy and horn button assy. (1) Disconnect the airbag connector (yellow colored one) from the spiral cable sub-assy. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (2) Connect the SST connector to the airbag connector of the spiral cable sub-assy. SST 09082-00700, 09082-00780 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3410 60-21 SUPPLEMENTAL RESTRAINT SYSTEM - (3) (4) Battery SST 10 m (33 ft) or more H40007 SST H40004 HORN BUTTON ASSY Move the SST at least 10 m (33 ft) away from the vehicle front side window. Maintaining enough clearance for the SST wire harness in the front side window, close all doors and windows of the vehicle. NOTICE: Take care not to damage the SST wire harness. (5) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the negative (-) terminal. (f) Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (33 ft) radius of the vehicle. (2) Press the SST activation switch and deploy the airbag. CAUTION:
When deploying the airbag, make sure that no one is near the vehicle.
The horn button assy becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a horn button assy with a deployed airbag.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a horn button assy with a deployed airbag. HINT: The airbag is deployed as the LED of the SST activation switch comes on. 2. DISPOSE OF HORN BUTTON ASSY (WHEN NOT INSTALLED IN VEHICLE) NOTICE:
When disposing of the horn button assy, never use the customer’s vehicle to deploy the airbag.
Be sure to follow the procedure detailed below when deploying the airbag. HINT: Prepare a battery as the power source to deploy the airbag. (a) Check the function of the SST (see step 1-(a)). (b) Remove the horn button assy (see page 60-17 ). CAUTION:
When removing the horn button assy, work must be started 90 seconds after the ignition switch is turned to the ”LOCK” position and the negative (-) terminal cable is disconnected from the battery.
When storing the horn button assy, keep the upper surface of the airbag deployment side facing upward. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3411 60-22 SUPPLEMENTAL RESTRAINT SYSTEM - HORN BUTTON ASSY (c) Wire Harness Diameter Stripped Wire Harness Section H40008 Using a service-purpose wire harness for the vehicle, tie down the horn button assy to the disc wheel. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.0019 in.2 or more) CAUTION: If the wire harness is too thin or an alternative object is used to tie down the horn button assy, it may be snapped by the shock when the airbag is deployed. This is highly dangerous. Always use a wire harness for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2). HINT: To calculate the area of the stripped wire harness section: Area = 3.14 x (Diameter)2 divided by 4 (1) L M H44253 SST Install the 2 bolts with washers into the 2 bolt holes on the horn button assy. Bolt: L: 35.0 mm (1.378 in.) M: 6.0 mm (0.236 in.) Pitch: 1.0 mm (0.039 in.) NOTICE:
Tighten the bolts by hand until they become difficult to turn.
Do not tighten the bolts excessively. (2) After connecting the SST below to each other, connect them to the horn button assy. SST 09082-00802 (09082-10801, 09082-30801) H44254 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3412 60-23 SUPPLEMENTAL RESTRAINT SYSTEM - (3) 2 times or more 2 times or more HORN BUTTON ASSY Using 3 wire harnesses, wind wire harness at least 2 times each around the bolts installed on the left and right sides of the horn button assy. CAUTION:
Tightly wind the wire harness around the bolts so that there is no slack.
Make sure that the wire harness is tight. If there is slack in wire harness, the horn button assy may become loose due to the shock when the airbag is deployed. This is highly dangerous. H44255 (4) H44256 SST H44257 Face the upper surface of the horn button assy upward. Separately tie the left and right sides of the horn button assy to the disc wheel through the hub nut holes. Position the SST connector so that it hangs downward through a hub hole in the disc wheel. CAUTION:
Make sure that the wire harness is tight. If there is slack in wire harness, the horn button assy may become loose due to the shock when the airbag is deployed. This is highly dangerous.
Always tie down the horn button assy with the pad side facing upward. It is highly dangerous if the horn button assy is tied down with the metal surface facing upward as the wire harness will be cut by the shock caused by the airbag deployment and the horn button assy will be thrown into the air. NOTICE: The disc wheel will be marked by the airbag deployment, so use an extra disc wheel. (d) Install the SST. CAUTION: Place the disc wheel on level ground. (1) Connect the SST connector. SST 09082-00700 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the disc wheel. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3413 60-24 SUPPLEMENTAL RESTRAINT SYSTEM (2) Battery - HORN BUTTON ASSY Move the SST at least 10 m (33 ft) away from the horn button assy tied down to the disc wheel. SST 10 m (33 ft) or more H40014 (e) Y Y X Weight H40176 Cover the horn button assy with a cardboard box or tires. (1) Covering method using a cardboard box: Cover the horn button assy with the cardboard box and place the weights on the cardboard box in 4 places with at least 190 N (19 kg, 43 lb). Size of cardboard box: Must exceed the following dimensions: X = 460 mm (18.11 in.) Y = 650 mm (25.59 in.) NOTICE:
When the dimension Y of the cardboard box exceeds the diameter of the disc wheel with tire which the horn button assy is tied to, X should be the following size. X = 460 mm (18.11 in.) + width of tire
If a cardboard box which is smaller than the specified size is used, the cardboard box will be broken by the shock from the airbag deployment. (2) Inner Diameter Width Tires (3 or more) H43247 Covering method using tires: Place at least 3 tires without disc wheels on top of the tire with disc wheel which the horn button assy is tied to. Tire size: Must exceed the following dimensions Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) CAUTION: Do not use tires with disc wheels. NOTICE:
The tires may be marked by the airbag deployment, so use an extra tire.
Do not place the SST connector under the tire because it could be damaged. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3414 60-25 SUPPLEMENTAL RESTRAINT SYSTEM - HORN BUTTON ASSY (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harness is tight. It is highly dangerous when looseness in the wire harness results in the tires coming free due to the shock when the airbag is deployed. H43722 (f) Horn Button Assy Battery SST 10 m (33 ft) or more H43724 H40177 Deploy the airbag. (1) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the battery negative (-) terminal. (2) Check that no one is within a 10 m (33 ft) radius of the disc wheel which the horn button assy is tied to. (3) Press the SST activation switch and deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tire. HINT: The airbag is deployed as the LED of the SST activation switch comes on. (g) Dispose of the horn button assy. CAUTION:
The horn button assy becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a horn button assy with a deployed airbag.
Do not apply water, etc. to a horn button assy with a deployed airbag.
Always wash your hands with water after completing the operation. (1) Remove the horn button assy from the disc wheel. (2) Place the horn button assy in a plastic bag, tie it tightly and dispose of it as other general parts disposal. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3415 60-17 SUPPLEMENTAL RESTRAINT SYSTEM - HORN BUTTON ASSY 6008Y-18 REPLACEMENT HINT: Installation is in the reverse order of removal. 1. PRECAUTION (SEE PAGE 60-1 ) 2. DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60-1 ) Screw Case Steering Wheel Cover Lower No. 3 Torx Screw Steering Wheel Cover Lower No. 2 H44345 H44250 3. (a) REMOVE STEERING WHEEL COVER LOWER NO.3 Using a screwdriver, remove the steering wheel cover lower No.3. HINT: Tape up the screwdriver tip before use. 4. REMOVE STEERING WHEEL COVER LOWER NO.2 (a) Using a screwdriver, remove the steering wheel cover lower No.2. HINT: Tape up the screwdriver tip before use. 5. REMOVE HORN BUTTON ASSY (a) Place the front wheels facing straight ahead. (b) Using a torx socket wrench (T30), loosen the 2 torx screws until the groove along the screw circumference catches on the screw case. (c) Pull out the horn button assy from the steering wheel assy and support the horn button assy with one hand as shown in the illustration. NOTICE: When removing the horn button assy, do not pull the airbag wire harness. (d) Disconnect the horn connector. (e) Disconnect the 2 connectors from the horn button assy. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (f) Remove the horn button assy. 6. (a) INSTALL HORN BUTTON ASSY Support the horn button assy with one hand as shown in the illustration. (b) Connect the 2 connectors to the horn button assy. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (c) Connect the horn connector. H44250 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3407 60-18 SUPPLEMENTAL RESTRAINT SYSTEM - HORN BUTTON ASSY (d) 7. Confirm that the circumference groove of the torx screw fits in the screw case, and place the horn button assy onto the steering wheel assy. (e) Using a torx socket wrench (T30), tighten the 2 torx screws. Torque: 8.8 N⋅m (90 kgf⋅cm, 78 in.⋅lbf) CONNECT BATTERY NEGATIVE TERMINAL 8. (a) H44341 9. INSPECT HORN BUTTON ASSY With the horn button assy installed on the vehicle, perform a visual check including the following: Cuts, minute cracks or marked discoloration on the horn button assy top surface and in the grooved portion. Make sure that the horn sounds. (b) HINT: If the horn does not sound, inspect the horn system (see page 69-2 ). INSPECT SRS WARNING LIGHT (SEE PAGE 05-1207 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3408 60-26 SUPPLEMENTAL RESTRAINT SYSTEM - SPIRAL CABLE SUB-ASSY SPIRAL CABLE SUB-ASSY 60091-11 REPLACEMENT HINT:

1. 2. 3. 4. 5. 6. 7. COMPONENTS: See page 60-16 . Installation is in the reverse order of removal. PRECAUTION (SEE PAGE 60-1 ) DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60-1 ) PLACE FRONT WHEELS FACING STRAIGHT AHEAD REMOVE STEERING WHEEL COVER LOWER NO.3 (SEE PAGE 60-17 ) REMOVE STEERING WHEEL COVER LOWER NO.2 (SEE PAGE 60-17 ) REMOVE HORN BUTTON ASSY (SEE PAGE 60-17 ) REMOVE STEERING WHEEL ASSY (SEE PAGE 50-8 ) SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021) 8. (a) 9. (a) REMOVE STEERING COLUMN COVER LWR Remove the 3 screws and the steering column cover LWR. REMOVE STEERING COLUMN COVER UPR Remove the steering column cover UPR. H44259 10. (a) REMOVE SPIRAL CABLE SUB-ASSY Disconnect the connectors from the spiral cable subassy. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (b) Disengage the 3 claws and remove the spiral cable subassy. : Claw H44302 11. (a) INSPECT SPIRAL CABLE SUB-ASSY If any of the following conditions occur, replace the spiral cable sub-assy with a new one. Condition: Scratches or cracks on the connector Cracks, dents or chips in the spiral cable sub-assy 12. PLACE FRONT WHEELS FACING STRAIGHT AHEAD (a) Check that the front wheels are facing straight ahead. 13. INSTALL SPIRAL CABLE SUB-ASSY (a) Set the turn signal switch to the neutral position. NOTICE: Make sure that the turn signal switch is in the neutral position or the pin of the turn signal switch may be snapped. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3416 60-27 SUPPLEMENTAL RESTRAINT SYSTEM - SPIRAL CABLE SUB-ASSY (b) Install the spiral cable sub-assy with the 3 claws. NOTICE: When replacing the spiral cable sub-assy with a new one, remove the lock pin before installing the steering wheel assy. (c) Connect the connectors to the spiral cable sub-assy. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. 14. INSTALL STEERING COLUMN COVER UPR 15. INSTALL STEERING COLUMN COVER LWR (a) Install the steering column cover LWR with the 3 screws. 16. ADJUST SPIRAL CABLE SUB-ASSY (a) Check that the ignition switch is off. (b) Check that the battery negative (-) terminal is disconnected. CAUTION: After removing the terminal, wait for at least 90 seconds before starting the operation. (c) Turn the spiral cable sub-assy counterclockwise slowly by hand until it feels firm. (d) Rotate the spiral cable sub-assy clockwise approximately 2.5 turns to align the marks. H44260 HINT: The spiral cable sub-assy will rotate approximately 2.5 turns to both the left and right from the center. Marks H44261 17. 18. 19. 20. 21. 22. INSTALL STEERING WHEEL ASSY (SEE PAGE 50-8 ) INSPECT STEERING WHEEL CENTER POINT INSTALL HORN BUTTON ASSY (SEE PAGE 60-17 ) CONNECT BATTERY NEGATIVE TERMINAL INSPECT HORN BUTTON ASSY (SEE PAGE 60-17 ) INSPECT SRS WARNING LIGHT (SEE PAGE 05-1207 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3417 60-28 SUPPLEMENTAL RESTRAINT SYSTEM - FRONT PASSENGER AIRBAG ASSY FRONT PASSENGER AIRBAG ASSY 600KE-05 COMPONENTS Front Passenger Airbag Assy 5.6 (57, 49 in.⋅lbf) 5.6 (57, 49 in.⋅lbf) 20 (204, 15) Instrument Panel Finish Panel Lower No.2 Glove Compartment Door Assy N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque H44262 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3418 60-31 SUPPLEMENTAL RESTRAINT SYSTEM - FRONT PASSENGER AIRBAG ASSY 600T0-01 DISPOSAL HINT: When scrapping a vehicle equipped with the SRS or disposing of the front passenger airbag assy, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION:
Never dispose of a front passenger airbag assy that has an undeployed airbag.
The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents.

SST
H40004


1. When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. When deploying the airbag, perform the operation at least 10 m (33 ft) away from the front passenger airbag assy. The front passenger airbag assy becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a front passenger airbag assy with a deployed airbag. Do not apply water, etc. to a front passenger airbag assy with a deployed airbag. Always wash your hands with water after completing the operation. DISPOSE OF FRONT PASSENGER AIRBAG ASSY (WHEN INSTALLED IN VEHICLE) HINT: Prepare a battery as the power source to deploy the airbag. (a) (b) (c) SST (d) (e) H40004 Check the function of the SST (see step 1-(a) on page 60-19 ). Precaution (see page 60-1 ). Disconnect the battery negative terminal (see page 60-1 ). Remove the glove compartment door assy (see page 71-10 ). Remove the instrument panel finish panel lower No.2 (see page 71-10 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3421 60-32 SUPPLEMENTAL RESTRAINT SYSTEM - FRONT PASSENGER AIRBAG ASSY (f) SST H44267 Install the SST. (1) Disconnect the connector from the front passenger airbag assy. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (2) Connect the SST connector to the front passenger airbag assy. SST 09082-00700, 09082-00780 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. (3) (4) Battery SST 10 m (33 ft) or more H40007 Move the SST at least 10 m (33 ft) away from the vehicle front side window. Maintaining enough clearance for the SST wire harness in the front side window, close all doors and windows of the vehicle. NOTICE: Take care not to damage the SST wire harness. (5) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the negative (-) terminal. (g) Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (33 ft) radius of the vehicle. (2) Press the SST activation switch and deploy the airbag. CAUTION:
When deploying the airbag, make sure that no one is near the vehicle.
The front passenger airbag assy becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a front passenger airbag assy with a deployed airbag.
Do not apply water, etc. to a front passenger airbag assy with a deployed airbag.
Always wash your hands with water after completing the operation. HINT: The airbag is deployed as the LED of the SST activation switch comes on. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3422 60-33 SUPPLEMENTAL RESTRAINT SYSTEM - FRONT PASSENGER AIRBAG ASSY 2. SST H40004 DISPOSE OF FRONT PASSENGER AIRBAG ASSY (WHEN NOT INSTALLED IN VEHICLE) NOTICE:
When disposing of the front passenger airbag assy, never use the customer’s vehicle to deploy the airbag.
Be sure to follow the procedure detailed below when deploying the airbag. HINT: Prepare a battery as the power source to deploy the airbag. (a) Check the function of the SST (see step 1-(a) on page 60-19 ). (b) Remove the front passenger airbag assy (see page 60-29 ). CAUTION:
When removing the front passenger airbag assy, work must be started 90 seconds after the ignition switch is turned to the ”LOCK” position and the negative (-) terminal cable is disconnected from the battery.
When storing the front passenger airbag assy, keep the upper surface of the airbag deployment side facing upward. (c) Install the 2 nuts in the front passenger airbag assy. H44328 (d) Wire Harness Diameter Stripped Wire Harness Section H40008 Using a service-purpose wire harness for the vehicle, tie down the front passenger airbag assy to the tire. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.0019 in.2 or more) CAUTION: If the wire harness is too thin or an alternative object is used to tie down the front passenger airbag assy, it may be snapped by the shock when the airbag is deployed. This is highly dangerous. Always use a wire harness for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3423 60-34 SUPPLEMENTAL RESTRAINT SYSTEM - FRONT PASSENGER AIRBAG ASSY HINT:
To calculate the area of the stripped wire harness section: Area = 3.14 x (Diameter)2 divided by 4
Position the front passenger airbag assy inside the tire with the airbag deployment side facing inside. Tire size: Must exceed the following dimensions Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) CAUTION:
Make sure that the wire harness is tight. If there is slack in wire harness, the front passenger airbag assy may become loose due to the shock when the airbag is deployed. This is highly dangerous.
Always tie down the front passenger airbag assy with the airbag deployment side facing inside the tire. NOTICE: The tire will be marked by the airbag deployment, so use an extra tire. Inner Diameter Width Tire H40311 (e) Install the SST. Connect the SST connector to the front passenger airbag assy. SST 09082-00780 SST H44269 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3424 60-35 SUPPLEMENTAL RESTRAINT SYSTEM - FRONT PASSENGER AIRBAG ASSY (f) Tires (5 or more) H44270 Place the tires. (1) Place at least 2 tires under the tire which the front passenger airbag assy is tied to. (2) Place at least 2 tires over the tire which the front passenger airbag assy is tied to. The top tire should have the disc wheel installed. NOTICE: Do not place the SST connector under the tire because it could be damaged. (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harness is tight. It is highly dangerous when looseness in the wire harness results in the tires coming free due to the shock when the airbag is deployed. H42763 (g) Front Passenger Airbag Assy Battery SST 10 m (33 ft) or more H44271 Install the SST. Connect the SST connector. SST 09082-00700 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire. (h) Deploy the airbag. (1) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the battery negative (-) terminal. (2) Check that no one is within a 10 m (33 ft) radius of the tire which the front passenger airbag assy is tied to. (3) Press the SST activation switch and deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tire. HINT: The airbag is deployed as the LED of the SST activation switch comes on. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3425 60-36 SUPPLEMENTAL RESTRAINT SYSTEM H41436 - FRONT PASSENGER AIRBAG ASSY (i) Dispose of the front passenger airbag assy. CAUTION:
The front passenger airbag assy becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a front passenger airbag assy with a deployed airbag.
Do not apply water, etc. to a front passenger airbag assy with a deployed airbag.
Always wash your hands with water after completing the operation. (1) Remove the front passenger airbag assy from the tire. (2) Place the front passenger airbag assy in a plastic bag, tie it tightly and dispose of it as other general parts disposal. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3426 60-29 SUPPLEMENTAL RESTRAINT SYSTEM - FRONT PASSENGER AIRBAG ASSY 600SZ-01 REPLACEMENT HINT: Installation is in the reverse order of removal. 1. PRECAUTION (SEE PAGE 60-1 ) 2. DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60-1 ) 3. REMOVE GLOVE COMPARTMENT DOOR ASSY (SEE PAGE 71-10 ) 4. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER NO.2 (SEE PAGE 71-10 ) 5. DISCONNECT FRONT PASSENGER AIRBAG ASSY CONNECTOR (a) Disconnect the connector from the front passenger airbag assy. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. H44263 6. (a) (b) REMOVE FRONT PASSENGER AIRBAG ASSY Remove the bolt and the 2 nuts. Remove the front passenger airbag assy. H44264 7. 8. (a) INSPECT FRONT PASSENGER AIRBAG ASSY (SEE PAGE 60-1 1) INSTALL FRONT PASSENGER AIRBAG ASSY Install the front passenger airbag assy with the bolt and the 2 nuts. Torque: Bolt: 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) Nut: 5.6 N⋅m (57 kgf⋅cm, 49 in.⋅lbf) 9. CONNECT FRONT PASSENGER AIRBAG ASSY CONNECTOR (a) Connect the connector to the front passenger airbag assy. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. H44266 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3419 60-30 SUPPLEMENTAL RESTRAINT SYSTEM 10. 11. - FRONT PASSENGER AIRBAG ASSY CONNECT BATTERY NEGATIVE TERMINAL INSPECT SRS WARNING LIGHT (SEE PAGE 05-1207 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3420 60-37 SUPPLEMENTAL RESTRAINT SYSTEM - CURTAIN SHIELD AIR BAG ASSY LH CURTAIN SHIELD AIR BAG ASSY LH 600KH-04 COMPONENTS Curtain Shield Airbag Assy LH 14 (143, 10) 14 (143, 10) 14 (143, 10) 14 (143, 10) 14 (143, 10) N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque H44273 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3427 60-40 SUPPLEMENTAL RESTRAINT SYSTEM - CURTAIN SHIELD AIR BAG ASSY LH 600OD-02 DISPOSAL HINT:


Disposal procedure of the RH side is the same as that for the LH side. The procedures listed below are for the LH side. When scrapping a vehicle equipped with the SRS or disposing of the curtain shield airbag assy LH, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION:
Never dispose of a curtain shield airbag assy LH that has an undeployed airbag.
The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents.

SST
H40004


1. When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. When deploying the airbag, perform the operation at least 10 m (33 ft) away from the curtain shield airbag assy LH. The curtain shield airbag assy LH becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a curtain shield airbag assy LH with a deployed airbag. Do not apply water, etc. to a curtain shield airbag assy LH with a deployed airbag. Always wash your hands with water after completing the operation. DISPOSE OF CURTAIN SHIELD AIR BAG ASSY LH (WHEN INSTALLED IN VEHICLE) HINT: Prepare a battery as the power source to deploy the airbag. (a) (b) (c) SST (d) Check the function of the SST (see step 1-(a) on page 60-19 ). Precaution (see page 60-1 ). Disconnect the battery negative terminal (see page 60-1 ). Remove the roof headlining assy (see page 76-21 ). H40004 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3430 60-41 SUPPLEMENTAL RESTRAINT SYSTEM - CURTAIN SHIELD AIR BAG ASSY LH (e) SST SST H44276 Install the SST. (1) Disconnect the connector from the curtain shield airbag assy LH. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (2) After connecting the SST below to each other, connect them to the curtain shield airbag assy LH. SST 09082- 00700, 09082- 00802 (09082- 10801, 09082-20801) NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. (3) (4) Battery SST 10 m (33 ft) or more H41078 Move the SST at least 10 m (33 ft) away from the vehicle rear side window. Maintaining enough clearance for the SST wire harness in the rear side window, close all doors and windows of the vehicle. NOTICE: Take care not to damage the SST wire harness. (5) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the negative (-) terminal. (f) Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (33 ft) radius of the vehicle. (2) Press the SST activation switch and deploy the airbag. CAUTION:
When deploying the airbag, make sure that no one is near the vehicle.
The curtain shield airbag assy LH becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a curtain shield airbag assy LH with a deployed airbag.
Do not apply water, etc. to a curtain shield airbag assy LH with a deployed airbag.
Always wash your hands with water after completing the operation. HINT: The airbag is deployed as the LED of the SST activation switch comes on. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3431 60-42 SUPPLEMENTAL RESTRAINT SYSTEM - CURTAIN SHIELD AIR BAG ASSY LH 2. DISPOSE OF CURTAIN SHIELD AIR BAG ASSY LH (WHEN NOT INSTALLED IN VEHICLE) NOTICE:
When disposing of the curtain shield airbag assy LH, never use the customer’s vehicle to deploy the airbag.
Be sure to follow the procedure detailed below when deploying the airbag. HINT: Prepare a battery as the power source to deploy the airbag. (a) Check the function of the SST (see step 1-(a) on page 60-19 ). SST (b) H40004 Remove the curtain shield airbag assy LH (see page 60-38 ). CAUTION: When removing the curtain shield airbag assy LH, work must be started 90 seconds after the ignition switch is turned to the ”LOCK” position and the negative (-) terminal cable is disconnected from the battery. (c) Remove the clamp from the curtain shield airbag assy LH. (d) Cut off the deployment section of the curtain shield airbag assy LH. Clamp H44329 H44278 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3432 60-43 SUPPLEMENTAL RESTRAINT SYSTEM - CURTAIN SHIELD AIR BAG ASSY LH (e) Wire Harness Diameter Stripped Wire Harness Section H40008 Width Inner Diameter H44279 Using a service-purpose wire harness for the vehicle, tie down the curtain shield airbag assy LH to the tire. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.0019 in.2 or more) CAUTION: If the wire harness is too thin or an alternative object is used to tie down the curtain shield airbag assy LH, it may be snapped by the shock when the airbag is deployed. This is highly dangerous. Always use a wire harness for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2). HINT:
To calculate the area of the stripped wire harness section: Area = 3.14 x (Diameter)2 divided by 4
Position the curtain shield airbag assy LH inside the tire as shown in the illustration. Tire size: Must exceed the following dimensions Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) CAUTION:
Make sure that the wire harness is tight. If there is slack in wire harness, the curtain shield airbag assy LH may become loose due to the shock when the airbag is deployed. This is highly dangerous. NOTICE: The tire will be marked by the airbag deployment, so use an extra tire. (f) Install the SST. After connecting the SST below to each other, connect them to the curtain shield airbag assy LH. SST 09082-00802 (09082-10801, 09082-20801) SST H44280 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3433 60-44 SUPPLEMENTAL RESTRAINT SYSTEM Tires (5 or more) H44281 - CURTAIN SHIELD AIR BAG ASSY LH (g) Place the tires. CAUTION: Do not place the deployment direction of the curtain shield airbag assy LH facing toward the ground. (1) Place at least 2 tires under the tire which the curtain shield airbag assy LH is tied to. (2) Place at least 2 tires over the tire which the curtain shield airbag assy LH is tied to. The top tire should have the disc wheel installed. NOTICE: Do not place the SST connector under the tire because it could be damaged. (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harness is tight. It is highly dangerous when looseness in the wire harness results in the tires coming free due to the shock when the airbag is deployed. H42763 (h) Curtain Shield Airbag Assy LH Battery SST 10 m (33 ft) or more H44282 Install the SST. Connect the SST connector. SST 09082-00700 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire. (i) Deploy the airbag. (1) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the battery negative (-) terminal. (2) Check that no one is within a 10 m (33 ft) radius of the tire which the curtain shield airbag assy LH is tied to. (3) Press the SST activation switch and deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tire. HINT: The airbag is deployed as the LED of the SST activation switch comes on. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3434 60-45 SUPPLEMENTAL RESTRAINT SYSTEM H42873 - CURTAIN SHIELD AIR BAG ASSY LH (j) Dispose of the curtain shield airbag assy LH. CAUTION:
The curtain shield airbag assy LH becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a curtain shield airbag assy LH with a deployed airbag.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a curtain shield airbag assy LH with a deployed airbag. (1) Remove the curtain shield airbag assy LH from the tire. (2) Place the curtain shield airbag assy LH in a plastic bag, tie it tightly and dispose of it as other general parts disposal. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3435 60-38 SUPPLEMENTAL RESTRAINT SYSTEM - CURTAIN SHIELD AIR BAG ASSY LH 600OC-02 REPLACEMENT HINT:


Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. Installation is in the reverse order of removal. 1. PRECAUTION (SEE PAGE 60-1 ) 2. DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60-1 ) 3. REMOVE ROOF HEADLINING ASSY (SEE PAGE 76-21 ) 4. REMOVE CURTAIN SHIELD AIR BAG ASSY LH (a) Disconnect the connector from the curtain shield airbag assy LH. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (b) Remove the 3 clips. (c) Remove the 9 bolts and the curtain shield airbag assy LH in the order shown in the illustration. 2 3 Clip 1 8 9 Clip 7 6 Clip 5 4 H44274 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3428 60-39 SUPPLEMENTAL RESTRAINT SYSTEM - CURTAIN SHIELD AIR BAG ASSY LH 5. 6. (a) (b) INSPECT CURTAIN SHIELD AIR BAG ASSY LH (SEE PAGE 60-1 1) INSTALL CURTAIN SHIELD AIR BAG ASSY LH Install the curtain shield airbag assy LH with the 9 bolts in the order shown in the illustration. Install the 3 clips. Torque: 14 N⋅m (143 kgf⋅cm, 10 ft⋅lbf) (c) Connect the connector to the curtain shield airbag assy LH. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. 8 7 Clip 1 : RH Side 2 : RH Side 2 : LH Side 1 : LH Side 9 3 4 Clip Clip 5 6 H44274 7. 8. 9. INSTALL ROOF HEADLINING ASSY (SEE PAGE 76-21 ) CONNECT BATTERY NEGATIVE TERMINAL INSPECT SRS WARNING LIGHT (SEE PAGE 05-1207 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3429 60-52 SUPPLEMENTAL RESTRAINT SYSTEM - AIR BAG SENSOR ASSY CENTER AIR BAG SENSOR ASSY CENTER 600KO-05 COMPONENTS 17.5 (179, 13) 17.5 (179, 13) Air Duct Rear No.2 Air Duct Rear No.1 Airbag Sensor Assy Center Floor Carpet Cover Center RH Floor Carpet Cover Center LH Instrument Cluster Finish Panel Assy Center Console Box Assy w/ Rear Seat Entertainment: Box Bottom Mat Rear Console Box Lower N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque H44291 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3442 60-53 SUPPLEMENTAL RESTRAINT SYSTEM - AIR BAG SENSOR ASSY CENTER 600OF-02 REPLACEMENT HINT: Installation is in the reverse order of removal. 1. PRECAUTION (SEE PAGE 60-1 ) 2. DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60-1 ) 3. REMOVE FLOOR CARPET COVER CENTER LH (SEE PAGE 71-10 ) 4. REMOVE FLOOR CARPET COVER CENTER RH (SEE PAGE 71-10 ) 5. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSY CENTER (SEE PAGE 71-10 ) 6. REMOVE REAR CONSOLE BOX LOWER (W/ REAR SEAT ENTERTAINMENT) (SEE PAGE 71-10 ) 7. REMOVE BOX BOTTOM MAT (SEE PAGE 71-10 ) 8. REMOVE CONSOLE BOX ASSY (SEE PAGE 71-10 ) 9. REMOVE AIR DUCT REAR NO.2 (SEE PAGE 55-29 ) 10. REMOVE AIR DUCT REAR NO.1 (SEE PAGE 55-29 ) 11. (a) (b) REMOVE AIR BAG SENSOR ASSY CENTER Disconnect the 3 connectors from the airbag sensor assy center. Remove the 3 bolts and the airbag sensor assy center. H44292 12. INSTALL AIR BAG SENSOR ASSY CENTER (a) Check that the ignition switch is off. (b) Check that the battery negative (-) terminal is disconnected. CAUTION: After removing the terminal, wait for at least 90 seconds before starting the operation. (c) Temporarily install the airbag sensor assy center with the 3 bolts. NOTICE:
If the airbag sensor assy center has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one.
When installing the airbag sensor assy center, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Tighten the 3 bolts to the specified torque. Torque: 17.5 N⋅m (179 kgf⋅cm, 13 ft⋅lbf) (e) Connect the 3 connectors to the airbag sensor assy center. (f) Check that there is no looseness in the installation parts of the airbag sensor assy center. (g) Check that the water-proof sheet is properly set. 13. CONNECT BATTERY NEGATIVE TERMINAL 14. INSPECT SRS WARNING LIGHT (SEE PAGE 05-1207 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3443 60-54 SUPPLEMENTAL RESTRAINT SYSTEM - AIRBAG SENSOR FRONT LH AIRBAG SENSOR FRONT LH 600KQ-06 COMPONENTS RH Headlamp Assy LH Headlamp Assy Airbag Sensor Front LH 9.0 (92, 80 in.⋅lbf) 9.0 (92, 80 in.⋅lbf) Airbag Front RH Sensor Radiator Grille Front Bumper Cover N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque H44293 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3444 60-55 SUPPLEMENTAL RESTRAINT SYSTEM - AIRBAG SENSOR FRONT LH 600KR-06 REPLACEMENT HINT:


1. 2. 3. 4. 5. Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. Installation is in the reverse order of removal. PRECAUTION (SEE PAGE 60-1 ) DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60-1 ) REMOVE FRONT BUMPER COVER (SEE PAGE 76-2 ) REMOVE RADIATOR GRILLE (SEE PAGE 76-2 ) REMOVE LH HEADLAMP ASSY (SEE PAGE 65-10 ) 6. (a) (b) REMOVE AIRBAG SENSOR FRONT LH Disconnect the connector from the airbag sensor front LH. Remove the 2 bolts and the airbag sensor front LH. H44294 7. INSTALL AIRBAG SENSOR FRONT LH (a) Check that the ignition switch is off. (b) Check that the battery negative (-) terminal is disconnected. CAUTION: After removing the terminal, wait for at least 90 seconds before starting the operation. (c) Install the airbag sensor front LH with the 2 bolts. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) NOTICE:
If the airbag sensor front LH has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one.
When installing the airbag sensor front LH, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Connect the connector to the airbag sensor front LH. (e) Check that there is no looseness in the installation parts of the airbag sensor front LH. 8. INSTALL LH HEADLAMP ASSY (SEE PAGE 65-10 ) 9. HEADLIGHT AIM ONLY (SEE PAGE 65-14 ) 10. CONNECT BATTERY NEGATIVE TERMINAL 11. INSPECT SRS WARNING LIGHT (SEE PAGE 05-1207 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3445 60-1 1 SUPPLEMENTAL RESTRAINT SYSTEM - SUPPLEMENTAL RESTRAINT SYSTEM 600SY-01 ON-VEHICLE INSPECTION CAUTION: Be sure to perform the initialization of the occupant classification ECU if any of the following conditions occur (see page 05-1207 ). If the initialization is not performed, the SRS may not operate properly.
The occupant classification ECU is replaced.
Accessories (seatback tray, seat cover, etc.) are installed to the vehicle.
The passenger seat is removed from the vehicle.
Both the SRS warning light and passenger airbag ON/OFF indicator light (”OFF”) come on.
The vehicle is brought to the workshop for repair due to an accident or collision. 1. (a) (b) HORN BUTTON ASSY (VEHICLE NOT INVOLVED IN COLLISION) Perform a diagnostic system check (see page 05-1215 ). With the horn button assy installed on the vehicle, perform a visual check including the following: Cuts, minute cracks or marked discoloration on the horn button assy top surface and in the grooved portion. H44341 2. (a) (b) H40187 HORN BUTTON ASSY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED) Perform a diagnostic system check (see page 05-1215 ). With the horn button assy removed from the vehicle, perform a visual check including the following:
Cuts, minute cracks or marked discoloration on the horn button assy top surface and in the grooved portion.
Cracks or other damage to the connectors.
Deformation of the steering wheel assy.
Deformation of the horn button contact plate of the horn button assy. HINT:
If the horn button contact plate of the horn button assy is deformed, never repair it. Always replace the horn button assy with a new one. Horn Button Contact Plate H44238 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3401 60-12 SUPPLEMENTAL RESTRAINT SYSTEM - SUPPLEMENTAL RESTRAINT SYSTEM
There should be no interference between the horn button assy and steering wheel assy, and the clearance should be uniform all the way around when the new horn button assy is installed on the steering wheel assy. CAUTION: For removal and installation procedures of the horn button assy, see ”Replacement” on page 60-17 , and be sure to follow the correct procedure. H44342 3. (a) (b) FRONT PASSENGER AIRBAG ASSY (VEHICLE NOT INVOLVED IN COLLISION) Perform a diagnostic system check (see page 05-1215 ). With the front passenger airbag assy installed on the vehicle, perform a visual check including the following: Cuts, minute cracks or marked discoloration on the instrument panel around the front passenger airbag assy. H40190 4. (a) (b) H40191 FRONT PASSENGER AIRBAG ASSY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED) Perform a diagnostic system check (see page 05-1215 ). With the front passenger airbag assy removed from the vehicle, perform a visual check including the following:
Cuts, minute cracks or marked discoloration on the front passenger airbag assy.
Cracks or other damage to the connector.
Deformation or cracks on the instrument panel or instrument panel reinforcement. HINT:
If the instrument panel or instrument panel reinforcement is deformed or cracked, never repair it. Always replace it with a new one. H44242
There should be no interference between the instrument panel and the front passenger airbag assy. CAUTION: For removal and installation procedures of the front passenger airbag assy, see ”Replacement” on page 60-29 , and be sure to follow the correct procedure. H44306 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3402 60-13 SUPPLEMENTAL RESTRAINT SYSTEM 5. (a) (b) - SUPPLEMENTAL RESTRAINT SYSTEM FRONT SEAT AIRBAG ASSY (VEHICLE NOT INVOLVED IN COLLISION) Perform a diagnostic system check (see page 05-1215 ). With the front seat airbag assy installed on the vehicle, perform a visual check including the following: Cuts, minute cracks or marked discoloration on the front seatback assy around the front seat airbag assy. H44244 6. (a) (b) H44245 7. (a) (b) FRONT SEAT AIRBAG ASSY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED) Perform a diagnostic system check (see page 05-1215 ). With the front seat airbag assy removed from the vehicle, perform a visual check including the following:
Cuts, minute cracks or marked discoloration on the front seat airbag assy.
Cracks or other damage to the wire harness or connector. CURTAIN SHIELD AIRBAG ASSY (VEHICLE NOT INVOLVED IN COLLISION) Perform a diagnostic system check (see page 05-1215 ). With the curtain shield airbag assy installed on the vehicle, perform a visual check including the following: Cuts, minute cracks or marked discoloration on the front pillar garnish and roof headlining assy around the curtain shield airbag assy. H44246 8. (a) (b) H44247 9. (a) 10. (a) CURTAIN SHIELD AIRBAG ASSY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED) Perform a diagnostic system check (see page 05-1215 ). With the curtain shield airbag assy removed from the vehicle, perform a visual check including the following:
Cuts, minute cracks or marked discoloration on the curtain shield airbag assy.
Cracks or other damage to the connector. AIRBAG SENSOR ASSY CENTER (VEHICLE NOT INVOLVED IN COLLISION) Perform a diagnostic system check (see page 05-1215 ). AIRBAG SENSOR ASSY CENTER (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED) Perform a diagnostic system check (see page 05-1215 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3403 60-14 SUPPLEMENTAL RESTRAINT SYSTEM 11. - SUPPLEMENTAL RESTRAINT SYSTEM AIRBAG SENSOR ASSY CENTER (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) Replace the airbag sensor assy center (see page 60-53 ). (a) HINT: The airbag sensor assy center should be replaced after any of the airbags has deployed, as it has been subjected to the impact. 12. AIRBAG FRONT SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page 05-1215 ). 13. AIRBAG FRONT SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED) (a) Perform a diagnostic system check (see page 05-1215 ). (b) When the front bumper of the vehicle or its periphery is damaged, check if there is any damage to the airbag front sensor. If there are any defects as mentioned below, replace the airbag front sensor with a new one:
Cracks, dents or chips in the case.
Cracks or other damage to the connector.
Peeling off of the label or damage to the serial number. 14. AIRBAG FRONT SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the airbag front sensor (see page 60-55 ). HINT: The airbag front sensor on the impacted side should be replaced after the horn button assy or front passenger airbag assy has deployed. 15. SIDE AIRBAG SENSOR ASSY (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page 05-1215 ). 16. SIDE AIRBAG SENSOR ASSY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED) (a) Perform a diagnostic system check (see page 05-1215 ). (b) When the center pillar of the vehicle or its periphery is damaged, check if there is any damage to the side airbag sensor assy. If there are any defects as mentioned below, replace the side airbag sensor assy with a new one:
Cracks, dents or chips in the case.
Cracks or other damage to the connector.
Peeling off of the label or damage to the serial number. 17. SIDE AIRBAG SENSOR ASSY (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the side airbag sensor assy (see page 60-57 ). HINT: The side airbag sensor assy on the impacted side should be replaced after the front seat airbag assy and curtain shield airbag assy have deployed. 18. AIRBAG SENSOR REAR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page 05-1215 ). 19. AIRBAG SENSOR REAR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED) (a) Perform a diagnostic system check (see page 05-1215 ). (b) When the quarter panel of the vehicle or its periphery is damaged, check if there is any damage to the airbag sensor rear. If there are any defects as mentioned below, replace the airbag sensor rear with a new one:
Cracks, dents or chips in the case.
Cracks or other damage to the connector.
Peeling off of the label or damage to the serial number. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3404 60-15 SUPPLEMENTAL RESTRAINT SYSTEM - SUPPLEMENTAL RESTRAINT SYSTEM 20. AIRBAG SENSOR REAR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) (a) Replace the airbag sensor rear (see page 60-59 ). HINT: The airbag sensor rear on the impacted side should be replaced after the curtain shield airbag assy has deployed. 21. SEAT POSITION AIRBAG SENSOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page 05-1215 ). 22. SEAT POSITION AIRBAG SENSOR (VEHICLE INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page 05-1215 ). (b) Even if the airbag was not deployed, perform a visual check for damage to the seat position airbag sensor including the following:
Cracks, dents or chips in the case.
Cracks or other damage to the connector. 23. OCCUPANT CLASSIFICATION ECU (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page 05-1215 ). 24. OCCUPANT CLASSIFICATION ECU (VEHICLE INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page 05-1215 ). (b) Even if the airbag was not deployed, perform a visual check for damage to the occupant classification ECU including the following:
Cracks, dents or chips in the case.
Cracks or other damage to the connectors. 25. WIRE HARNESS AND CONNECTOR (VEHICLE NOT INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page 05-1215 ). 26. WIRE HARNESS AND CONNECTOR (VEHICLE INVOLVED IN COLLISION) (a) Perform a diagnostic system check (see page 05-1215 ). (b) Check for breaks in all wires of the SRS wire harness and exposed conductors. (c) Check to see if the SRS wire harness connectors are cracked or chipped. HINT: The SRS wire harness is integrated with the engine room main wire, cowl wire, front seat wire RH and floor wire. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3405 60-1 SUPPLEMENTAL RESTRAINT SYSTEM - SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM 600SX-01 PRECAUTION CAUTION:  HIGHLANDER is equipped with SRS, which consists of a driver airbag, front passenger airbag, side airbag and curtain shield airbag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to serious accident. Further, if a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when required. Before performing servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedures indicated in the repair manual.  Wait at least 90 seconds after the ignition switch is turned to the ”LOCK” position and the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source, so that if work is started within 90 seconds after disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.)  Do not expose the horn button assy, front passenger airbag assy, airbag sensor assy center, airbag front sensor, front seat airbag assy, side airbag sensor assy, curtain shield airbag assy, airbag sensor rear, seat position airbag sensor or occupant classification ECU directly to hot air or flames.  Be sure to perform the initialization of the occupant classification ECU if any of the following conditions occur (see page 05-1203 ). If the initialization is not performed, the SRS may not operate properly.  The occupant classification ECU is replaced.  Accessories (seatback tray or seat cover, etc.) are installed to the vehicle.  The passenger seat is removed from the vehicle.  Both the SRS warning light and passenger airbag ON/OFF indicator light (”OFF”) come on.  The vehicle is brought to the workshop for repair due to an accident or collision. NOTICE:  Malfunction symptoms of the SRS are difficult to confirm, so DTCs are the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect DTCs before disconnecting the battery.  Even in the case of a minor collision when the SRS does not deploy, the horn button assy, front passenger airbag assy, airbag sensor assy center, airbag front sensor, front seat airbag assy, side airbag sensor assy, curtain shield airbag assy, airbag sensor rear, seat position airbag sensor and occupant classification ECU should be inspected (see page 60-1 1).  Before repair work, remove the airbag sensor if any kind of shock is likely to occur to the airbag sensor during the operation.  Never use SRS parts from another vehicle. When replacing the parts, replace them with new ones.  Never disassemble or repair the horn button assy, front passenger airbag assy, airbag sensor assy center, airbag front sensor, front seat airbag assy, side airbag sensor assy, curtain shield airbag assy, airbag sensor rear, seat position airbag sensor or occupant classification ECU in order to reuse it.  If the horn button assy, front passenger airbag assy, airbag sensor assy center, airbag front sensor, front seat airbag assy, side airbag sensor assy, curtain shield airbag assy, airbag sensor rear, seat position airbag sensor or occupant classification ECU has been dropped, or if there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3391 60-2 SUPPLEMENTAL RESTRAINT SYSTEM      - SUPPLEMENTAL RESTRAINT SYSTEM Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting the electrical circuits. Information labels are attached to the periphery of the SRS components. Follow the instructions in the caution. After work on the SRS is completed, perform the SRS warning light check (see page 05-1207 ). When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio system as it was before and adjust the clock. Never use a back-up power supply from outside the vehicle to avoid erasing the memory in each memory system. If the vehicle is equipped with a mobile communication system, refer to the precaution in the INTRODUCTION section (see page 01-5 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3392 60-3 SUPPLEMENTAL RESTRAINT SYSTEM - SUPPLEMENTAL RESTRAINT SYSTEM 1. SRS CONNECTORS HINT: SRS connectors are located as shown in the following illustration. 11 Occupant 17 18 Classification ECU 12 31 Airbag Sensor Rear (RH) Curtain Shield Airbag 9 Assy (RH) (Squib) 10 Side Airbag Sensor Assy (RH) 32 29 Seat Belt 7 Pretensioner (RH) 8 30 27 Airbag Front RH Sensor Front Seat Airbag 15 5 16 Assy (RH) (Squib) 6 25 28 Front Passenger 3 Airbag Assy (Squib) 4 Airbag Sensor Assy Center 26 1 2 23 21 3 4 Airbag Sensor Front LH Horn Button Spiral Cable Sub-assy Assy (Squib) 22 27 5 Front Seat Airbag 16 Assy (LH) (Squib) 6 29 Side Airbag Sensor Assy (LH) 24 15 28 Seat Belt 7 Pretensioner (LH) 8 31 Airbag Sensor Rear (LH) 30 Curtain Shield Airbag 9 13 Assy (LH) (Squib) 10 Seat Position 32 19 Airbag Sensor 20 14 H44236 No. Connector Type Application (1) Terminal Twin-Lock Mechanism Connectors 2, 3, 4, 5, 6, 9, 10 (2) Activation Prevention Mechanism Connectors 2, 4, 22, 24, 26, 28, 30, 32 (3) Electrical Connection Check Mechanism Connectors 1, 2 (4) Half Connection Prevention Mechanism Connectors 6, 8, 10, 15, 18, 21, 27, 31 (5) Connector Lock Mechanism Connectors 23, 25, 29 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3393 60-4 SUPPLEMENTAL RESTRAINT SYSTEM (a) Housing (2) Female Male Z05953 SUPPLEMENTAL RESTRAINT SYSTEM All connectors in the SRS are colored yellow to distinguish them from other connectors, except the seat position airbag sensor connector and the occupant classification ECU connector. Some connectors have special functions, and are specially designed for the SRS. These connectors use durable gold-plated terminals, and are placed in the locations shown on the previous page to ensure high reliability. (1) Spacer - Terminal twin-lock mechanism: Each connector has a two-piece component consisting of a housing and a spacer. This design enables the terminal to be locked securely by two locking devices (the retainer and the lance) to prevent terminals from coming out. Activation prevention mechanism: Each connector contains a short spring plate. When the connector is disconnected, the short spring plate automatically connects the positive (+) terminal and the negative (-) terminal of the squib. When Connector is Connected When Connector is Disconnected Short Spring Plate Short Spring Plate Contacting Male Terminal Housing Housing Short Spring Plate ON Terminal Squib Connectors Squib Short Spring Plate Closed Circuit R10587 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3394 60-5 SUPPLEMENTAL RESTRAINT SYSTEM - (3) Disconnection Detection Pin Airbag Sensor Assy Center SUPPLEMENTAL RESTRAINT SYSTEM Electrical connection check mechanism: This mechanism electrically checks that the connectors are connected correctly and completely. The electrical connection check mechanism is designed so that the disconnection detection pin connects with the diagnosis terminals when the connector housing lock is locked. H41646
Half Connection
Complete Connection Terminal for Diagnosis Terminal for Diagnosis Disconnection Detection Pin H01315 (4) Stopper Locking Part Locking Arm Half connection prevention mechanism: If the connector is not completely connected, the connector is disconnected due to the spring operation so that no continuity exists. Spring Slider Stopper Rebounded by Slider (Spring) H40180 C51019 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3395 60-6 SUPPLEMENTAL RESTRAINT SYSTEM (5) - SUPPLEMENTAL RESTRAINT SYSTEM Connector lock mechanism: Locking the connector lock button connects the connector securely. 1.75 Lock Button Claw Groove H40181 (b) Fig.1 Power Source Fig.2 Safing Sensor Squibs When the vehicle is involved in a frontal collision in the hatched area (Fig.1) and the shock is larger than the predetermined level, the SRS is activated automatically. The safing sensor is designed to go on at a smaller deceleration rate than the airbag sensor. As illustrated in Fig.2, ignition is caused when current flows to the squib, which happens when the safing sensor and the deceleration sensor go on simultaneously. When a deceleration force acts on the sensors, 2 squibs in the driver airbag and front passenger airbag ignite and generate gas. The gas discharging into the driver airbag and front passenger airbag rapidly increases the pressure inside the bags, breaking the horn button assy and instrument panel. The deployment of the bags then ends, and the bags deflate as the gas is discharged through discharge holes at the bag’s rear or side. Deceleration Sensor Z14034 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3396 60-7 SUPPLEMENTAL RESTRAINT SYSTEM 2. (a) (b) - SUPPLEMENTAL RESTRAINT SYSTEM DISCONNECTION OF CONNECTORS FOR HORN BUTTON ASSY AND CURTAIN SHIELD AIRBAG ASSY Release the lock button (yellow part) of the connector using a screwdriver. Insert the screwdriver tip between the connector and the base, and then raise the connector. (a) Lock Button (Yellow Part) Lock Button (Yellow Part) (b) H42906 3. (a) (b) CONNECTION OF CONNECTORS FOR HORN BUTTON ASSY AND CURTAIN SHIELD AIRBAG ASSY Connect the connector. Push down securely on the lock button (yellow part) of the connector. (When locking, a click sound can be heard.) Lock Button (Yellow Part) H43151 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3397 60-8 SUPPLEMENTAL RESTRAINT SYSTEM 4. (a) (b) (c) - SUPPLEMENTAL RESTRAINT SYSTEM DISCONNECTION OF CONNECTOR FOR FRONT SEAT AIRBAG ASSY Place a finger on the slider. Slide the slider to release lock. Disconnect the connector. Slider Slider Disconnection is completed H01584 5. (a) CONNECTION OF CONNECTOR FOR FRONT SEAT AIRBAG ASSY Connect the connector as shown in the illustration. (When locking, make sure that the slider returns to its original position and a click sound can be heard.) HINT: When connecting, the slider will slide. Be sure not to touch the slider while connecting, as it may result in an insecure fit. Slider Slider Connection is completed H43169 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3398 60-9 SUPPLEMENTAL RESTRAINT SYSTEM 6. (a) (b) (c) - SUPPLEMENTAL RESTRAINT SYSTEM DISCONNECTION OF CONNECTOR FOR FRONT PASSENGER AIRBAG ASSY Place a finger on the slider. Slide the slider to release lock. Disconnect the connector. Slider Slider Disconnection is completed H01586 7. (a) CONNECTION OF CONNECTOR FOR FRONT PASSENGER AIRBAG ASSY Connect the connector as shown in the illustration. (When locking, make sure that the slider returns to its original position and a click sound can be heard.) HINT: When connecting, the slider will slide. Be sure not to touch the slider while connecting, as it may result in an insecure fit. Slider Slider Connection is completed H43731 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3399 60-10 SUPPLEMENTAL RESTRAINT SYSTEM 8. Outer (a) (b) H02763 - SUPPLEMENTAL RESTRAINT SYSTEM DISCONNECTION OF CONNECTORS FOR AIRBAG FRONT SENSOR, SIDE AIRBAG SENSOR AND AIRBAG SENSOR REAR While holding both outer flank sides, slide the outer in the direction shown by the arrow. When the connector lock is released, the connectors are disconnected . HINT: Be sure to hold both outer flank sides. Holding the top and bottom sides will make disconnection difficult. Connector lock is released Disconnection is completed H02764 9. (a) CONNECTION OF CONNECTORS FOR AIRBAG FRONT SENSOR, SIDE AIRBAG SENSOR AND AIRBAG SENSOR REAR Connect the connector as shown in the illustration. (When locking, make sure that the outer returns to its original position and a click sound can be heard.) HINT: When connecting, the outer will slide. Be sure not to hold the outer while connecting, as it may result in an insecure fit. Outer Outer Connection is completed H02768 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3400 60-58 SUPPLEMENTAL RESTRAINT SYSTEM - AIR BAG SENSOR REAR LH AIR BAG SENSOR REAR LH 600KU-06 COMPONENTS Deck Side Trim Cover LH Airbag Sensor Rear LH Deck Trim Side Panel Assy LH 17.5 (179, 13) Rope Hook Deck Side Trim Box LH Rope Hook Deck Floor Box Rear Deck Side Trim Box RH Tonneau Cover Assy N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque Rear Floor Finish Plate H44408 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3448 60-59 SUPPLEMENTAL RESTRAINT SYSTEM - AIR BAG SENSOR REAR LH 6009I-12 REPLACEMENT HINT:


1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. Installation is in the reverse order of removal. PRECAUTION (SEE PAGE 60-1 ) DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60-1 ) REMOVE TONNEAU COVER ASSY (SEE PAGE 76-21 ) REMOVE DECK FLOOR BOX REAR (SEE PAGE 76-21 ) REMOVE REAR FLOOR FINISH PLATE (SEE PAGE 76-21 ) REMOVE DECK SIDE TRIM BOX LH (SEE PAGE 76-21 ) REMOVE DECK SIDE TRIM BOX RH (SEE PAGE 76-21 ) REMOVE DECK SIDE TRIM COVER LH (SEE PAGE 76-21 ) REMOVE ROPE HOOK (SEE PAGE 76-21 ) REMOVE DECK TRIM SIDE PANEL ASSY LH (SEE PAGE 76-21 ) 11. (a) (b) REMOVE AIR BAG SENSOR REAR LH Disconnect the connector from the airbag sensor rear LH. Remove the 2 bolts and the airbag sensor rear LH. H44298 12. INSTALL AIR BAG SENSOR REAR LH (a) Check that the ignition switch is off. (b) Check that the battery negative (-) terminal is disconnected. CAUTION: After removing the terminal, wait for at least 90 seconds before starting the operation. (c) Install the airbag sensor rear LH with the 2 bolts. Torque: 17.5 N⋅m (179 kgf⋅cm, 13 ft⋅lbf) NOTICE:
If the airbag sensor rear LH has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one.
When installing the airbag sensor rear LH, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Connect the connector to the airbag sensor rear LH. (e) Check that there is no looseness in the installation parts of the airbag sensor rear LH. 13. CONNECT BATTERY NEGATIVE TERMINAL 14. INSPECT SRS WARNING LIGHT (SEE PAGE 05-1207 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3449 60-56 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIR BAG SENSOR ASSY LH SIDE AIR BAG SENSOR ASSY LH 600T2-01 COMPONENTS Rear Door Weatherstrip LH 17.5 (179, 13) Side Airbag Sensor Assy LH Front Door Weatherstrip LH 17.5 (179, 13) 7.5 (75, 67 in.⋅lbf) Rear Door Scuff Plate LH Front Seat Outer Belt Assy LH 42 (430, 31) Center Pillar Garnish Lower LH Front Door Scuff Plate LH N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque H44295 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3446 60-57 SUPPLEMENTAL RESTRAINT SYSTEM - SIDE AIR BAG SENSOR ASSY LH 600T3-01 REPLACEMENT HINT:


1. 2. 3. 4. 5. 6. 7. 8. Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. Installation is in the reverse order of removal. PRECAUTION (SEE PAGE 60-1 ) DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60-1 ) REMOVE REAR DOOR SCUFF PLATE LH (SEE PAGE 76-21 ) REMOVE FRONT DOOR SCUFF PLATE LH (SEE PAGE 76-21 ) REMOVE REAR DOOR WEATHERSTRIP LH (SEE PAGE 76-21 ) REMOVE FRONT DOOR WEATHERSTRIP LH (SEE PAGE 76-21 ) REMOVE CENTER PILLAR GARNISH LOWER LH (SEE PAGE 76-21 ) REMOVE FRONT SEAT OUTER BELT ASSY LH (SEE PAGE 61-4 ) 9. (a) (b) REMOVE SIDE AIR BAG SENSOR ASSY LH Disconnect the connector from the side airbag sensor assy LH. Remove the 3 bolts and the side airbag sensor assy LH. H44296 10. INSTALL SIDE AIR BAG SENSOR ASSY LH (a) Check that the ignition switch is off. (b) Check that the battery negative (-) terminal is disconnected. CAUTION: After removing the terminal, wait for at least 90 seconds before starting the operation. (c) Install the side airbag sensor assy LH with the 3 bolts. Torque: 17.5 N⋅m (179 kgf⋅cm, 13 ft⋅lbf) NOTICE:
If the side airbag sensor assy LH has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one.
When installing the side airbag sensor assy LH, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. (d) Connect the connector to the side airbag sensor assy LH. (e) Check that there is no looseness in the installation parts of the side airbag sensor assy LH. 11. CONNECT BATTERY NEGATIVE TERMINAL 12. INSPECT SRS WARNING LIGHT (SEE PAGE 05-1207 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3447 60-60 SUPPLEMENTAL RESTRAINT SYSTEM - SEAT POSITION AIR BAG SENSOR SEAT POSITION AIR BAG SENSOR 600KV-07 COMPONENTS Slide & Vertical Power Seat Switch Knob Front LH Seat Assy Power Seat: Reclining Power Seat Switch Knob 36.7 (374, 27) Front Seat Cushion Shield Assy 36.7 (374, 27) 36.7 (374, 27) Manual Seat: Seat Slide Position Sensor Protector Front Seat Cushion Shield Inner RH Torx Screw 8.0 (82, 71 in.⋅lbf) Seat Position Airbag Sensor N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque H44299 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3450 60-61 SUPPLEMENTAL RESTRAINT SYSTEM - SEAT POSITION AIR BAG SENSOR 600OI-05 REPLACEMENT HINT: Installation is in the reverse order of removal. 1. PRECAUTION (SEE PAGE 60-1 ) 2. DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60-1 ) 3. REMOVE FRONT LH SEAT ASSY (SEE PAGE 72-1 1 (POWER SEAT) OR 72-19 (MANUAL SEAT)) 4. REMOVE SLIDE & VERTICAL POWER SEAT SWITCH KNOB (POWER SEAT) (SEE PAGE 72-1 1) 5. REMOVE RECLINING POWER SEAT SWITCH KNOB (POWER SEAT) (SEE PAGE 72-1 1) 6. REMOVE FRONT SEAT CUSHION SHIELD ASSY (POWER SEAT) (SEE PAGE 72-1 1) 7. REMOVE FRONT SEAT CUSHION SHIELD INNER RH (MANUAL SEAT) (SEE PAGE 72-19 ) 8. (a) 9. (a) (b) REMOVE SEAT SLIDE POSITION SENSOR PROTECTOR Remove the seat slide position sensor protector from the seat position airbag sensor. REMOVE SEAT POSITION AIR BAG SENSOR Disconnect the connector from the seat position airbag sensor. Using a torx socket wrench (T30), remove the torx screw and the seat position airbag sensor. Seat Slide Position Sensor Protector Seat Position Airbag Sensor Torx Screw H44300 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3451 60-62 SUPPLEMENTAL RESTRAINT SYSTEM - SEAT POSITION AIR BAG SENSOR 10. (a) (b) INSTALL SEAT POSITION AIR BAG SENSOR Check that the ignition switch is off. Check that the battery negative (-) terminal is disconnected. CAUTION: After removing the terminal, wait for at least 90 seconds before starting the operation. Using a feeler gauge 1 mm (0.039 in.), install the seat position airbag sensor. NOTICE:
If the seat position airbag sensor has been dropped, or there are any cracks, dents or other defects in the 1 mm case, bracket or connector, replace the seat position airbag sensor with a new one.
When installing the seat position airbag sensor, be Seat Rail careful that the SRS wiring does not interfere with H44333 other parts and that it is not pinched between other parts. HINT: Be sure to maintain a clearance between the seat position airbag sensor and the seat rail is within 0.6 mm (0.023 in.) to 2 mm (0.079 in.). (d) Using a torx socket wrench (T30), tighten the torx screw to install the seat position airbag sensor. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) (e) Make sure that a clearance between the seat position airbag sensor and the seat rail is within 0.6 mm (0.023 in.) to 2 mm (0.079 in.). (f) Connect the connector to the seat position airbag sensor. (g) Check that there is no looseness in the installation parts of the seat position airbag sensor. INSTALL FRONT LH SEAT ASSY (SEE PAGE 72-1 1 (POWER SEAT) OR 72-19 (MANUAL SEAT)) CONNECT BATTERY NEGATIVE TERMINAL INSPECT SRS WARNING LIGHT (SEE PAGE 05-1207 ) Seat Position Airbag Sensor 11. 12. 13. (c) Feeler Gauge 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3452 60-46 SUPPLEMENTAL RESTRAINT SYSTEM - FRONT SEAT AIRBAG ASSY LH FRONT SEAT AIRBAG ASSY LH 600OE-02 DISPOSAL HINT:


Disposal procedure of the RH side is the same as that for the LH side. The procedures listed below are for the LH side. When scrapping a vehicle equipped with the SRS or disposing of the front seat airbag assy LH, be sure to deploy the airbag first in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION:
Never dispose of a front seat airbag assy LH that has an undeployed airbag.
The airbag produces an exploding sound when it is deployed, so perform the operation outdoors and where it will not create a nuisance to nearby residents.

SST
H40004


1. When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. When deploying the airbag, perform the operation at least 10 m (33 ft) away from the airbag assy. The front seat airbag assy LH becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment. Use gloves and safety glasses when handling a front seat airbag assy LH with a deployed airbag. Always wash your hands with water after completing the operation. Do not apply water, etc. to a front seat airbag assy LH with a deployed airbag. DISPOSE OF FRONT SEAT AIRBAG ASSY LH (WHEN INSTALLED IN VEHICLE) HINT: Prepare a battery as the power source to deploy the airbag. (a) (b) (c) SST (d) H40004 Check the function of the SST (see step 1- (a) on page 60-19 ). Precaution (see page 60-1 ). Disconnect the battery negative terminal (see page 60-1 ). Remove the 4 bolts from the front seat assy LH (see page 72-1 1 (power seat) or 72-19 (manual seat)). HINT: Keep the front seat assy LH in the cabin. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3436 60-47 SUPPLEMENTAL RESTRAINT SYSTEM - FRONT SEAT AIRBAG ASSY LH (e) SST H44284 Install the SST. (1) Disconnect the connector (yellow colored one) from the front seat airbag assy LH. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (2) Connect the SST connector to the front seat airbag connector. SST 09082-00700, 09082-00750 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. (3) Install the 4 bolts to the front seat assy LH. Torque: 36.7 N⋅m (374 kgf⋅cm, 27 ft⋅lbf) (4) Battery (5) SST 10 m (33 ft) or more H40007 Move the SST at least 10 m (33 ft) away from the vehicle front side window. Maintaining enough clearance for the SST wire harness in the front side window, close all doors and windows of the vehicle. NOTICE: Take care not to damage the SST wire harness. (6) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the battery negative (-) terminal. (f) Deploy the airbag. (1) Check that no one is inside the vehicle or within a 10 m (33 ft) radius of the vehicle. (2) Press the SST activation switch and deploy the airbag. CAUTION:
When deploying the airbag, make sure that no one is near the vehicle.
The front seat airbag assy LH becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a front seat airbag assy LH with a deployed airbag.
Do not apply water, etc. to a front seat airbag assy LH with a deployed airbag.
Always wash your hands with water after completing the operation. HINT: The airbag is deployed as the LED of the SST activation switch comes on. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3437 60-48 SUPPLEMENTAL RESTRAINT SYSTEM - FRONT SEAT AIRBAG ASSY LH 2. DISPOSE OF FRONT SEAT AIRBAG ASSY LH (WHEN NOT INSTALLED IN VEHICLE) NOTICE:
When disposing of the front seat airbag assy LH, never use the customer’s vehicle to deploy the airbag.
Be sure to follow the procedure detailed below when deploying the airbag. HINT: Prepare a battery as the power source to deploy the airbag. (a) SST H40004 Wire Harness Diameter Stripped Wire Harness Section H40008 Check the function of the SST (see step 1- (a) on page 60-19 ). (b) Remove the front seat airbag assy LH. (1) Remove the front seat assy LH (see page 72-1 1 (power seat) or 72-19 (manual seat)). (2) Remove the 2 nuts and the front seat airbag assy LH from the seatback assy. CAUTION:
When removing the front seat airbag assy LH, work must be started 90 seconds after the ignition switch is turned to the ”LOCK” position and the negative (-) terminal cable is disconnected from the battery.
When storing the front seat airbag assy LH, keep the upper surface of the airbag deployment side facing upward. (c) Using a service-purpose wire harness for the vehicle, tie down the front seat airbag assy LH. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.0019 in.2 or more) HINT: To calculate the area of the stripped wire harness section: Area = 3.14 x (Diameter)2 divided by 4 CAUTION: If the wire harness is too thin or an alternative object is used to tie down the front seat airbag assy LH, it may be snapped by the shock when the airbag is deployed. This is highly dangerous. Always use a wire harness for vehicle use with an area of at least 1.25 mm2 (0.0019 in.2). (1) Install the 2 nuts in the front seat airbag assy LH. H44285 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3438 60-49 SUPPLEMENTAL RESTRAINT SYSTEM - (2) FRONT SEAT AIRBAG ASSY LH Wind the wire harness around the stud bolts of the front seat airbag assy LH as shown in the illustration. H44286 (3) Width Inner Diameter H44287 Position the front seat airbag assy LH inside the tire with the airbag deployment direction facing inside. Tire size: Must exceed the following dimensions Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) CAUTION:
Make sure that the wire harness is tight. If there is slack in wire harness, the front seat airbag assy LH may become loose due to the shock when the airbag is deployed. This is highly dangerous.
Always tie down the front seat airbag assy LH with the airbag deployment direction facing inside the tire. NOTICE: The tire will be marked by the airbag deployment, so use an extra tire. (d) Install the SST. (1) Connect the SST connector to the front seat airbag assy LH connector. SST 09082-00750 SST H44288 (e) Tires (5 or more) H42898 Place the tires. (1) Place at least 2 tires under the tire which the front seat airbag assy LH is tied to. (2) Place at least 2 tires over the tire which the front seat airbag assy LH is tied to. The top tire should have the disc wheel installed. NOTICE: Do not place the SST connector under the tire because it could be damaged. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3439 60-50 SUPPLEMENTAL RESTRAINT SYSTEM - FRONT SEAT AIRBAG ASSY LH (3) Tie the tires together with 2 wire harnesses. CAUTION: Make sure that the wire harness is tight. It is highly dangerous when looseness in the wire harness results in the tires coming free due to the shock when the airbag is deployed. H42763 (f) Front Seat Airbag Assy LH Battery SST 10 m (33 ft) or more H01337 Install the SST. Connect the SST connector. SST 09082-00700 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the tire. (g) Deploy the airbag. (1) Connect the red clip of the SST to the battery positive (+) terminal and the black clip of the SST to the battery negative (-) terminal. (2) Check that no one is within a 10 m (33 ft) radius of the tire which the front seat airbag assy LH is tied to. (3) Press the SST activation switch and deploy the airbag. CAUTION: When deploying the airbag, make sure that no one is near the tire. HINT: The airbag is deployed as the LED of the SST activation switch comes on. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3440 60-51 SUPPLEMENTAL RESTRAINT SYSTEM H00544 - FRONT SEAT AIRBAG ASSY LH (h) Dispose of the front seat airbag assy LH. CAUTION:
The front seat airbag assy LH becomes extremely hot when the airbag is deployed, so do not touch it for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a front seat airbag assy LH with a deployed airbag.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a front seat airbag assy LH with a deployed airbag. (1) Remove the front seat airbag assy LH from the tire. (2) Place the front seat airbag assy LH in a plastic bag, tie it tightly and dispose of it as other general parts disposal. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3441 60-63 SUPPLEMENTAL RESTRAINT SYSTEM - OCCUPANT CLASSIFICATION ECU OCCUPANT CLASSIFICATION ECU 600KX-06 COMPONENTS Front RH Seat Assy 36.7 (374, 27) 36.7 (374, 27) Occupant Classification ECU N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque H44301 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3453 60-64 SUPPLEMENTAL RESTRAINT SYSTEM - OCCUPANT CLASSIFICATION ECU 600T1-01 REPLACEMENT HINT: Installation is in the reverse order of removal. 1. PRECAUTION (SEE PAGE 60-1 ) 2. DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60-1 ) 3. REMOVE FRONT RH SEAT ASSY (SEE PAGE 72-1 1 (POWER SEAT) OR 72-19 (MANUAL SEAT)) 4. (a) (b) REMOVE OCCUPANT CLASSIFICATION ECU Disconnect the 2 connectors from the occupant classification ECU. Using a screwdriver, remove the occupant classification ECU. H44303 5. INSTALL OCCUPANT CLASSIFICATION ECU (a) Check that the ignition switch is off. (b) Check that the battery negative (-) terminal is disconnected. CAUTION: After removing the terminal, wait for at least 90 seconds before starting the operation. (c) Install the occupant classification ECU. (d) Connect the 2 connectors to the occupant classification ECU. NOTICE:
If the occupant classification ECU has been dropped, or there are cracks, dents or other defects in the case, bracket or connector, replace it with a new one.
When installing the occupant classification ECU, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts. 6. INSTALL FRONT RH SEAT ASSY (SEE PAGE 72-1 1 (POWER SEAT) OR 72-19 (MANUAL SEAT)) 7. CONNECT BATTERY NEGATIVE TERMINAL 8. INSPECT SRS WARNING LIGHT (SEE PAGE 05-1207 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3454 61-3 SEAT BELT - FRONT SEAT BELT FRONT SEAT BELT 610JU-01 COMPONENTS Front Door Opening Trim Weatherstrip RH Rear Door Opening trim Weatherstrip RH 42 (428, 31) Shoulder Anchor Cover Rear Door Scuff Plate RH 42 (428, 31) Center Pillar Garnish Lower RH 7.5 (77, 66 in. ⋅lbf) 42 (428, 31) Front Door Scuff Plate RH Floor Anchor Cover Manual Seat Type Power Seat Type 42 (428, 31) 42 (428, 31) Front Seat Inner Belt Assy RH Front Seat Inner Belt Assy RH N⋅m (kgf⋅cm ft⋅lbf) : Specified torque B77526 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3457 61-8 SEAT BELT - FRONT SEAT BELT 610JW-01 DISPOSAL HINT: When scrapping vehicles equipped with a seat belt pretensioner or disposing of a front seat outer belt (with seat belt pretensioner), always first activate the seat belt pretensioner in accordance with the procedures described below. If any abnormality occurs during activation of the seat belt pretensioner, contact the SERVICE DEPARTMENT of TOYOTA MOTOR SALES, U.S.A., INC. When disposing of a front seat outer belt assy (with seat belt pretensioner) that was activated in a collision, start with step 1-(f) in this section. SST B50515 CAUTION:
Never dispose of a front seat outer belt assy that has an inactivated pretensioner.
The seat belt pretensioner produces a loud, exploding sound when it activates. Perform the operation where it will not be a nuisance to nearby residents.
When activating a front seat outer belt (with seat belt pretensioner), stand at least 10 m (33 ft) away from the front seat outer belt.
Use gloves and safety glasses when handling a front seat belt with an activated pretensioner.
Always wash your hands with water after completing activation.
Do not apply water to a front seat outer belt that has an activated pretensioner
When activating the seat belt pretensioner, always use the specified SST (SRS airbag deployment tool).
Perform operation in a place away from electrical interference. SST 09082-00700 1. DISPOSE OF FRONT SEAT OUTER BELT ASSY RH (WHEN INSTALLED IN VEHICLE) HINT: Prepare a battery to power activation of the seat belt pretensioner. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3462 61-9 SEAT BELT - FRONT SEAT BELT (a) Check if SST is functioning. CAUTION: When activating the seat belt pretensioner, always use the specified SST. SST 09082-00700, 09082-00770 SST B50515 (1) Connect SST red clip to the battery’s positive (+) terminal and the black clip to the negative (-) terminal. HINT: Do not connect the yellow connector. The yellow connector is used to connect to the seat belt pretensioner. Battery SST B50511 (2) SST B50514 Press SST activation switch and check that the LED of SST activation switch turn on. CAUTION: If the LED turns on when the activation switch is not being pressed, SST may be malfunctioning. Do not use SST. (b) Disconnect SST from the battery. (c) Disconnect the pretensioner connector. (1) Disconnect the battery’s negative (-) terminal. (2) Check the SRS airbag system (see page 60-53 ). (3) Remove the front door scuff plate RH (see page 76-21 ). (4) Remove the rear door scuff plate RH (see page 76-21 ). (5) Remove the front door opening trim weatherstrip RH (see page 76-21 ). (6) Remove the rear door opening trim weatherstrip RH (see page 76-21 ). (7) Remove the center pillar garnish lower RH (see page 76-21 ). (8) Remove the center pillar garnish upper RH (see page 76-21 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3463 61-10 SEAT BELT - FRONT SEAT BELT (9) (d) Disconnect the pretensioner connector, as shown in the illustration. Connect SST. (1) Install the floor anchor of the seat belt. B61489 B60414 (2) SST Connect 2 SSTs, then connect the yellow connector to the seat belt pretensioner. SST 09082-00700, 09082-00770 NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. SST B51763 (3) (4) 10 m or more B50513 Move SST at least 10 m (33 ft) away from the front of the vehicle. Close all the doors and windows of the vehicle. HINT: Do not close the windows fully. Leave a gap for inserting SST wire harness. NOTICE: Take care not to damage SST wire harness. (5) Connect SST red clip to the battery’s positive (+) terminal and the black clip to the negative (-) terminal. (e) Activate the seat belt pretensioner. (1) Confirm that no one is inside the vehicle or within 10 m (33 ft) of the vehicle. (2) Press SST activation switch and activate the seat belt pretensioner. HINT: The seat belt pretensioner operates simultaneously with the LED light for SST activation switch. (f) Dispose of the outer belt (with the seat belt pretensioner). CAUTION:
Do not touch the outer belt for at least 30 minutes after the seat belt pretensioner has been activated. It is very hot.
Use gloves and safety glasses when handling an outer belt with a pretensioner that has been activated.
Always wash your hands with water after completing the operation.
Do not apply water to a front seat outer belt that has an activated pretensioner 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3464 61-1 1 SEAT BELT - FRONT SEAT BELT HINT: When scrapping a vehicle, activate the seat belt pretensioner, and then scrap the vehicle with the activated outer belt installed. 2. DISPOSE OF FRONT SEAT OUTER BELT ASSY RH (WHEN NOT INSTALLED IN VEHICLE) NOTICE:
When disposing of the front seat outer belt (with the seat belt pretensioner) only, never use the customer’s vehicle to activate the seat belt pretensioner.
Be sure to follow the procedures listed below when activating the seat belt pretensioner. HINT: Prepare a battery as the power source to activate the seat belt pretensioner. (a) Cut Here B79201 Remove the outer belt (see page 61-4 ). (1) Wind the seat belt with the retractor. (2) When the seat belt is sufficiently wound, cut the seat belt approximately 10 cm from the retractor, as shown in the illustration HINT: The seat belt is designed so that winding the seat belt as much as possible before pretensioner activation will decrease the pulling power of the seat belt during pretensioner activation. (b) Check if SST is functioning (see step 1-(a)). CAUTION: When activating the seat belt pretensioner, always use the specified SST. SST 09082-00700, 09082-00770 Battery SST B50511 (c) SST Connect SST. (1) Connect SST, then connect them to the seat belt pretensioner. NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. SST B51763 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3465 61-12 SEAT BELT (2) - FRONT SEAT BELT Place the outer belt on the ground and cover it with a tire with a wheel attached. NOTICE: Set up the front seat outer belt assy as shown in the illustration. SST SST B69491 (3) 10 m or More B50541 Move the SST at least 10 m (33 ft) away from the wheel. NOTICE: Take care not to damage the SST wire harness. (d) Activate the seat belt pretensioner. (1) Connect SST red clip to the battery’s positive (+) terminal and the black clip to the battery’s negative (-) terminal. (2) Check that no one is within 10 m (33 ft) of the wheel. (3) Press SST activation switch and activate the seat belt pretensioner. HINT: The seat belt pretensioner operates simultaneously with the LED light for SST activation switch. (e) Dispose of the outer belt (with the seat belt pretensioner). CAUTION:
Do not touch the outer belt for at least 30 minutes after the seat belt pretensioner has been activated. It is very hot.
Use gloves and safety glasses when handling an outer belt assy with a pretensioner that has been activated.
Always wash your hands with water after completing operation.
Do not apply water to an outer belt assy that has an activated pretensioner. (1) Remove the wheel and SST. (2) Place the outer belt in a plastic bag, tie the end tightly and dispose of it in the same way as other general parts. B60422 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3466 61-4 SEAT BELT - FRONT SEAT BELT 610JV-03 REPLACEMENT HINT:



The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. Use the same procedures for the RH side and LH side. The procedures listed below are for the RH side. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). 1. Manual seat type: REMOVE FRONT SEAT INNER BELT ASSY RH CAUTION:
Removal of the seat belt pretensioner must be started at least 90 seconds after the ignition switch is turned OFF and the negative (-) terminal cable is disconnected from the battery.
Carefully read the notices for the ”pretensioner” in the SRS airbag system section and the front seat outer belt section (see page 60-1 ). (a) Remove the front seat RH (see page 72-1 1). (b) Remove the front seat cushion shield inner RH (see page 72-1 1). (c) Remove the front seat inner belt RH. (1) Disconnect the connector and clamp. (2) Remove the nut and belt. (d) Protruding Part B78495 Install the front seat inner belt RH. (1) Install the belt with the nut. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) NOTICE: Do not allow the anchor part of the front belt and the protruding part of the floor panel to overlap. (e) Connect the clamp and connector. (f) Connect the battery’s negative battery terminal. (g) Initialize the occupant classification sensor (see page 72-1 1 or 72-19 ). (h) Check the SRS warning lamp (see page 60-1 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3458 61-5 SEAT BELT - FRONT SEAT BELT 2. Power seat type: REMOVE FRONT SEAT INNER BELT ASSY RH CAUTION:
Removal of the seat belt pretensioner must be started at least 90 seconds after the ignition switch is turned OFF and the negative (-) terminal cable is disconnected from the battery.
Carefully read the notices for the ”pretensioner” in the SRS airbag system section and the front seat outer belt section (see page 60-1 ). (a) Remove the front seat assy RH (see page 72-1 1). (b) Remove the power seat switch knobs (see page 72-1 1). (c) Disconnect the connector and clamp. (d) Remove the nut and belt. (e) Protruding Part B77530 Install the belt with the nut. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) NOTICE: Do not allow the anchor part of the front belt and the protruding part of the floor panel to overlap. (f) Connect the clamp and connector. (g) Connect the battery’s negative battery terminal. (h) Initialize the occupant classification sensor (see page 72-1 1 or 72-19 ). (i) Check the SRS warning lamp (see page 60-1 ). 3. REMOVE FRONT SEAT OUTER BELT ASSY RH CAUTION:
Removal of the seat belt pretensioner must be started at least 90 seconds after the ignition switch is turned OFF and the negative (-) terminal cable is disconnected from the battery.
Carefully read the notices for the ”pretensioner” in the SRS airbag system section and the front seat outer belt section (see page 60-1 ). (a) Remove the front door scuff plate RH (see page 76-21 ). (b) Remove the rear door scuff plate RH (see page 76-21 ). (c) Remove the front door opening trim weatherstrip (see page 76-21 ). (d) Remove the rear door opening trim weatherstrip (see page 76-21 ). (e) Remove the center pillar garnish lower RH (see page 76-21 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3459 61-6 SEAT BELT (f) - FRONT SEAT BELT Remove the front seat outer belt assy RH. (1) Using a screwdriver, disengage the 4 claws and remove the shoulder belt anchor cover. HINT: Tape the screwdriver tip before use. (2) Remove the bolt and shoulder anchor. Claw Protective Tape B78496 (3) Claw Using a screwdriver, disengage the 2 claws and remove the floor belt anchor cover. HINT: Tape the screwdriver tip before use. B77537 (4) (5) B61489 B60414 Unlock (g) 45 Lock B60413 Disconnect the pretensioner connector, as shown in the illustration. Remove the 2 bolts and outer belt. B61488 Install the front seat outer belt assy RH. (1) Check the amount of inclination required to lock the retractor.
When the inclination of the retractor is 15 or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45, check that the belt locks. NOTICE: Do not disassemble the retractor. If operation is not as specified, replace the outer belt assy. (2) Install the front seat outer belt assy RH. Torque: 7.5 N⋅m (77 kgf⋅cm, 66 in.⋅lbf) for upper bolt 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) for lower bolt 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3460 61-7 SEAT BELT - FRONT SEAT BELT (3) (h) (i) B78597 (j) (k) (l) (m) (n) (o) (p) Connect the pretensioner connector, as shown in the illustration. (4) Install the shoulder belt anchor to the shoulder belt anchor adjuster with the bolt. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) Install the center pillar garnish lower. Install the floor anchor to the front seat with the bolt. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) Install the front door scuff plate. Install the rear door scuff plate. Install the front door opening trim weatherstrip. Install the rear door opening trim weatherstrip. Connect the battery’s negative battery terminal. Initialize the occupant classification sensor (see page 72-1 1 or 72-19 ). Check the SRS warning lamp (see page 60-1 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3461 61-13 SEAT BELT - REAR NO.1 SEAT BELT REAR NO.1 SEAT BELT 610JX-01 COMPONENTS 7.5 (77, 66 in. ⋅lbf) 42 (428, 31) Rear Seat Inner Belt Assy LH 42 (428, 31) 42 (428, 31) 42 (428, 31) 42 (428, 31) 42 (428, 31) Rear No. 1 Seat Outer Belt Assy RH Rear Seat Inner Belt Assy RH 42 (428, 31) Rear Seat Inner Belt Assy N⋅m (kgf⋅cm ft⋅lbf) : Specified torque B78506 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3467 61-14 SEAT BELT - REAR NO.1 SEAT BELT Rear Door Opening Trim Weatherstrip RH Quarter Pillar Garnish RH Tonneau Cover Back Door Weather Strip Deck Trim Side Panel RH Deck Board No. 2 Rope Hook Rear Floor Finish Plate Deck Board Cover Rear Door Scuff Plate RH Deck Board No. 3 Deck Side Trim Box RH Deck Floor Box RR Deck Floor Box FR Deck Side Trim Box LH w/ Rear No. 2 Seat Deck Trim Foot Air Duct Deck Board Rear Seat Reclining Cover RH Rear Door Scuff Plate RH Rear Floor Silencer Floor Carpet B78297 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3468 61-15 SEAT BELT - REAR NO.1 SEAT BELT 610JY-02 REPLACEMENT HINT:



1. (a) (b) (c) (d) 2. (a) (b) (c) (d) The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. Use the same procedures for the RH side and LH side. The procedures listed below are for the RH side. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). REMOVE REAR SEAT INNER BELT ASSY RH w/o Rear No. 2 seat: Remove the deck board (see page 76-21 ). Remove the rear No.1 seat RH (see page 72-35 or 72-54 ). Remove the rear seat belt assy inner RH. (1) Remove the bolt and belt. Install the rear seat belt assy inner RH. (1) Install the belt with the bolt. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) REMOVE REAR SEAT OUTER BELT ASSY CENTER w/o Rear No. 2 seat: Remove the deck board (see page 76-21 ). Remove the rear No. 1 seat RH (see page 72-35 or 72-54 ). Remove the rear seatback cover (see page 72-35 or 72-54 ). Remove the rear seat outer belt assy center. (1) Remove the nut, bolt and belt. (e) Unlock 45 Lock B77535 Install the rear seat outer belt assy center. (1) Check the degree of tilt when the belt begins to lock the ELR. NOTICE: Do not disassemble the retractor.
When the inclination of the retractor is 15 or less, check that the belt can be pulled from the retractor. When the inclination of the inclination of the retractor is over 45 check that the belt locks. If operation is not as specified, replace the belt assy. (2) Install the seat belt with bolt and nut. Torque: 7.5 N⋅m (77 kgf⋅cm, 66 in.⋅lbf) for bolt 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) for nut (3) Install the seatback cover (see page 72-35 or 72-54 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3469 61-16 SEAT BELT Protruding Part B76375 - REAR NO.1 SEAT BELT (4) Install the floor anchor with the bolt. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) NOTICE: Do not allow the anchor part of the rear belt and the protruding parts of the seat cushion frame to overlap.
With the belt installed, check that the belt locks when it is pulled out quickly. If operation is not as specified, replace the seat belt assy. (5) Check the ELR lock. NOTICE: The check should be performed with the assembly installed.
With the belt installed, check that the belt locks when it is pulled out quickly. If operation is not as specified, replace the belt assy. 3. (a) REMOVE REAR SEAT INNER BELT ASSY w/o Rear No. 2 seat: Remove the deck board (see page 76-21 ). (b) Remove the rear No. 1 seat LH (see page 72-35 or 72-54 ). (c) Remove the rear seat inner belt assy. (1) Remove the bolt and belt. (d) Install the rear seat inner belt assy. (1) Install the belt with the bolt. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) NOTICE: Do not allow the anchor part of the rear belt and the protruding parts of the floor panel to overlap. Protruding Part Protruding Part B77533 4. (a) (b) (c) (d) REMOVE REAR SEAT INNER BELT ASSY LH w/o Rear No. 2 seat: Remove the deck board (see page 76-21 ). Remove the rear No.1 seat LH (see page 72-35 or 72-54 ). Remove the rear seat inner belt assy LH. (1) Remove the bolt and belt. Install the rear seat inner belt assy LH. (1) Install the belt with the bolt. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3470 61-17 SEAT BELT 5. (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) (q) (r) (s) (t) (u) (v) - REAR NO.1 SEAT BELT REMOVE REAR SEAT OUTER BELT ASSY RH Remove the tonneau cover (see page 76-21 ). Remove the deck board cover (see page 76-21 ). Remove the deck board cover No. 2 (see page 76-21 ). Remove the deck board cover No. 3 (see page 76-21 ). w/ Rear No. 2 seat: Remove the rear seat reclining cover RH (see page 76-21 ). Remove the deck floor box RR (see page 76-21 ). w/o Rear No. 2 seat: Remove the deck floor box FR (see page 76-21 ). Remove the rear floor finish plate (see page 76-21 ). Remove the deck side trim box LH (see page 76-21 ). Remove the deck side trim box RH (see page 76-21 ). Remove the rear No. 1 seat LH (see page 76-21 ). Remove the rear No. 1 seat RH (see page 76-21 ). Remove the rear door scuff plate RH (see page 76-21 ). Remove the rear door opening trim weatherstrip RH (see page 76-21 ). Remove the back door weatherstrip (see page 76-21 ). Remove the rope hook (see page 76-21 ). Remove the deck trim side panel RH (see page 76-21 ). w/ Rear No. 2 seat: Remove the quarter pillar garnish RH (see page 76-21 ). w/ Rear No. 2 seat: Remove the 3 clips and turn over the front floor carpet. w/ Rear No. 2 seat: Remove the 2 clips and rear floor silencer LH and RH. w/ Rear A/C: Remove the 4 clips and foot air duct rear. Remove the rear seat outer belt assy RH. (1) Remove the bolt and shoulder anchor. (2) Remove the bolt and belt. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3471 61-18 SEAT BELT - REAR NO.1 SEAT BELT (w) Unlock 45 Lock B77535 Install the rear seat outer belt assy RH. (1) Check the degree of tilt when the belt begins to lock the ELR. NOTICE: Do not disassemble the retractor.
When the inclination of the retractor is 15 or less, check that the belt can be pulled from the retractor. When the inclination of the inclination of the retractor is over 45 check that the belt locks. If operation is not as specified, replace the belt assy. (2) Claw Claw Install the belt assy with the bolt, as shown in the illustration. B78498 Protruding Part Front Side Floor Anchor B78499 (3) Install the rear outer belt with the bolt. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) NOTICE: Do not allow the anchor part of the rear belt and the protruding parts of the floor panel to overlap.
With the belt installed, check that the belt locks when it is pulled out quickly. If operation is not as specified, replace the seat belt assy. (4) Check the ELR lock. NOTICE: The check should be performed with the outer belt assy installed.
With the belt installed, check that the belt locks when it is pulled out quickly. If operation is not as specified, replace the belt assy. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3472 61-19 SEAT BELT - (5) REAR NO.1 SEAT BELT Check the fastening function of the child restraint system. NOTICE: The check should be performed with the outer belt assy installed.
When the belt is pulled out fully, the belt should automatically try to retract.
After the belt has fully retracted, the belt should be able to be pulled out and retracted again. If operation is not as specified, replace the belt assy. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3473 61-20 SEAT BELT - REAR NO.2 SEAT BELT REAR NO.2 SEAT BELT 610JZ-01 COMPONENTS 42 (428, 31) Rear No. 2 Seat Outer Belt Assy RH 42 (428, 31) 42 (428, 31) 7.5 (77, 66 in. ⋅lbf) 42 (428, 31) 42 (428, 31) Rear Seat Lap Type Belt Assy RH Rear Seat Inner Belt Assy Rear Seat Lap Type Belt Assy LH N⋅m (kgf⋅cm ft⋅lbf) : Specified torque B77529 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3474 61-21 SEAT BELT - REAR NO.2 SEAT BELT Rear Door Opening Trim Weatherstrip RH Deck Trim Side Cover Deck Trim Side Panel RH Rear Seat Reclining Cover RH Rear Door Scuff Plate RH Tonneau Cover Back Door Weatherstrip Deck Board No. 2 Deck Board Cover Rear Floor Finish Plate Deck Board No. 3 Rear Floor Box RR Rear Floor Trim Box RH Deck Floor Box FR Deck Side Trim Box LH B78296 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3475 61-22 SEAT BELT - REAR NO.2 SEAT BELT 610K0-02 REPLACEMENT HINT:



1. (a) (b) (c) 2. (a) (b) The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. Use the same procedures for the RH side and LH side. The procedures listed below are for the RH side. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). REMOVE REAR SEAT LAP TYPE BELT RH Remove the rear No. 2 seat (see page 72-61 ). Remove the rear seat lap type belt assy RH. (1) Remove the bolt and belt. Install the rear seat lap type belt assy RH. (1) Remove the bolt and belt. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) REMOVE REAR SEAT INNER BELT ASSY Remove the rear No. 2 seat (see page 72-61 ). Remove the rear seat inner belt assy. (1) Remove the 2 bolts and 2 belts. (c) Protruding Part B77531 Install the rear seat inner belt assy. (1) Remove the 2 bolts and 2 belts. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) NOTICE: Do not allow the anchor part of the rear belt and the protruding parts of the floor panel to overlap. 3. REMOVE REAR NO.2 SEAT OUTER BELT ASSY RH (a) Remove the tonneau cover (see page 76-21 ). (b) Remove the deck board cover (see page 76-21 ). (c) Remove the deck board cover No. 2 (see page 76-21 ). (d) Remove the deck board cover No. 3 (see page 76-21 ). (e) Remove the rear seat reclining cover LH (see page 76-21 ). (f) Remove the rear seat reclining cover RH (see page 76-21 ). (g) Remove the deck floor box RR (see page 76-21 ). (h) Remove the rear floor finish plate (see page 76-21 ). (i) Remove the deck side trim box LH (see page 76-21 ). (j) Remove the deck side trim box RH (see page 76-21 ). (k) Remove the rear No. 1 seat LH (see page 76-21 ). (l) Remove the rear No. 1 seat RH (see page 76-21 ). (m) Remove the rear No. 2 seat RH (see page 76-21 ). (n) Remove the rear door opening trim weatherstrip RH (see page 76-21 ). (o) Remove the back door weatherstrip (see page 76-21 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3476 61-23 SEAT BELT (p) (q) (r) (s) Seat Belt Anchor Cover (t) - REAR NO.2 SEAT BELT Remove the rope hook (see page 76-21 ). Remove the rear door scuff plate RH (see page 76-21 ). Remove the deck trim side panel RH (see page 76-21 ). Remove the quarter pillar garnish RH (see page 76-21 ). Remove the rear No. 2 seat belt assy outer RH. (1) Using a screwdriver, open the seat belt anchor cover HINT: Tape the screwdriver tip before use. (2) Remove the bolt and shoulder anchor. (3) Remove the 2 bolts and belt. Protective Tape Claw B77538 (u) Unlock 45 Lock B77534 Install the rear No. 2 seat belt assy outer RH. (1) Check the amount of inclination required to lock the retractor.
When the inclination of the retractor is 15 or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45, check that the belt locks. NOTICE: Do not disassemble the retractor. If operation is not as specified, replace the outer belt assy. (2) Install the belt with the 2 bolts. Torque: 7.5 N⋅m (77 kgf⋅cm, 66 in.⋅lbf) for upper bolt 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) for lower bolt (3) Install the shoulder anchor with the bolt. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3477 61-1 SEAT BELT - SEAT BELT WARNING SYSTEM SEAT BELT WARNING SYSTEM 610JS-01 LOCATION Passenger Seat Occupant Classification Sensor Rear Occupant Classification Sensor Front A/C Control Assy
Passenger Side Seat Belt Warning Lamp Combination Meter Assy
Driver Side Seat Belt Warning Lamp Occupant Classification ECU Instrument Panel J/B
AM1 M-fuse
IG1 Fuse
RAD NO. 2 Fuse Front Seat Inner Belt Assy RH Airbag Sensor Assy Front Seat Inner Belt Assy LH B79063 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3455 61-2 SEAT BELT - SEAT BELT WARNING SYSTEM 610JT-01 PROBLEM SYMPTOMS TABLE Symptom Suspected Area See Page Driver side seat belt warning lamp does not flash 1. 2. 3. 4. 5. 6. 7. IG1 fuse AM1 M-fuse RAD NO. 2 fuse Combination meter Front seat inner belt assy LH Airbag sensor assy Wire harness 61-1 61-1 61-1 05-1898 05-1228 05-1228 Passenger side seat belt warning lamp does not flash 1. 2. 3. 4. 5. 6. 7. 8. IG1 fuse AM1 M-fuse RAD NO. 2 fuse A/C control assy Front seat inner belt assy RH Occupant classification sensor Occupant classification ECU Wire harness 61-1 61-1 61-1 05-1228 05-1228 05-1228 05-1228 NOTICE: The front seat inner belt RH and LH cannot be inspected. When the front seat inner belt seems to be malfunctioning, use the hand-held tester to check for DTCs. HINT: The seat belt warning system is part of the large-scale multiplex communication system. This system features shared communication wiring that reduces the wiring complexity of the communication lines. The first step in any repair is to confirm the proper operation of the communication system. Proceed with troubleshooting after the communication has been verified (see multiplex communication system). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3456 65-14 LIGHTING - LH HEADLAMP ASSY 6512D-01 ADJUSTMENT 1. (a) VEHICLE PREPARATION FOR HEADLAMP AIM ADJUSTMENT Prepare the vehicle:
Ensure there is no damage or deformation to the body around the headlamps.
Fill the fuel tank.
Make sure that the oil is filled to the specified level.
Make sure that the coolant is filled to the specified level.
Inflate the tires to the appropriate pressure.
Place the spare tire, tools, and jack in their original position.
Unload the trunk.
Sit a person of average weight (68 kg, 150 lbs) in the driver’s seat. 2. PREPARATION FOR HEADLAMP AIMING (Using a screen) (a) Prepare the vehicle according to the following conditions:
Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the headlamps can be observed and above which it cannot.
Place the vehicle at a 90 angle to the wall.
Create a 7.62 m (25 ft) distance between the vehicle and the wall.
Place the vehicle on a level surface.
Bounce the vehicle up and down to settle the suspension. NOTICE: A distance of 7.62 m (25 ft) between the vehicle and the wall is necessary for proper aim adjustment. If unavailable, secure a distance of exactly 3 m (9.84 ft) for check and adjustment. (The target zone will change with the distance so follow the instructions in the illustration.) (b) Prepare a piece of thick white paper (approximately 2 m (height) x 4 m (width)) to use as a screen. (c) Draw a vertical line down the center of screen (V line). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3491 65-15 LIGHTING - LH HEADLAMP ASSY (d) Set the screen as shown in the illustration. HINT:
Stand the screen perpendicular to the ground.
Align the V line on the screen with the center of the vehicle. Aligning distance is 7.62 m (25 ft): Aligning distance is 3 m (9.84 ft): V RH Line V RH Line 90 90 V Line V Line 7.62 m (25 ft) 3 m (9.84 ft) V LH Line V LH Line H Line H Line 90 7.62 m (25 ft) 90 3 m (9.84 ft) I41220 (e) V LH Line V Line V RH Line Draw base lines (H line, V LH, V RH lines) on the screen as shown in the illustration. HINT: H Line


Ground I33423 The base lines differ for ”low- beam inspection” and ”high-beam inspection”. Follow the same procedures for ”high-beam inspection”. Mark the headlamp bulb center marks on the screen. If the center mark cannot be observed on the headlamp, use the center of the headlamp bulb or the manufacturer’s name marked on the headlamp as the center mark. (1) H Line (Headlamp height): Draw a horizontal line across the screen so that it passes through the center marks. The H line should be at the same height as the headlamp bulb center marks of the low-beam headlamps. (2) V LH Line, V RH Line (Center mark position of lefthand (LH) and right-hand (RH) headlamps): Draw two vertical lines so that they intersect the H Line at each center mark (aligned with the center of the low-beam headlamp bulbs). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3492 65-16 LIGHTING - LH HEADLAMP ASSY 3. (a) HEADLAMP AIMING INSPECTION Cover or disconnect the connector of the headlamp on the opposite side to prevent light from the headlamp not being inspected from affecting headlamp aiming inspection. NOTICE: Do not keep the headlamp covered for more than 3 minutes. The headlamp lens is made of synthetic resin, and may easily melt or be damaged due to heat. HINT: When checking the aim of the high-beam, cover the low-beam or disconnect the connector. (b) Start the engine. NOTICE: Engine rpm must be 1,500 or more. (c) Turn on the headlamp and make sure that the cutoff line falls within the specified area, as shown in the illustration. HINT: Since the low-beam light and the high-beam light are a unit, if the aim on one is correct, the other should also be correct. However, check both beams just to make sure. Aligning distance is 7.62 m (25 ft): Low Beam: 101 mm (3.97 in.) H Line Aligning distance is 3 m (9.84 ft): V LH Line V RH Line 40 mm (1.57 in.) 53 mm (2.08 in.) H Line 40 mm (1.57 in.) 101 mm (3.97 in.) 101 mm (3.97 in.) High Beam: High Beam: 101 mm (3.97 in.) 40 mm (1.57 in.) H Line H Line 101 mm (3.97 in.) 40 mm (1.57 in.) 101 mm (3.97 in.) 21 mm (0.82 in.) 40 mm (1.57 in.) 101 mm (3.97 in.) V LH Line V RH Line V LH Line V RH Line Low Beam: 101 mm (3.97 in.) 40 mm (1.57 in.) V LH Line V RH Line 40 mm (1.57 in.) 40 mm (1.57 in.) I41213 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3493 65-17 LIGHTING - LH HEADLAMP ASSY 4. (a) Aiming Screw I41122 HEADLAMP AIMING ADJUSTMENT Adjust the aim vertically: Adjust the headlamp aim into the specified range by turning aiming screw with a screwdriver. NOTICE: The final turn of the aiming screw should be made in the clockwise direction. If the screw is tightened excessively, loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction. HINT:
Perform low-beam aim adjustment.
The headlamp aim moves up when turning the aiming screw clockwise, and moves down when turning the aiming screw counterclockwise. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3494 65-9 LIGHTING - LH HEADLAMP ASSY LH HEADLAMP ASSY 6512B-01 COMPONENTS Headlamp Protector Retainer LWR LH Headlamp Protector Retainer Upper LH Headlamp Bracket LWR LH LH Headlamp Assy Headlamp, No.2 Bulb Headlamp, No.1 Bulb Clearance Lamp Bulb Clearance Lamp Socket & Wire Headlamp Unit LH I39810 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3486 65-10 LIGHTING - LH HEADLAMP ASSY 6512C-01 OVERHAUL HINT:



1. 2. 3. 4. COMPONENTS: See page 65-9 Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. Installation is in the reverse order of removal. REMOVE RADIATOR GRILLE (SEE PAGE 76-2 ) REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSY LH (SEE PAGE 76-2 ) REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSY RH (SEE PAGE 76-2 ) REMOVE FRONT BUMPER COVER (SEE PAGE 76-2 ) 5. (a) REMOVE LH HEADLAMP ASSY Remove the 2 screws. (b) Pull out the LH headlamp assy forward, then release the pin and the headlamp bracket. Disconnect the connectors, and remove the LH head lamp assy. I40998 Pin (c) Bracket I40999 6. (a) REMOVE HEADLAMP, NO.1 BULB Remove the headlamp, No.1 bulb as shown in the illustration. E54941 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3487 65-1 1 LIGHTING - LH HEADLAMP ASSY 7. (a) REMOVE HEADLAMP, NO.2 BULB Remove the headlamp, No.2 bulb as shown in the illustration. 8. (a) REMOVE CLEARANCE LAMP BULB Remove the clearance lamp bulb and the socket as shown in the illustration. Remove the clearance lamp bulb from the socket as shown in the illustration. E51840 (b) E74195 9. 10. REMOVE CLEARANCE LAMP SOCKET & WIRE REMOVE HEADLAMP UNIT LH 11. INSTALL HEADLAMP PROTECTOR RETAINER UPPER LH HINT: To minimize damage to the headlamp unit in case of a collision, the stays for the headlamp unit have been constructed to break off. The stays are available as supply parts for low-cost repair. (a) Cut off the part shaded in the illustration and sand smooth with sandpaper. NOTICE: After cutting off the part, place the headlamp protector retainer upper LH against the bosses and gradually file away until installation is possible. E52144 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3488 65-12 LIGHTING E52145 - LH HEADLAMP ASSY (b) Install the headlamp protector retainer upper LH with the 2 screws. 12. INSTALL HEADLAMP PROTECTOR RETAINER LWR LH HINT: To minimize damage to the headlamp unit in case of a collision, the stays for the headlamp unit have been constructed to break off. The stays are available as supply parts for low-cost repair. (a) Cut off the part shaded in the illustration and sand smooth with sandpaper. NOTICE: After cutting off the part, place the headlamp protector retainer LWR LH against the bosses and gradually file away until installation is possible. E52179 (b) E52147 Install the headlamp protector retainer LWR LH with the 2 screws. 13. INSTALL HEADLAMP BRACKET LWR LH HINT: To minimize damage to the headlamp unit in case of a collision, the stays for the headlamp unit have been constructed to break off. The stays are available as supply parts for low-cost repair. (a) Cut off the part shaded in the illustration and sand smooth with sandpaper. NOTICE: After cutting off the part, place the headlamp bracket LWR LH against the bosses and gradually file away until installation is possible. E52146 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3489 65-13 LIGHTING (b) - LH HEADLAMP ASSY Install the headlamp bracket LWR LH with the screw. E52149 14. 15. 16. 17. VEHICLE PREPARATION FOR HEADLAMP AIM ADJUSTMENT (SEE PAGE 65-14 ) PREPARATION FOR HEADLAMP AIMING (Using a screen) (SEE PAGE 65-14 ) HEADLAMP AIMING INSPECTION (SEE PAGE 65-14 ) HEADLAMP AIMING ADJUSTMENT (SEE PAGE 65-14 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3490 65-19 LIGHTING - FOG LAMP ASSY LH 6512F-01 ADJUSTMENT 1. (a) VEHICLE PREPARATION FOR FOGLAMP AIM ADJUSTMENT Prepare the vehicle:
Ensure there is no damage or deformation to the body around the headlamps.
Fill the fuel tank.
Make sure that the oil is filled to the specified level.
Make sure that the coolant is filled to the specified level.
Inflate the tires to the appropriate pressure.
Place the spare tire, tools, and jack in their original position.
Unload the trunk.
Sit a person of average weight (68 kg, 150 lbs) in the driver’s seat. 2. (a) PREPARATION FOR FOGLAMP AIMING Prepare the vehicle according to the following conditions:
Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the headlamps can be observed and above which it cannot.
Place the vehicle at a 90 angle to the wall.
Create a 7.62 m (25 ft) distance between the vehicle and the wall.
Place the vehicle on a level surface.
Bounce the vehicle up and down to settle the suspension. NOTICE: A distance of 7.62 m (25 ft) between the vehicle and the wall is necessary for proper aim adjustment. If unavailable, secure a distance of exactly 3 m (9.84 ft) for check and adjustment. (The target zone will change with the distance so follow the instructions in the illustration.) (b) Prepare a piece of thick white paper to use as a screen. (c) Draw a vertical line down the center of screen (V line). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3496 65-20 LIGHTING - FOG LAMP ASSY LH (d) Set the screen as shown in the illustration. HINT:
Stand the screen perpendicular to the ground.
Align the V line on the screen with the center of the vehicle. Aligning distance is 7.62 m (25 ft): Aligning distance is 3 m (9.84 ft): V RH Line V RH Line 90 90 V Line V Line 7.62 m (25 ft) 3 m (9.84 ft) V LH Line V LH Line H Line H Line 90 7.62 m (25 ft) 90 3 m (9.84 ft) I41220 (e) V LH Line V Line V RH Line H Line Ground I33423 Draw base lines (H line, V LH, V RH lines) on the screen as shown in the illustration. HINT: Mark the fog lamp bulb center marks on the screen. If the center mark cannot be observed on the fog lamp, use the center of the fog lamp bulb or the manufacturer’s name marked on the fog lamp as the center mark. (1) H Line (Fog lamp height): Draw a horizontal line across the screen so that it passes through the center marks. The H line should be at the same height as the fog lamp bulb center marks of the low-beam fog lamps. (2) V LH Line, V RH Line (Center mark position of lefthand (LH) and right-hand (RH) fog lamps): Draw two vertical lines so that they intersect the H Line at each center mark. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3497 65-21 LIGHTING - FOG LAMP ASSY LH 3. (a) FOGLAMP AIMING INSPECTION Cover or disconnect the connector of the fog lamp on the opposite side to prevent light from the fog lamp not being inspected from affecting fog lamp aiming inspection. (b) Start the engine. NOTICE: Engine rpm must be 1,500 or more. (c) Turn on the fog lamp and make sure that the cutoff line falls within the specified area, as shown in the illustration. Aligning distance is 7.62 m (25 ft): V LH Line V RH Line Aligning distance is 3 m (9.84 ft): 93 - 172 mm (3.66 - 6.77 in.) H Line V LH Line 37 - 68 mm (1.45 - 2.67 in.) V RH Line H Line I41221 Aiming Screw 4. (a) FOGLAMP AIMING ADJUSTMENT Adjust the fog lamp aim into the specified range by turning aiming screw with a screwdriver. NOTICE: The final turn of the aiming screw should be made in the clockwise direction. If the screw is tightened excessively, loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction. I30351 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3498 65-18 LIGHTING - FOG LAMP ASSY LH FOG LAMP ASSY LH 6512E-01 OVERHAUL HINT:


1. Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. Installation is in the reverse order of removal. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSY LH (SEE PAGE 76-2 ) : 2 Claws : 3 Claws 2. (a) REMOVE FOG LAMP PROTECTOR LH Disengage the 2 claws, and remove the fog lamp protector RH. 3. (a) (b) REMOVE FOG LAMP ASSY LH Disconnect the connector. Disengage the 3 claws, and remove the fog lamp assy LH. 4. (a) REMOVE FOG LAMP BULB Remove the fog lamp bulb as shown in the illustration. I39806 I39807 I39808 5. 6. 7. 8. 9. 10. REMOVE BEARING FOG LAMP REMOVE FOG LAMP LAMP UNIT LH VEHICLE PREPARATION FOR FOGLAMP AIM ADJUSTMENT (SEE PAGE 65-19 ) PREPARATION FOR FOGLAMP AIMING (SEE PAGE 65-19 ) FOGLAMP AIMING INSPECTION (SEE PAGE 65-19 ) FOGLAMP AIMING ADJUSTMENT (SEE PAGE 65-19 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3495 65-22 LIGHTING - REAR COMBINATION LAMP ASSY LH REAR COMBINATION LAMP ASSY LH 6512G-01 OVERHAUL HINT:


1. Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. Installation is in the reverse order of removal. REMOVE REAR COMBINATION LAMP SERVICE COVER LH 2. (a) (b) REMOVE REAR COMBINATION LAMP ASSY LH Disconnect the connector. Remove the 2 nuts and the rear combination lamp assy LH. I30352 3. 4. (a) (b) 5. 6. REMOVE REAR COMBINATION LAMP LENS GASKET RH REMOVE REAR COMBINATION LAMP BULB Remove the rear combination lamp bulb and the socket and wire. Remove the rear combination lamp bulb from the socket and wire. REMOVE REAR COMBINATION LAMP SOCKET AND WIRE SUB-ASSY LH REMOVE REAR COMBINATION LAMP LENS LH 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3499 65-23 LIGHTING - LICENSE PLATE LAMP ASSY LICENSE PLATE LAMP ASSY 6512H-01 REPLACEMENT HINT: Installation is in the reverse order of removal. 1. REMOVE ASSIST STRAP HOLE COVER (SEE PAGE 75-20 ) 2. REMOVE ASSIST STRAP ASSY RH (SEE PAGE 75-20 ) 3. REMOVE BACK DOOR TRIM PANEL ASSY (SEE PAGE 75-20 ) 4. REMOVE BACK DOOR LOCK ASSY (SEE PAGE 75-20 ) 5. REMOVE BACK DOOR HANDLE ASSY OUTSIDE (SEE PAGE 75-20 ) 6. REMOVE LUGGAGE COMPARTMENT DOOR GARNISH SUB-ASSY OUTSIDE (SEE PAGE 76-13 ) 7. (a) (b) REMOVE LICENSE PLATE LAMP ASSY Remove the 4 screws and the 2 license plate lamp lenses. Remove the license plate lamp assy from the luggage compartment door garnish sub-assy outside. I30353 8. INSTALL BACK DOOR LOCK ASSY (SEE PAGE 75-20 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3500 65-24 LIGHTING - CENTER STOP LAMP ASSY CENTER STOP LAMP ASSY 6512I-01 REPLACEMENT HINT: Installation is in the reverse order of removal. 1. REMOVE BACK WINDOW PANEL TRIM UPPER (SEE PAGE 75-20 ) 2. REMOVE CENTER STOP LAMP SOCKET & WIRE (a) Disconnect the connector, and remove the center stop lamp socket & wire. 3. (a) (b) REMOVE CENTER STOP LAMP ASSY Remove the 2 screws. Disengage the 4 claws, and remove the center stop lamp assy. I30354 4. 5. (a) (b) (c) REMOVE CENTER STOP LAMP GASKET INSTALL CENTER STOP LAMP ASSY Remove adhesive tape from the body. Wipe off stains with a cleaner. Install the center stop lamp assy with the 2 screws. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3501 65-25 LIGHTING - HEADLAMP DIMMER SWITCH ASSY HEADLAMP DIMMER SWITCH ASSY 6512J-01 REPLACEMENT HINT: Installation is in the reverse order of removal. 1. REMOVE STEERING COLUMN COVER LWR (SEE PAGE 50-8 ) 2. REMOVE STEERING COLUMN COVER UPR (SEE PAGE 50-8 ) 3. (a) (b) REMOVE HEADLAMP DIMMER SWITCH ASSY Disconnect the connector. Using a screwdriver, disengage the claw, and remove the headlamp dimmer switch assy. NOTICE: Pressing the claw hard breaks the claw. HINT: Tape the screwdriver tip before use. : Claw I39848 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3502 65-4 LIGHTING - LIGHTING SYSTEM 6511Y-01 INSPECTION 1. (a) Connector Front View: C13 E11948 (b) (c) (d) HEADLAMP DIMMER SWITCH ASSY Inspect light control switch. (1) Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 12 - 16 13 - 16 14 - 16 OFF 10 kΩ or higher 14 - 16 TAIL Below 1 Ω 13 - 16 14 - 16 HEAD Below 1 Ω 12 - 16 AUTO Below 1 Ω Inspect headlamp dimmer switch. (1) Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 16 - 17 LOW Below 1 Ω 7 - 16 HIGH Below 1 Ω 7 - 16 8 - 16 FLASH Below 1 Ω Inspect turn signal switch. (1) Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 2-3 Right turn Below 1 Ω 1-2 2-3 Neutral 10 kΩ or higher 1-2 Left turn Below 1 Ω w/ Front Fog Lamp: Inspect front fog light switch. (1) Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 10 - 11 OFF 10 kΩ or higher 10 - 11 ON Below 1 Ω 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3481 65-5 LIGHTING 2. (a) Connector Front View: A10 - LIGHTING SYSTEM HAZARD WARNING SWITCH ASSY w/o navigation system: Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition A10-8 - A10-11 OFF 10 kΩ or higher A10-8 - A10-11 ON Below 1 Ω E72987 (b) Connector Front View: M3 w/ navigation system: Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition M3-3 - M3-8 OFF 10 kΩ or higher M3-3 - M3-8 ON Below 1 Ω E74072 ON OFF 3. (a) FRONT DOOR COURTESY LAMP SWITCH ASSY Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 1 - Body ground OFF (When shaft is pressed) 10 kΩ or higher 1 - Body ground ON (When shaft is not pressed) Below 1 Ω E71371 ON OFF 4. (a) REAR DOOR COURTESY LAMP SWITCH ASSY Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 1 - Body ground OFF (When shaft is pressed) 10 kΩ or higher 1 - Body ground ON (When shaft is not pressed) Below 1 Ω E71371 5. (a) Connector Front View: R12 BACK DOOR LOCK ASSY Inspect back door courtesy lamp switch assy. (1) Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 1-2 Back door is closed 10 kΩ or higher 1-2 Back door is open Below 1 Ω E74073 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3482 65-6 LIGHTING 6. (a) Connector Front View: I16 (b) E69434 E50228 (c) 7. (a) Connector Front View: R11 (b) E69434 E50228 (c) 8. (a) Connector Front View: O5 E72986 9. (a) Connector Front View: D5 D6 - LIGHTING SYSTEM ROOM LAMP ASSY NO.1 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 1-2 1-3 OFF 10 kΩ or higher Connect the positive (+) lead from the battery to the terminal 1 and negative (-) lead to the terminal 2, then check that the lamp comes on when the switch is in the DOOR position. Connect the positive (+) lead from the battery to the terminal 1 and negative (-) lead to the terminal 3, then check that the lamp comes on when the switch is in the ON position. ROOM LAMP ASSY NO.2 Measure the resistance according to the value(s) in the table below. Standard: Tester connection Condition Specified condition 1-2 1-3 OFF 10 kΩ or higher Connect the positive (+) lead from the battery to the terminal 1 and negative (-) lead to the terminal 2, then check that the lamp comes on when the switch is in the DOOR position. Connect the positive (+) lead from the battery to the terminal 1 and negative (-) lead to the terminal 3, then check that the lamp comes on when the switch is in the ON position. MAP LAMP ASSY Inspect the map lamp in the overhead J/B. (1) Connect the positive (+) lead from the battery to terminal 12 and negative (-) lead to terminal 1, then check that the lamp comes on when the switch is in the ON position. (2) Connect the positive (+) lead from the battery to terminal 12 and negative (-) lead to terminal 7, then check that the lamp comes on when the switch is in the DOOR position. COURTESY LAMP ASSY Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2, then check that the lamp comes on. E69342 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3483 65-7 LIGHTING 10. (a) 11. (a) 12. (a) - LIGHTING SYSTEM LH VISOR ASSY Connect the positive (+) lead from the battery to one of the terminals and the negative (-) lead to other terminal, then check that the lamp comes on when the switch is in the ON position. RH VISOR ASSY Connect the positive (+) lead from the battery to one of the terminals and the negative (-) lead to other terminal, then check that the lamp comes on when the switch is in the ON position. GLOVE BOX LAMP ASSY Connect the positive (+) lead from the battery to one of the terminals and the negative (-) lead to other terminal, then check that the lamp comes on when the switch is in the ON position. Connector Front View: 13. (a) KEY CYLINDER LAMP w/ Theft deterrent system: Connect the positive (+) lead from the battery to terminal 2 and negative (-) lead to terminal 6, then check that the lamp comes on. (b) w/o Theft deterrent system: Connect the positive (+) lead from the battery to terminal 2 and negative (-) lead to terminal 1, then check that the lamp comes on. 14. (a) HEADLAMP RELAY Measure the resistance according to the value(s) in the table below. Standard: T7 E74066 Connector Front View: I14 E69342 3 1 4 4 3 1 2 Tester connection Specified condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (When battery voltage is applied to terminals 1 - 2) 2 Z09181 15. (a) TAIL LAMP RELAY Measure the resistance according to the value(s) in the table below. Standard: Tester connection Specified condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (When battery voltage is applied to terminals 1 - 2) B16200 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3484 65-8 LIGHTING 16. (a) - LIGHTING SYSTEM FOG LAMP RELAY Measure the resistance according to the value(s) in the table below. Standard: Tester connection Specified condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (When battery voltage is applied to terminals 1 - 2) B16200 17. (a) DRL NO.2 RELAY Measure the resistance according to the value(s) in the table below. Standard: Tester connection Specified condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (When battery voltage is applied to terminals 1 - 2) E64835 18. (a) DRL NO.3 RELAY Measure the resistance according to the value(s) in the table below. Standard: Tester connection Specified condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (When battery voltage is applied to terminals 1 - 2) 3-4 10 kΩ or higher (When battery voltage is applied to terminals 1 - 2) E74095 19. (a) DRL NO.4 RELAY Measure the resistance according to the value(s) in the table below. Standard: Tester connection Specified condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (When battery voltage is applied to terminals 1 - 2) E64835 2 4 S15 1 3 Free Pushed in E65594 20. (a) STOP LAMP SWITCH ASSY Measure the resistance according to the value(s) in the table below. Standard: Tester connection Switch position Specified resistance 1-2 Switch pin free Below 1 Ω 3-4 Switch pin free 10 kΩ or higher 1-2 Switch pin pushed in 10 kΩ or higher 3-4 Switch pin pushed in Below 1 Ω 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3485 65-2 LIGHTING - LIGHTING SYSTEM 6511X-01 ON-VEHICLE INSPECTION 1. (a) Connector Front View: T8 (b) INSPECT TURN SIGNAL FLASHER CIRCUIT Disconnect the connector from the turn signal flasher relay. Measure the voltage according to the value(s) in the table below. E15683 Standard: Tester connection Condition Specified condition 1 - body ground Turn ignition switch ON 10 to 14 V 1 - body ground Turn ignition switch OFF Below 1 V 4 - body ground Always 10 to 14 V 7 - body ground Always Below 1 V (c) (d) Reconnect the connector to the turn signal flasher. Measure the voltage according to the valve(s) in the table below. Standard: Tester connection Condition Specified condition 2 - body ground Hazard switch OFF → ON 0V ⇔ 10 to 14 V (60 to 120 times per minute) 2 - body ground Turn signal switch (right turn) OFF → ON 0V ⇔ 10 to 14 V (60 to 120 times per minute) 3 - body ground Hazard switch OFF → ON 0V ⇔ 10 to 14 V (60 to 120 times per minute) 3 - body ground Turn signal switch (left turn) OFF → ON 0V ⇔ 10 to 14 V (60 to 120 times per minute) 5 - body ground Turn signal switch (left turn) OFF → ON 10 to 14 V → 0 V 6 - body ground Turn signal switch (right turn) OFF → ON 10 to 14 V → 0 V 8 - body ground Hazard switch OFF → ON 10 to 14 V → 0 V 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3479 65-3 LIGHTING 2. (a) Connector Front View: T9 - LIGHTING SYSTEM INSPECT TOWING CONVERTER RELAY Measure the voltage according to the value(s) in the table below. E74074 Tester connection Condition Specified condition 1 - Body ground Light control switch OFF → TAIL Below 1 V → 10 to 14 V 2 - Body ground Turn signal switch (left turn) OFF → ON 0 ⇔ 10 to 14 V (60 to 120 times per minute) 2 - Body ground Brake pedal OFF → ON (depressed) Below 1 V → 10 to 14 V 3 - Body ground Light control switch OFF → TAIL Below 1 V → 10 to 14 V 4 - Body ground Turn signal switch (left turn) OFF → ON 0 ⇔ 10 to 14 V (60 to 120 times per minute) 5 - Body ground Always Below 1 V 6 - Body ground Turn signal switch (right turn) OFF → ON 0 ⇔ 10 to 14 V (60 to 120 times per minute) 6 - Body ground Brake pedal OFF → ON (depressed) Below 1 V → 10 to 14 V 8 - Body ground Always 10 to 14 V 9 - Body ground Brake pedal OFF → ON (depressed) 10 to 14 V 10 - Body ground Turn signal switch (right turn) OFF → ON 0 ⇔ 10 to 14 V (60 to 120 times per minute) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3480 65-1 LIGHTING - LIGHTING SYSTEM LIGHTING SYSTEM 650PD-07 PRECAUTION 1. (a) (b) (c) (d) (e) PRECAUTION OF HEADLAMP BULB REPLACEMENT If even a thin film of oil is left on the surface of the halogen lamp, the bulb may be damaged because the lamp will burn at a higher temperature. Handle any halogen lamp with great care. Dropping, hitting or damaging the bulb, in any way, may result in it exploding and shattering because the internal pressure is high. Always prepare a new bulb for immediate replacement. While replacing the bulb, the lens may attract dust and moisture if removed from the vehicle for too long. Always use a bulb of the same wattage for replacement. Firmly reinstall the socket after bulb replacement. The lens may become cloudy or the light cavity may fill with water through the gaps around the socket. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3478 66-7 WIPER & WASHER - WINDSHIELD WIPER MOTOR ASSY WINDSHIELD WIPER MOTOR ASSY 660HP-02 REPLACEMENT HINT: Installation is in the reverse order of removal. 1. REMOVE WINDSHIELD WIPER ARM COVER 2. REMOVE FR WIPER ARM & BLADE ASSY LH (a) Stop the windshield wiper motor assy at the automatic stop position. (b) Remove the nut and the FR wiper arm & blade assy LH. 3. REMOVE FR WIPER ARM & BLADE ASSY RH (a) Remove the nut and the FR wiper arm & blade assy RH. 4. (a) : 6 Claws : 9 Claws REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY Disengage the 6 claws. I30311 (b) (c) Remove the 2 clips. Disengage the 9 claws, and remove the cowl top ventilator louver sub-assy. 5. (a) (b) (c) REMOVE WINDSHIELD WIPER MOTOR & LINK ASSY Disconnect the connector. Remove the 2 bolts. Remove the windshield wiper motor & link assy by disengaging the pin as shown in the illustration. I30312 I30492 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3509 66-8 WIPER & WASHER - WINDSHIELD WIPER MOTOR ASSY 6. (a) REMOVE WINDSHIELD WIPER MOTOR ASSY Using a screwdriver, disengage the meshing of the 2 rods at the crank arm pivot of the windshield wiper motor assy. (b) Using a torx socket wrench, remove the 2 bolts and the windshield wiper motor assy. 7. (a) INSTALL WINDSHIELD WIPER MOTOR ASSY Apply MP grease to the clank arm pivot of the windshield wiper motor assy. Using a torx socket wrench, install the windshield wiper motor assy with the 2 bolts. Torque: 5.39 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) E50396 E50397 E50398 (b) E50398 8. (a) (b) (c) INSTALL WINDSHIELD WIPER MOTOR & LINK ASSY Temporarily install the windshield wiper & Link assy by engaging the pin. Install the windshield wiper motor & link assy with the 2 bolts. Torque: 7.0 N⋅m (71 kgf⋅cm, 61 in.⋅lbf) Connect the connecter. I39852 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3510 66-9 WIPER & WASHER Wire Brush WINDSHIELD WIPER MOTOR ASSY 9. (a) INSTALL FR WIPER ARM & BLADE ASSY RH Stop the windshield wiper motor assy at the automatic stop position. (b) Scrape off the serration part of the wiper arm with a round file or equivalent. Clean the wiper pivot serration with a wire brush. (c) Wiper Arm Serration - Wiper Pivot Serration E58837 24.2 mm (0.95 in.) (d) Install the front wiper arm & blade assy RH with the nut to the position shown in the illustration. Torque: 24 N⋅m (245 kgf⋅cm, 18 ft⋅lbf) HINT: Hold down the arm hinge by hand in order to fasten the nut. 23.6 mm (0.93 in.) 17.0 mm (0.66 in.) 26.3 mm (1.04 in.) I30319 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3511 66-10 WIPER & WASHER 10. (a) Wiper Arm Serration (b) Wire Brush - WINDSHIELD WIPER MOTOR ASSY INSTALL FR WIPER ARM & BLADE ASSY LH Scrape off the serration part of the wiper arm with a round file or equivalent. Clean the wiper pivot serration with a wire brush. Wiper Pivot Serration E58837 (c) 28.8 mm (1.13 in.) HINT: Hold down the arm hinge by hand in order to fasten the nut. (d) Operate the wiper while running water or washer fluid over the window, and check the wiping condition and that the front wiper does not scrape against the body. 34.3 mm (1.35 in.) 23.4 mm (0.92 in.) 68.5 mm (2.70 in.) Install the front wiper arm & blade assy LH with the 2 nuts to the position shown in the illustration. Torque: 24 N⋅m (245 kgf⋅cm, 18 ft⋅lbf) I30320 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3512 66-1 1 WIPER & WASHER - WIPER RUBBER LH WIPER RUBBER LH 660HQ-01 REPLACEMENT HINT:


Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. Installation is in the reverse order of removal. 1. REMOVE FR WIPER BLADE LH (a) Remove the front wiper blade LH from the front wiper arm LH. NOTICE: Do not fold down the front wiper arm with the front wiper blade removed from it. 2. REMOVE WIPER RUBBER LH (a) Remove the front wiper rubber LH from the front wiper blade. (b) Remove the 2 wiper rubber backing plates from the wiper rubber LH. 3. (a) INSTALL WIPER RUBBER LH Install the 2 wiper rubber backing plates to the wiper rubber LH. NOTICE: Install the backing plates in the correct direction. Curve E59361 (b) Install the wiper rubber LH so that the head part (larger side) of the wiper rubber faces the arm axle side. NOTICE: Push the front wiper blade into the grooves of the wiper rubber to engage them completely. E57398 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3513 66-12 WIPER & WASHER - REAR WIPER MOTOR ASSY REAR WIPER MOTOR ASSY 660HR-01 REPLACEMENT HINT: Installation is in the reverse order of removal. 1. REMOVE RR WIPER ARM & BLADE ASSY (a) Remove the rear wiper arm cover. (b) Remove the nut and the RR wiper arm & blade assy. 2. REMOVE REAR WIPER MOTOR GROMMET 3. REMOVE ASSIST STRAP HOLE COVER (SEE PAGE 75-20 ) 4. REMOVE ASSIST STRAP ASSY RH (SEE PAGE 75-20 ) 5. REMOVE BACK DOOR TRIM PANEL ASSY (SEE PAGE 75-20 ) 6. (a) (b) REMOVE REAR WIPER MOTOR ASSY Disconnect the connector. Remove the 3 bolts and the rear wiper motor assy. 7. (a) INSTALL REAR WIPER MOTOR ASSY Install the rear wiper motor assy with the 3 bolts. Torque: 5.5 N⋅m (56 kgf⋅cm, 48 in.⋅lbf) Connect the connector. I30314 (b) I30314 Installation Position Mark Rear Wiper Grommet 8. (a) INSTALL REAR WIPER MOTOR GROMMET As shown in the illustration, install the rear wiper motor grommet with its position mark upside. 9. (a) INSTALL RR WIPER ARM & BLADE ASSY Stop the rear wiper motor assy at the automatic stop position. I30315 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3514 66-13 WIPER & WASHER (b) (c) Wiper Arm Serration Wire Brush - REAR WIPER MOTOR ASSY Scrape off the wiper arm serration with a round file or equivalent. Clean the rear wiper pivot serration with a wire brush. Wiper Pivot Serration E58837 (d) (e) Ceramic Line I30316 Install the RR wiper arm & blade assy in the position shown in the illustration. Install the RR wiper arm & blade assy with the nut. Torque: 5.5 N⋅m (56 kgf⋅cm, 48 in.⋅lbf) HINT: Hold down the arm hinge by hand in order to fasten the nut. (f) Install the rear wiper arm cover. (g) Operate the wiper while running water or washer fluid over the window, and check the wiping condition and that the rear wiper does not scrape against the body. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3515 66-14 WIPER & WASHER - REAR WIPER RUBBER REAR WIPER RUBBER 660HS-01 REPLACEMENT HINT: Installation is in the reverse order of removal. 1. (a) REMOVE REAR WIPER BLADE ASSY Raise the rear wiper blade assy to the position where the claw disengages with a click sound as shown in the illustration. NOTICE: Be careful not to damage the claw. Claw Position I40017 (b) Pull the rear wiper blade straight toward the left side of the vehicle to remove it from the rear wiper arm. NOTICE: Do not fold down the rear wiper arm with the rear wiper blade removed from it. I30318 Slightly (Push) Raise Stopper (Blade Base End) Tip End Pull Out I40018 2. (a) REMOVE REAR WIPER RUBBER Make the rear wiper rubber protrude from the base end stopper of the rear wiper blade. NOTICE: Do not forcibly pull out the wiper rubber as the backing plates may be deformed or blade claws may be damaged. HINT:
When removing the wiper rubber, pull it out from the base end, as the wiper blade has more space at the base end (section B as shown in the illustration).
Slightly pushing the wiper blade claw and the surrounding central area will allow the rubber to be pulled out more easily. Base End I40019 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3516 66-15 WIPER & WASHER - REAR WIPER RUBBER (b) Pull out the rear wiper rubber from the rear wiper blade completely. 3. (a) INSTALL REAR WIPER RUBBER Insert the rear wiper rubber from the claw position in the middle of the rear wiper blade to the base end. (b) After passing the rear wiper rubber through the base end claw, make it stick out from the base end stopper to pass it through the tip end claw. (c) Make sure that the rear wiper blade claws are fit in the rear wiper rubber groove. Pull Out I40020 Base End Tip End I40021 Base End Base End Stopper Tip End I40022 Slide (Rubber) I40023 Raise HINT:
If the blade claws are not fit in the rubber groove, slide the rubber several times to make the blade claw fit.
Applying a small amount of the window washer fluid to the rubber makes the blade claws fit easily.
Raise the middle part of the wiper rubber as shown in the illustration to maintain a longer stroke length for sliding the rubber. NOTICE: Do not forcibly slide the wiper rubber as the backing plates may be deformed or the blade claw may be damaged. Slide I40024 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3517 66-16 WIPER & WASHER - WINDSHIELD WIPER SWITCH ASSY WINDSHIELD WIPER SWITCH ASSY 660HT-01 REPLACEMENT HINT: Installation is in the reverse order of removal. 1. REMOVE STEERING COLUMN COVER LWR (SEE PAGE 50-8 ) 2. REMOVE STEERING COLUMN COVER UPR (SEE PAGE 50-8 ) 3. (a) (b) REMOVE WINDSHIELD WIPER SWITCH ASSY Disconnect the connector. Using a screwdriver, disengage the claw, and remove the windshield wiper switch assy. NOTICE: Pressing the claw hard breaks the claw. HINT: Tape the screwdriver tip before use. : Claw I39843 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3518 66-17 WIPER & WASHER - WASHER NOZZLE WASHER NOZZLE 660HU-01 INSPECTION 1. (a) INSPECT WASHER NOZZLE With the engine running, check that the washer fluid hits in the range indicated by the hatched areas on the windshield and the rear window. HINT: This washer nozzle does not have an adjustment function because this nozzle is a spray type. Front: A B D C A: 206.9 mm (8.14 in.) B: 401.8 mm (15.82 in.) C: 114.7 mm (4.51 in.) D: 385.6 mm (15.18 in.) Rear: A H I B J F G K D C E A: 111.9 mm (4.4 in.) B: 43.4 mm (1.7 in.) C: 106.7 mm (4.2 in) D: 150 mm (5.9 in.) E: 181.8 mm (7.15 in.) D F: 185.6 mm (7.3 in.) G: 60.5 mm (2.38 in.) H: 51.4 mm (2.02 in.) I: 6.5 mm (0.25 in.) J: 105 mm (4.13 in.) K: 200.8 mm (7.9 in.) I39811 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3519 66-4 WIPER & WASHER - WIPER AND WASHER SYSTEM 660HH-01 INSPECTION 1. (a) WINDSHIELD WIPER SWITCH ASSY Continuity Check (1) Measure the resistance according to the value(s) in the table below. Standard: Front Wiper Switch Connector Front View: C14 I30405 Tester connection Switch operation Specified condition 7 (+1) - 17 (+B) MIST Below 1 Ω 7 (+1) - 16 (+S) OFF Below 1 Ω 7 (+1) - 16 (+S) INT Below 1 Ω 7 (+1) - 17 (+B) LO Below 1 Ω 8 (+2) - 17 (+B) HI Below 1 Ω Tester connection Switch operation Specified condition 2 (EW) - 11 (WF) OFF 10 kΩ or higher 2 (EW) - 11 (WF) ON Below 1 Ω Front Washer Switch Rear Wiper and Washer Switch (b) Tester connection Switch operation Specified condition 2 (EW) - 12 (WR) WASH (Rear wiper switch OFF side) Below 1 Ω 2 (EW) - 10 (+1R) 2 (EW) - 12 (WR) 2 (EW) - 13 (C1R) OFF 10 kΩ or higher 2 (EW) - 13 (C1R) INT Below 1 Ω 2 (EW) - 10 (+1R) ON Below 1 Ω 2 (EW) - 10 (+1R) 2 (EW) - 12 (WR) WASH (Rear wiper switch OFF side) Below 1 Ω Intermittent Operation Check (1) Connect the voltmeter (+) terminal to terminal 7 (+1) of the connector, the voltmeter (-) terminals to terminal 2 (EW) of the connector. (2) Connect the battery (+) to terminal 17 (+B) of the connector, the battery (-) to terminal 2 (EW) and 16 (+S) of the connector. (3) Turn the wiper switch to INT. (4) Connect the battery (+) to terminal 16 (+S) of the connector for 5 seconds. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3506 66-5 WIPER & WASHER - (5) FAST: Connect the battery (-) to terminal 16 (+S) WIPER AND WASHER SYSTEM Connect the battery (-) to terminal 16 (+S) of the connector. Operate the intermittent wiper relay and check voltage between terminal 7 (+1) and terminal 2 (EW). SLOW: Connect the battery (-) to terminal 16 (+S) 7 (+1) ⇔ 2 (EW) Voltage between terminals 1.6 ± 1 seconds (c) Washer Switch ON OFF 10 to 14 V 7 (+1) ⇔ 2 (EW) 0V Voltage between terminals Approx. 0.3 seconds Approx. 2.2 seconds E74268 2. (a) Connector Front View: F6 (b) E34081 (c) 9.53
+ 5
- 10
Automatic Stop Position I19521 10.7 ± 5 seconds E56399 Operation Check (Front Wiper) (1) Turn the wiper switch OFF. (2) Connect the positive (+) lead from the battery to terminal 17 (+B) and the negative (-) lead to terminals 2 (EW) and 16 (+S). (3) Connect the positive (+) lead from the voltmeter to terminal 7 (+1) and the negative (-) lead to terminal 2 (EW).Turn the washer switch ON and OFF and check voltage between terminal 7 (+1) and terminal 2 (EW). WINDSHIELD WIPER MOTOR ASSY LO Operation Check (1) Connect the positive (+) lead from the battery to terminal 1 (+1) and the negative (-) lead to terminal 5 (E), check that the motor operates at low speed. HI Operation Check (1) Connect the positive (+) lead from the battery to terminal 4 (+2) and the negative (-) lead to terminal 5 (E), and check that the motor operates at high speed. Automatic Stop Operation Check (1) Connect the positive (+) lead from the battery to terminal 1 (+1) and the negative (-) lead to terminal 5 (E), and operate the motor at low speed and stop the motor operation anywhere except at the stop position by disconnecting positive (+) lead from terminal 1 (+1). (2) Connect terminals 1 (+1) and 3 (S). (3) Connect the positive (+) lead from the battery to terminal 2 (B), and check that the motor stops running at the stop position after the motor operates again. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3507 66-6 WIPER & WASHER REAR WIPER MOTOR ASSY Operation Check (1) Connect the positive (+) lead from the battery to terminal 1 (+B) and the negative (-) lead to terminal 3 (LS), and check that the motor operates. NOTICE: The body earth should be connected. R18 E34836 2 WIPER AND WASHER SYSTEM 3. (a) Connector Front View: 1 - 3 E74201 (b) Ceramic Line I30316 Automatic Stop Position Operation Check (1) Connect the positive (+) lead from the battery to terminal 1 (+B) and the negative (-) lead to terminal 3 (LS). NOTICE: The body earth should be connected. (2) With the motor being rotated, disconnect terminal 1 (+B) and terminal 3 (LS) to stop the motor operation at any position except the automatic stop position. (3) Connect the positive (+) lead from the battery to terminal 1 (+B), and check that the motor is restarted and automatically stopped. NOTICE: The body earth should be connected. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3508 66-3 WIPER & WASHER - WIPER AND WASHER SYSTEM 660HG-01 ON-VEHICLE INSPECTION F14 1. (a) FRONT WASHER MOTOR Operation Check (1) Fill the washer jar with the washer fluid. (2) Connect the positive battery (+) lead to terminal 1 of the windshield washer motor and pump assy, and the negative battery (-) lead to terminal 2. Check that washer fluid flows from the washer jar. 2. (a) REAR WASHER MOTOR Operation Check (1) Fill the washer jar with the washer fluid. (2) Connect the positive battery (+) lead to terminal 1 of the windshield washer motor and pump assy, and the negative battery (-) lead to terminal 2. Check that washer fluid flows from the washer jar. E66575 R21 E67367 3. (a) (b) (c) LEVEL WARNING SWITCH ASSY Check washer level warning switch continuity. Check that no continuity exists between terminals with switch OFF (float up). Check that continuity exists between terminals with switch ON (float down). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3505 66-1 WIPER & WASHER - WIPER AND WASHER SYSTEM WIPER AND WASHER SYSTEM 6605A-09 PRECAUTION 1. (a) (b) PRECAUTION OF WASHER NOZZLE ADJUSTMENT Do not clean or adjust the washer nozzle with a safety pin, etc. because; (1) the washer nozzle tip is made of resin and could be damaged. (2) adjustment is not necessary because the washer nozzle is spray type. In case the washer nozzle is clogged with wax, etc., remove it and clean the nozzle hole with a soft resin brush, etc. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3503 66-2 WIPER & WASHER - WIPER AND WASHER SYSTEM 660HF-02 PROBLEM SYMPTOMS TABLE WIPER AND WASHER SYSTEM Symptom Suspected Area See page Front wipers and washers do not operate. 1. WIPER/WASHER Fuse 2. Front Wiper Switch 3. Wire Harness or Connector 66-4 - Front wipers do not operate in LO or HI. 1. WIPER Fuse 2. Front Wiper Switch 3. Front Wiper Motor 4. Wire Harness or Connector 66-4 66-4 - Front wipers do not operate in INT. 1. Front Wiper Switch 2. Front Wiper Motor 3. Wire Harness or Connector 66-4 66-4 - Front washer motor does not operate. 1. WASHER Fuse 2. Front Washer Switch 3. Front Washer Motor 4. Wire Harness or Connector 66-4 66-3 - Front wipers do not operate when washer switch is ON. 1. Front Wiper Switch 2. Front Wiper Motor 3. Wire Harness or Connector 66-4 66-4 - Rear wipers and washers do not operate. 1. RR WIP Fuse 2. Rear Wiper and Washer Switch 3. Wire Harness or Connector 66-4 - Rear wipers do not operate in INT. 1. Rear Wiper and Washer Switch 2. Rear Wiper Motor 3. Wire Harness or Connector 66-4 66-4 - Rear washer motor does not operate. 1. WASHER Fuse 2. Rear Wiper and Washer Switch 3. Rear Washer Motor 4. Wire Harness or Connector 66-4 66-3 - Rear wipers do not operate when washer switch is ON. 1. Rear Wiper and Washer Switch 2. Rear Wiper Motor 3. Wire Harness or Connector 66-4 66-4 - Washer fluid does not operate. 1. Washer Hose and Nozzle
When the wiper switch is OFF, the wiper blade does not retract or the retract position is wrong. 1. *1Wiper Motor Washer fluid level warning does not operate. 66-7 1. Level Warning Switch Assy 2. Combination Meter Assy 3. Wire Harness or Connector 66-7 05-1882 - *1: Inspect wiper arm and blade set position 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3504 67-17 AUDIO & VISUAL SYSTEM - W/HOLDER ANTENNA ASSY W/HOLDER ANTENNA ASSY 6702K-04 REPLACEMENT HINT:

1. 2. 3. 4. COMPONENTS: See page 76-21 Installation is in the reverse order of removal. REMOVE GLOVE COMPARTMENT DOOR ASSY (SEE PAGE 71-10 ) REMOVE INSTRUMENT PANEL FINISH PANEL LOWER NO.2 (SEE PAGE 71-10 ) REMOVE FRONT PILLAR GARNISH RH (SEE PAGE 71-10 ) REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSY LH (SEE PAGE 76-2 ) 2 Clamps 5. (a) (b) REMOVE W/HOLDER ANTENNA ASSY Disconnect the connector,and remove the bolt. Remove the 2 clamps. (c) (d) Tie the string at the tip of the cable of the w/holder antenna assy. Remove the antenna nut and ornament antenna. (e) Remove the nut and w/holder antenna assy. I30432 String I30433 I30434 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3536 67-18 AUDIO & VISUAL SYSTEM 6. (a) (b) (c) (d) (e) - W/HOLDER ANTENNA ASSY INSTALL W/HOLDER ANTENNA ASSY Install the w/holder antenna assy with the nut. Install the antenna nut and ornament antenna. Use the string to put the cable of the w/holder antenna assy. Install the 2 clamps. Connect the connector, install the bolt. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3537 67-15 AUDIO & VISUAL SYSTEM - AMPLIFIER ANTENNA ASSY AMPLIFIER ANTENNA ASSY 6716C-01 REPLACEMENT HINT:

COMPONENTS: See page 76-21 Installation is in the reverse order of removal. REMOVE ROOF HEADLINING ASSY (SEE PAGE 76-21 ) 1. HINT: Refer to the procedures up to ”REMOVE ROOF HEAD LINING ASSY”. 2. (a) REMOVE ROOF SIDE RAIL BRACKET LH Remove the 4 bolts and roof side rail bracket LH. 3. (a) (b) REMOVE AMPLIFIER ANTENNA ASSY Disconnect the 2 connectors. Remove the 4 clamps, bolt and amplifier antenna assy. I30429 4 Clamps I30430 4. INSTALL ROOF HEADLINING ASSY (SEE PAGE 76-21 ) HINT: Refer to the procedures from ”INSTALL ROOF HEAD LINING ASSY”. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3534 67-14 AUDIO & VISUAL SYSTEM - ANTENNA CORD SUB-ASSY NO.3 ANTENNA CORD SUB-ASSY NO.3 6715X-01 REPLACEMENT HINT:

COMPONENTS: See page 76-21 Installation is in the reverse order of removal. REMOVE ROOF HEADLINING ASSY (SEE PAGE 76-21 ) 1. HINT: Refer to the procedures up to ”REMOVE ROOF HEAD LINING ASSY”. 2. REMOVE ANTENNA CORD SUB-ASSY NO.3 (a) Remove the antenna cord sub assy No. 3 from the roof headlining. 3. INSTALL ANTENNA CORD SUB-ASSY NO.3 (a) Tape the antenna cord sub-assy No. 3 at the position of the roof headlining shown in the illustration. NOTICE: The antenna cord sub assy should come to the center of the tape (100 mm x 25 mm) when taped. Try not to touch the adhesive side of the tape when taping. w/o Sliding Roof : w/ Sliding Roof : : Tape position I30428 4. INSTALL ROOF HEADLINING ASSY (SEE PAGE 76-21 ) HINT: Refer to the procedures from ”INSTALL ROOF HEAD LINING ASSY”. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3533 67-13 AUDIO & VISUAL SYSTEM - ANTENNA CORD SUB-ASSY NO.2 ANTENNA CORD SUB-ASSY NO.2 670I9-03 REPLACEMENT HINT:

1. COMPONENTS: See page 67-2 Installation is in the reverse order of removal. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY W/PASSENGER AIR BAG ASSY (SEE PAGE 71-10 ) HINT: Refer to the procedures up to ”REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY W/ PASSENGER AIRBAG ASSY”. 2. (a) REMOVE ANTENNA CORD SUB-ASSY NO.2 Remove the 4 clamps and antenna cord sub-assy. 4 Clamps I30424 3. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY W/PASSENGER AIR BAG ASSY (SEE PAGE 71-10 ) HINT: Refer to the procedures from ”INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY W/ PASSENGER AIRBAG ASSY”. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3532 67-32 AUDIO & VISUAL SYSTEM - POWER OUTLET SOCKET ASSY POWER OUTLET SOCKET ASSY 6716A-01 REPLACEMENT HINT:

1. 2. 3. COMPONENTS: See page 67-2 Installation is in the reverse order of removal. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSY CENTER REMOVE FRONT SEAT ARMREST ASSY CENTER REMOVE CONSOLE BOX ASSY 3 Claws 2 Claws 4. (a) REMOVE POWER OUTLET SOCKET ASSY Remove the power outlet socket assy together with the console box rear cover as shown in the illustration. (b) (c) Disconnect the connector. Release the 2 claw fittings and remove the power outlet socket assy. I39470 I39471 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3551 67-22 AUDIO & VISUAL SYSTEM - VOLTAGE INVERTER ASSY VOLTAGE INVERTER ASSY 67162-01 REPLACEMENT HINT:

1. 2. 3. COMPONENTS: See page 67-2 Installation is in the reverse order of removal. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSY CENTER (SEE PAGE 71-10 ) REMOVE FRONT SEAT ARMREST ASSY CENTER (SEE PAGE 71-10 ) REMOVE CONSOLE BOX ASSY (SEE PAGE 71-10 ) 4. (a) (b) 2 Clamps REMOVE VOLTAGE INVERTER ASSY Disconnect the connector. Remove the 2 clamps and the voltage inverter assy. I38950 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3541 67-23 AUDIO & VISUAL SYSTEM - MULTI-DISPLAY CONTROLLER SUB-ASSY MULTI-DISPLA Y CONTROLLER SUB-ASSY 67163-01 REPLACEMENT HINT:

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. COMPONENTS: See page 67-2 Installation is in the reverse order of removal. REMOVE REAR SEAT ASSY RH (SEE PAGE 72-35 ) REMOVE REAR SEAT ASSY LH (SEE PAGE 72-28 ) REMOVE REAR DOOR SCUFF PLATE RH (SEE PAGE 76-21 ) REMOVE REAR DOOR SCUFF PLATE LH (SEE PAGE 76-21 ) REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH (SEE PAGE 76-21 ) REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (SEE PAGE 76-21 ) REMOVE TONNEAU COVER ASSY (SEE PAGE 76-21 ) REMOVE DECK BOARD SUB-ASSY (SEE PAGE 76-21 ) REMOVE DECK BOARD SUB-ASSY NO.2 (SEE PAGE 76-21 ) REMOVE DECK BOARD SUB-ASSY NO.3 (SEE PAGE 76-21 ) REMOVE DECK SIDE TRIM BOX RH (SEE PAGE 76-21 ) REMOVE DECK SIDE TRIM BOX LH (SEE PAGE 76-21 ) REMOVE REAR FLOOR FINISH PLATE (SEE PAGE 76-21 ) REMOVE DECK TRIM SIDE PANEL ASSY RH (SEE PAGE 76-21 ) REMOVE DECK TRIM SIDE PANEL ASSY LH (SEE PAGE 76-21 ) 16. (a) REMOVE REAR SEAT SUB FLOOR PANEL ASSY (W/O RR NO.2 SEAT) Remove the 3 bolts, 3 nuts and rear seat sub floor panel. I30435 17. W/o RR No.2 Seat : (a) (b) REMOVE MULTI- DISPLAY CONTROLLER W/BRACKET Disconnect the connectors. W/o RR No.2 Seat: Remove the 2 bolts and nut and the multi-display controller w/bracket. I39464 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3542 67-24 AUDIO & VISUAL SYSTEM W/ RR No.2 Seat : - MULTI-DISPLAY CONTROLLER SUB-ASSY (c) W/ RR No.2 Seat: Remove the 2 nuts and bolt and the multi-display controller w/bracket. 18. (a) REMOVE MULTI-DISPLA Y CONTROLER BRACKET A Remove the 2 screws and the multi-display controller bracket A. 19. (a) REMOVE MULTI-DISPLA Y CONTROLER BRACKET B Remove the 2 screws and the multi-display controller bracket B. I39467 W/ RR No.2 Seat : I39468 W/o RR No.2 Seat : I39466 W/ RR No.2 Seat : I39465 W/o RR No.2 Seat : I39469 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3543 67-25 AUDIO & VISUAL SYSTEM 20. - MULTI-DISPLAY CONTROLLER SUB-ASSY REMOVE MULTI-DISPLA Y CONTROLLER SUB-ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3544 67-26 AUDIO & VISUAL SYSTEM - TELEVISION DISPLAY ASSY TELEVISION DISPLAY ASSY 67164-01 REPLACEMENT HINT:

COMPONENTS: See page 67-2 Installation is in the reverse order of removal. 4 Claws 1. (a) REMOVE TELEVISION BASE Release the 4 claws and remove the television base. 2. (a) REMOVE TELEVISION DISPLAY ASSY Disconnect the connector and remove the 4 nuts and the television display assy. I39462 I39463 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3545 67-27 AUDIO & VISUAL SYSTEM - VIDEO(VIDEO ADAPTER) TERMINAL VIDEO(VIDEO ADAPTER) TERMINAL 67165-01 REPLACEMENT HINT:

COMPONENTS: See page 67-2 Installation is in the reverse order of removal. 3 Claws 4 Claws 1. (a) REMOVE VIDEO(VIDEO ADAPTER) TERMINAL Remove the video (video adapter) terminal together with the console box rear cover as shown in the illustration. (b) (c) Disconnect the connector. Release the 4 claw fittings and remove the video (video adapter) terminal. I39470 I39472 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3546 67-28 AUDIO & VISUAL SYSTEM - STEERING PAD SWITCH LH STEERING PAD SWITCH LH 67166-01 REPLACEMENT HINT:

COMPONENTS: See page 67-2 Installation is in the reverse order of removal. PRECAUTION (SEE PAGE 60-1 ) SEPARATE BATTERY NEGATIVE TERMINAL (SEE PAGE 60-1 ) REMOVE STEERING WHEEL COVER LOWER NO.2 (SEE PAGE 50-8 ) REMOVE STEERING WHEEL COVER LOWER NO.3 (SEE PAGE 50-8 ) REMOVE HORN BUTTON ASSY (SEE PAGE 50-8 ) 1. 2. 3. 4. 5. 6. (a) (b) (c) REMOVE STEERING PAD SWITCH LH Disconnect the connector. Disconnect the connector of cruise control main switch. Remove the screw. (d) Release the 2 pin fittings and remove the steering pad switch LH. E62430 E62431 2 Pins 7. 8. 9. 10. I33301 INSTALL HORN BUTTON ASSY (SEE PAGE 60-1 1) CONNECT BATTERY NEGATIVE TERMINAL INSPECT HORN BUTTON ASSY (SEE PAGE 50-8 ) INSPECT SRS WARNING LIGHT (SEE PAGE 05-1207 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3547 67-2 AUDIO & VISUAL SYSTEM - AUDIO & VISUAL SYSTEM 6715P-01 COMPONENTS Instrument Cluster Finish Panel Sub-assy Center Integration Control & Panel Assy Radio Bracket No.1 Radio Bracket No.2 Radio Receiver Assy Integration Control And Panel Assy w/ EMV Navigation System: Multi-Display (CRT Display) Display Multi-display Controller Bracket A Multi-display Controller Bracket B Radio Receiver Assy I39620 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3521 67-3 AUDIO & VISUAL SYSTEM Antenna Cord Sub-Assy No.2 - AUDIO & VISUAL SYSTEM w/ Antenna cord sub-assy No.3: Antenna Cord Sub-Assy No.2 Navigation Antenna Assy Power Outlet Socket Assy Power Outlet Socket Cover Steering Pad Switch LH Cigarette Lighter Assy Power Outlet Socket Assy CTR Cigarette Lighter Cover Power Outlet Socket Cover CTR I39621 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3522 67-4 AUDIO & VISUAL SYSTEM - AUDIO & VISUAL SYSTEM Antenna Cord Sub-Assy No.3 W/ Holder Antenna Assy Front No.2 Speaker Assy Amplifier Antenna Assy Front No.1 Speaker Assy Amplifier Antenna Assy Rear Speaker Assy Power Outlet Socket Assy RR Voltage Inverter Assy Power Outlet Socket Cover RR I39622 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3523 67-5 AUDIO & VISUAL SYSTEM - AUDIO & VISUAL SYSTEM Television Display Assy Television Base Stereo Component Amplifier Assy Video (Video Adapter) Terminal Navigation Computer Cover w/o RR No.2 Seat: Multi- display Controller Sub-assy Power Outlet Socket Assy Multi- display Controller Bracket A Multi- display Controller Bracket B Disc Player Bracket w/ RR No.2 Seat: Navigation ECU Navigation ECU Cover Multi- display Controller Sub-assy Multi- display Controller Bracket A Multi- display Controller Bracket B I39623 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3524 67-1 AUDIO & VISUAL SYSTEM - AUDIO & VISUAL SYSTEM AUDIO & VISUAL SYSTEM 6715Q-01 PRECAUTION 1. (a) (b) OBSERVE HANDLING AND OPERATIONAL PRECAUTIONS Explain to the customer that when the negative terminal is disconnected from the battery, the AM/FM channel presets in the radio receiver are cleared. If necessary, make a note of the recorded channel information before the negative terminal is disconnected, then reset the information after the negative terminal is reconnected. The removal/installation of the radio receiver should be performed after all cassette tapes and audio CDs are ejected from the radio receiver. HINT: If a cassette tape or audio CD cannot be ejected due to malfunction of the radio receiver, do not attempt to remove it forcefully. Bring the vehicle to the repair plant. (c) Fasten the earth bolt securely when the antenna cord is removed or installed. HINT: Failure to fasten the earth bolt securely causes noise when receiving radio waves. (d) Do not touch the cone paper of the speaker. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3520 67-6 AUDIO & VISUAL SYSTEM - RADIO RECEIVER ASSY RADIO RECEIVER ASSY 6715R-01 REPLACEMENT HINT:

1. COMPONENTS: See page 67-2 Installation is in the reverse order of removal. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY CENTER (SEE PAGE 71-10 ) 2. (a) (b) REMOVE INTEGRATION CONTROL & PANEL ASSY Remove the 6 bolts. Disconnect the connectors and remove the integration control & panel assy. 3. REMOVE RADIO BRACKET NO.1 (W/O EMV & NAVIGATION SYSTEM) Remove the 4 bolts, 2 screws and radio bracket No. 1. E51908 (a) E51909 4. (a) REMOVE MULTI-DISPLA Y CONTROLER BRACKET A (W/ EMV & NAVIGATION SYSTEM) Remove the 7 screws and multi-display controller bracket A. E51911 5. (a) REMOVE RADIO BRACKET NO.2 (W/O EMV & NAVIGATION SYSTEM) Remove the 4 bolts, 2 screws and radio bracket No. 2. E51910 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3525 67-7 AUDIO & VISUAL SYSTEM 6. (a) - RADIO RECEIVER ASSY REMOVE MULTI-DISPLA Y CONTROLER BRACKET B (W/ EMV & NAVIGATION SYSTEM) Remove the 7 screws and multi-display controller bracket B. E51912 7. REMOVE RADIO RECEIVER ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3526 67-8 AUDIO & VISUAL SYSTEM - MULTI-DISPLAY (CRT DISPLAY) DISPLAY MULTI-DISPLA Y (CRT DISPLAY) DISPLAY 6715S-01 REPLACEMENT HINT:

1. COMPONENTS: See page 67-2 Installation is in the reverse order of removal. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY CENTER (SEE PAGE 71-10 ) 2. (a) (b) REMOVE INTEGRATION CONTROL & PANEL ASSY Remove the 6 bolts. Disconnect the connectors and remove the integration control & panel assy. 3. (a) REMOVE MULTI-DISPLA Y CONTROLER BRACKET A Remove the 7 screws and multi-display controller bracket A. 4. (a) REMOVE MULTI-DISPLA Y CONTROLER BRACKET B Remove the 7 screws and multi-display controller bracket B. I40943 E51911 E51912 5. REMOVE MULTI-DISPLA Y (CRT DISPLAY) DISPLAY 6. INSTALL MULTI-DISPLA Y (CRT DISPLAY) DISPLAY HINT: Perform the screen noise automatic adjustment when screen noise occurs (see page 05-1803 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3527 67-9 AUDIO & VISUAL SYSTEM - NAVIGATION ECU NAVIGATION ECU 6715T-01 REPLACEMENT HINT:

1. COMPONENTS: See page 67-2 Installation is in the reverse order of removal. REMOVE FRONT SEAT ASSEMBLY LH POWER SEAT (SEE PAGE 72-1 1) MANUAL SEAT (SEE PAGE 72-19 ) 4 Claws 2. (a) REMOVE NAVIGATION ECU COVER Remove the 4 claws and the navigation ECU cover. 3. (a) (b) REMOVE NAVIGATION ECU W/BRACKET Disconnect the connector. Remove the 2 bolts and the navigation ECU w/ bracket. 4. (a) REMOVE DISC PLAYER BRACKET Remove the 4 screws and the disc player bracket. I39625 I39624 I39626 5. REMOVE NAVIGATION ECU 6. INSTALL NAVIGATION ECU HINT: Perform the screen noise automatic adjustment when screen noise occurs (see page 05-1803 ). 7. INSTALL FRONT SEAT ASSEMBLY LH POWER SEAT (SEE PAGE 72-1 1) MANUAL SEAT (SEE PAGE 72-19 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3528 67-10 AUDIO & VISUAL SYSTEM - FRONT NO.1 SPEAKER ASSY FRONT NO.1 SPEAKER ASSY 6715U-01 REPLACEMENT HINT:

1. 2. 3. 4. 5. COMPONENTS: See page 67-2 Installation is in the reverse order of removal. REMOVE MULTIPLEX NETWORK MASTER SWITCH ASSY (SEE PAGE 75-6 ) REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (SEE PAGE 75-6 ) REMOVE DOOR PULL HANDLE (SEE PAGE 75-6 ) REMOVE FRONT DOOR TRIM BOARD SUB-ASSY LH (SEE PAGE 75-6 ) REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSY LH (SEE PAGE 75-6 ) 6. (a) (b) REMOVE FRONT NO.1 SPEAKER ASSY Disconnect the connector. Remove the 3 screws and front No. 1 speaker assy. 7. (a) (b) INSTALL FRONT NO.1 SPEAKER ASSY Install the front No.1 speaker assy with the 3 screws. Connect the connector. I30421 I30421 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3529 67-1 1 AUDIO & VISUAL SYSTEM - FRONT NO.2 SPEAKER ASSY FRONT NO.2 SPEAKER ASSY 6715V-01 REPLACEMENT HINT:

1. 2. 3. 4. 5. COMPONENTS: See page 67-2 Installation is in the reverse order of removal. REMOVE MULTIPLEX NETWORK MASTER SWITCH ASSY (SEE PAGE 75-6 ) REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (SEE PAGE 75-6 ) REMOVE DOOR PULL HANDLE (SEE PAGE 75-6 ) REMOVE FRONT DOOR TRIM BOARD SUB-ASSY LH (SEE PAGE 75-6 ) REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSY LH (SEE PAGE 75-6 ) 6. (a) (b) REMOVE FRONT NO.2 SPEAKER ASSY Disconnect the connector. Remove the screw and front No. 2 speaker assy. I30422 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3530 67-12 AUDIO & VISUAL SYSTEM - REAR SPEAKER ASSY REAR SPEAKER ASSY 6715W-01 REPLACEMENT HINT:

1. 2. 3. 4. COMPONENTS: See page 75-13 Installation is in the reverse order of removal. REMOVE DOOR PULL HANDLE (SEE PAGE 75-13 ) REMOVE REAR DOOR TRIM BOARD SUB-ASSY LH (SEE PAGE 75-13 ) REMOVE REAR DOOR INSIDE HANDLE SUB-ASSY LH (SEE PAGE 75-13 ) REMOVE REAR DOOR SERVICE HOLE COVER LH (SEE PAGE 75-13 ) 5. (a) (b) REMOVE REAR SPEAKER ASSY Disconnect the connector. Remove the 3 screws and rear speaker assy. 6. (a) (b) INSTALL REAR SPEAKER ASSY Install the rear speaker assy with the 3 screws. Connect the connector. I30423 I30423 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3531 67-16 AUDIO & VISUAL SYSTEM - AMPLIFIER ANTENNA ASSY AMPLIFIER ANTENNA ASSY 6715Y-01 REPLACEMENT HINT:

COMPONENTS: See page 76-21 Installation is in the reverse order of removal. REMOVE ROOF HEADLINING ASSY (SEE PAGE 76-21 ) 1. HINT: Refer to the procedures up to ”REMOVE ROOF HEAD LINING ASSY”. 2. (a) REMOVE ROOF SIDE RAIL BRACKET RH Remove the 4 bolts and roof side rail bracket RH. 3. (a) (b) REMOVE AMPLIFIER ANTENNA ASSY Disconnect the 2 connectors. Remove the 3 clamps, bolt and amplifier antenna assy. I30494 3 Clamps I30431 4. INSTALL ROOF HEADLINING ASSY (SEE PAGE 76-21 ) HINT: Refer to the procedures from ”INSTALL ROOF HEAD LINING ASSY”. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3535 67-20 AUDIO & VISUAL SYSTEM - STEREO COMPONENT AMPLIFIER ASSY STEREO COMPONENT AMPLIFIER ASSY 67160-01 REPLACEMENT HINT:

1. 2. 3. 4. 5. 6. 7. 8. COMPONENTS: See page 67-2 Installation is in the reverse order of removal. REMOVE TONNEAU COVER ASSY (SEE PAGE 76-21 ) REMOVE DECK BOARD SUB-ASSY NO.2 (SEE PAGE 76-21 ) REMOVE DECK BOARD SUB-ASSY NO.3 (SEE PAGE 76-21 ) REMOVE DECK FLOOR BOX REAR (SEE PAGE 76-21 ) REMOVE DECK FLOOR BOX FRONT (SEE PAGE 76-21 ) REMOVE REAR FLOOR FINISH PLATE (SEE PAGE 76-21 ) REMOVE DECK SIDE TRIM BOX RH (SEE PAGE 76-21 ) REMOVE DECK TRIM SIDE PANEL ASSY RH (SEE PAGE 76-21 ) 9. (a) (b) REMOVE STEREO COMPONENT AMPLIFIER ASSY Remove the 2 nuts and bolt. Disconnect the connectors, then remove the stereo component amplifier assy. I38962 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3539 67-19 AUDIO & VISUAL SYSTEM - NAVIGATION ANTENNA ASSY NAVIGATION ANTENNA ASSY 6715Z-01 REPLACEMENT HINT:

1. COMPONENTS: See page 67-2 Installation is in the reverse order of removal. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY W/PASSENGER AIR BAG ASSY (SEE PAGE 71-10 ) HINT: Refer to the procedures up to ”REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY W/ PASSENGER AIRBAG ASSY”. 2. (a) 3 Claws 3. REMOVE NAVIGATION ANTENNA ASSY Release the 3 clamps and remove the 2 screws and the navigation antenna assy. I39639 INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY W/PASSENGER AIR BAG ASSY (SEE PAGE 71-10 ) HINT: Refer to the procedures from ”INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY W/ PASSENGER AIRBAG ASSY”. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3538 67-21 AUDIO & VISUAL SYSTEM - NETWORK GATEWAY ECU NETWORK GATEWAY ECU 67161-01 REPLACEMENT HINT:

1. 2. COMPONENTS: See page 67-2 Installation is in the reverse order of removal. REMOVE GLOVE COMPARTMENT DOOR ASSY (SEE PAGE 71-10 ) REMOVE INSTRUMENT PANEL FINISH PANEL LOWER NO.2 (SEE PAGE 71-10 ) 3. (a) (b) REMOVE NETWORK GATEWAY ECU Disconnect the connector. Remove the bolt and the network gateway ECU. I39640 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3540 67-30 AUDIO & VISUAL SYSTEM - POWER OUTLET SOCKET ASSY CTR POWER OUTLET SOCKET ASSY CTR 67168-01 REPLACEMENT HINT:

COMPONENTS: See page 67-2 Installation is in the reverse order of removal. 1. (a) REMOVE POWER OUTLET SOCKET ASSY CTR Turn the socket in the circumference direction as shown in the illustration, disengage the claw between the socket and the power point socket cover, and push out the socket to the room side. E03722 2. (a) INSTALL POWER OUTLET SOCKET ASSY CTR Align the socket with the notch on the power point socket cover CTR and install the power socket assy CTR by pushing it in as hard as possible. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3549 67-31 AUDIO & VISUAL SYSTEM - POWER POINT SOCKET ASSY RR POWER POINT SOCKET ASSY RR 67169-01 REPLACEMENT HINT:

COMPONENTS: See page 67-2 Installation is in the reverse order of removal. 1. (a) Hole REMOVE POWER POINT SOCKET ASSY RR Using a screwdriver, disengage the claw on the power point socket cover from the hole in the power point socket, then pull out the power point socket approx. 10 mm (0.39 in.). HINT: Tape the screwdriver tip before use. H06011 (b) Trim Body Using a screwdriver, disengage the claw on the power point socket cover from the body and remove the power point socket and cover as a unit. HINT: Tape the screwdriver tip before use. (c) Disconnect the connector. (d) Disassemble the power point socket from the socket cover. Claw H06012 2. (a) (b) Trim Body (c) INSTALL POWER POINT SOCKET ASSY RR Assemble the power point socket to the power point socket cover at the position 10 mm (0.39 in.) away from full lock position and ensure that they are temporarily locked. Align the cut-out on the body with the claw on the power point socket cover and install the power point socket and cover to the body. After installing them, push in the power point socket approx. 10 mm (0.39 in.) to lock it. Claw Power Point Socket H06013 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3550 67-29 AUDIO & VISUAL SYSTEM - CIGARETTE LIGHTER ASSY CIGARETTE LIGHTER ASSY 67167-01 REPLACEMENT HINT:

1. COMPONENTS: See page 67-2 Installation is in the reverse order of removal. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSY CENTER (SEE PAGE 71-10 ) 2. (a) REMOVE CIGARETTE LIGHTER ASSY Remove the cigarette lighter cover. (b) Disengage the meshing of the cigarette lighter and the cigarette lighter indicator lens by rotating the cigarette lighter assy. Pull out the cigarette lighter assy. E51929 (c) E37339 3. (a) INSTALL CIGARETTE LIGHTER ASSY Aligning the socket with the cutout of the socket cover, fully push it to install. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3548 67-33 AUDIO & VISUAL SYSTEM - WINDOW GLASS (ANTENNA WIRE) WINDOW GLASS (ANTENNA WIRE) 6716B-01 REPAIR Tester Probe Heat Wire Tin Foil BE4029 1. INSPECT WINDOW GLASS (ANTENNA WIRE) NOTICE: When cleaning the glass, use a soft, dry cloth, and wipe the glass in the direction of the wire. Take care not to damage the wires. Do not use detergents or glass cleaners with abrasive ingredients. When measuring voltage, wind a piece of tin foil around the top of the negative probe and press the foil against the wire with your finger, as shown in the illustration. (a) Inspect the continuity at the center of each antenna wire as shown in the illustration. 2. (a) (c) REPAIR WINDOW GLASS (ANTENNA WIRE) Clean the broken wire tips with a grease, wax and silicone remover. Place the masking tape along both sides of the wire to be repaired. Throughly mix the repair agent (Dupont paste No. 4817). (d) (e) (f) Using a fine tip brush, apply a small amount to the wire. After a few minutes, remove the masking tape. Do not repair the defogger wire for at least 24 hours. E32576 Repair Point (b) Broken Wire Masking Tape BE0150 Fine Tip Brush Repair Point Glass BE0151 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3552 69-2 COMMUNICATION SYSTEM - HORN SYSTEM 6909D-01 INSPECTION 3 5 1 2 5 1 1. (a) (b) INSPECT RELAY (HORN) Remove the HORN relay from the engine room J/B. Measure the HORN relay resistance. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) 2 3 B60778 2. (a) INSPECT HIGH PITCHED HORN ASSY Check operation of the horn. Standard: Measurement Condition Specified Operation Battery positive (+) → Terminal 1 Battery negative (-) → Horn bracket Horn sounds If the result is not as specified, replace the horn assy. B72265 3. (a) INSPECT LOW PITCHED HORN ASSY Check operation of the horn. Standard: Measurement Condition Specified Operation Battery positive (+) → Terminal 1 Battery negative (-) → Horn bracket Horn sounds If the result is not as specified, replace the horn assy. B72265 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3554 69-1 COMMUNICATION SYSTEM - HORN SYSTEM HORN SYSTEM 6900G-04 LOCATION High Pitched Horn Low Pitched Horn Steering Wheel Pad
Horn Button Switch Engine Room J/B
HORN Relay
HORN Fuse B74626 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3553 70-1 WINDSHIELD/WINDOWGLASS/MIRROR - WINDSHIELD GLASS WINDSHIELD GLASS 700AE-03 COMPONENTS Assist Grip Assy Roof Headlining Assy Inner Rear View Mirror Assy Front Door Opening Trim Weatherstrip RH Inner Rear View Mirror Cover Roof Console Box Cover Inner RH Visor Assy LH Visor Assy Courtesy Lens Assist Grip Assy
Windshield Moulding Outer Upper Visor Holder Front Pillar Garnish RH Windshield Moulding Outside RH
Windshield Glass Stopper No. 2
Windshield Glass Stopper No. 1
Windshield Glass Stopper No. 2
Window Glass Adhesive Dam No. 2
Window Glass Adhesive Dam
Windshield Outside Moulding Clip No. 1 Windshield Moulding Outside LH
Windshield Outside Moulding Clip No. 1 Front Pillar Garnish LH Windshield Glass Cowl Top Ventilator Louver Hood to Cowl Top Seal Cowl Top Vent Louver Protector Front Door Opening Trim Weatherstrip LH Front Wiper Arm RH N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part 24 (245, 18) Front Wiper Arm LH B75810 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3555 70-2 WINDSHIELD/WINDOWGLASS/MIRROR - WINDSHIELD GLASS 7012T-01 REPLACEMENT HINT:
The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH (See page 76-21 ) REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH (See page 76-21 ) REMOVE FRONT PILLAR GARNISH LH (See page 76-21 ) REMOVE FRONT PILLAR GARNISH RH (See page 76-21 ) REMOVE LH VISOR ASSY (See page 76-21 ) REMOVE RH VISOR ASSY (See page 76-21 ) REMOVE VISOR HOLDER (See page 76-21 ) REMOVE ROOF CONSOLE BOX ASSY (See page 76-21 ) REMOVE ASSIST GRIP ASSY (See page 76-21 ) REMOVE ROOF HEADLINING ASSY (See page 76-21 )
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. HINT: It is not necessary to completely remove the roof headlining. Slightly lower the front section of the roof headlining so that the windshield glass can be removed later in step 19. 11. REMOVE INNER REAR VIEW MIRROR ASSY (See page 70-34 ) 12. REMOVE FR WIPER ARM LH (See page 66-7 ) 13. REMOVE FR WIPER ARM RH (See page 66-7 ) 14. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See page 66-7 ) Screwdriver Clip Clip Clip Protective Tape B51773 15. REMOVE WINDSHIELD MOULDING OUTSIDE LH (a) Put protective tape. (b) Using a screwdriver, pry out the 5 clips. HINT: Tape the screwdriver tip before use. (c) Using a screwdriver, pry out the hooks and windshield moulding outside LH. HINT: Tape the screwdriver tip before use. 16. REMOVE WINDSHIELD MOULDING OUTSIDE RH HINT: Use the same procedures described for the LH side. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3556 70-3 WINDSHIELD/WINDOWGLASS/MIRROR - 17. (a) 5 mm Protective Tape Drill Rivet WINDSHIELD GLASS REMOVE WINDSHIELD OUTSIDE MOULDING CLIP NO.1 Using a drill of less than φ 4 mm (0.16 in.), gently and perpendicularly place the drill tip onto the rivet and cut the rivet flanges. HINT: Wind tape around the drill blade so that the drill blade appears approximately 5 mm (0.20 in.) on the edge. NOTICE:
Be sure to gently place the drill perpendicular to the rivet to prevent the rivet hole and the drill itself from being damaged.
Be careful as the cut rivet will be very hot. (b) Even if the flange is taken off, continue drilling and push cut the remaining fragment with the drill. (c) Remove the windshield outside moulding clip No.1. Protective Tape B63756 Windshield Glass Cut 18. (a) Moulding Cut Vehicle Body B51745 REMOVE WINDSHIELD MOULDING OUTER UPPER Using a knife, cut off the moulding, as shown in the illustration. NOTICE: Be careful not to damage the vehicle body with the knife. (b) Remove the remaining moulding. HINT: Make a partial cut in the moulding. Then pull and remove it by hand. 19. (a) (b) Stopper (c) Piano Wire REMOVE WINDSHIELD GLASS w/ Window defogger: Disconnect the connector. From the interior, insert piano wire between the vehicle body and glass, as shown in the illustration. Tie objects that can serve as handles (for example, wooden blocks) to all wire ends. B51747 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3557 70-4 WINDSHIELD/WINDOWGLASS/MIRROR - Plastic Sheet Protective Tape B63724 WINDSHIELD GLASS HINT: Apply protective tape to the outer surface of the vehicle body to prevent its surface from being scratched. NOTICE:
When separating the glass from the vehicle, be careful not to damage the vehicle’s paint or interior/exterior ornaments.
To prevent the safety pad from being scratched when removing the glass, place a plastic sheet between the piano wire and safety pad. (d) Cut through the adhesive by pulling the piano wire around the glass. (e) Disengage the stoppers. (f) Using a suction cup, remove the glass. NOTICE: Leave as much adhesive on the vehicle body as possible when removing the glass. 20. (a) B73128 Backside Ceramic Line A B C C Stopper B75811 CLEAN WINDSHIELD GLASS Using a scraper, remove the damaged stoppers, dams and adhesive sticking to the glass. (b) Clean the outer circumference of the glass with white gasoline. NOTICE:
Do not touch the glass surface after cleaning it.
Even if using new glass, clean the glass with white gasoline. 21. INSTALL WINDSHIELD GLASS STOPPER NO.2 (a) Coat the installation part of the stoppers with Primer G. NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Throw away any leftover Primer G.
Do not apply too much Primer G. (b) Install 2 new stoppers onto the glass, as shown in the illustration. Specification: Area Measurement A 7.1 mm (0.28 in.) B 40 mm (1.58 in.) C 12.5 mm (0.49 in.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3558 70-5 WINDSHIELD/WINDOWGLASS/MIRROR - 22. (a) Stopper WINDSHIELD GLASS INSTALL WINDSHIELD GLASS STOPPER NO.1 Install 2 new stoppers to the vehicle body, as shown in the illustration. Vehicle Body B63758 Backside A A A A A A B A - A 23. (a) Dam No. 2 Dam B - B B a INSTALL WINDOW GLASS ADHESIVE DAM Coat the installation part of the windshield glass adhesive dam with Primer G. NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Throw away any leftover Primer G.
Do not apply too much Primer G. (b) Install a new dam, applying double-sided tape all the way around the glass except where the stoppers are installed, as shown in the illustration. Specification: b B51766 Adhesive Measurement a 7 mm (0.28 in.) b 37 mm (1.46 in.) 24. 25. (a) Adhesive Vehicle Body Area B73084 INSTALL WINDOW GLASS ADHESIVE DAM NO.2 INSTALL WINDSHIELD GLASS Clean and shape the contact surface of the vehicle body. (1) Using a knife, cut away any rough adhesive on the contact surface of the vehicle body to ensure the appropriate surface shape. NOTICE: Be careful not to damage the vehicle body. HINT: Leave as much of the adhesive on the vehicle body as possible. (2) Clean the contact surface of the vehicle body with a piece of shop rag saturated with cleaner. HINT: Even if all the adhesive has been removed, clean the vehicle body. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3559 70-6 WINDSHIELD/WINDOWGLASS/MIRROR - WINDSHIELD GLASS (b) Mark B73132 Position the glass. (1) Using a suction cup, place the glass in the correct position. (2) Check that the whole contact surface of the glass rim is perfectly even. (3) Place reference marks between the glass and vehicle body. NOTICE: Check that the stoppers are attached to the vehicle body correctly. HINT: When reusing the glass, check and correct the reference mark positions. (4) Using a suction cup, remove the glass. (c) Primer M Primer M Adhesive B76576 Using a brush, coat the exposed part of the vehicle body with Primer M. NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Do not coat the adhesive with Primer M.
Throw away any leftover Primer M.
Do not apply too much Primer M. (d) Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G. HINT: If the area other than that specified is coated by accident, wipe off the primer with a clean shop rag before it dries NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Throw away any leftover Primer G.
Do not apply too much Primer G. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3560 70-7 WINDSHIELD/WINDOWGLASS/MIRROR - (e) B A A A Apply adhesive. Adhesive: Part No. 08850-00801 or equivalent (1) Cut off the tip of the cartridge nozzle, as shown in the illustration. HINT: After cutting off the tip, use all adhesive within the time described in the table below. Usage timeframe: B B WINDSHIELD GLASS Temperature B51767 Usage Timeframe 35C (95F) 15 minutes 20C (68F) 1 hour 40 minutes 5C (41F) 8 hours (2) (3) Load the sealer gun with the cartridge. Coat the glass with adhesive, as shown in the illustration. Specification: Area Measurement A 8 mm (0.31 in.) B 12 mm (0.47 in.) (f) Mark B73132 Install the glass. (1) Using a suction cup, position the glass so that the reference marks are aligned. Press it in gently along the rim. NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Check that the stoppers are attached to the vehicle body correctly.
Check that the vehicle body and glass have a small gap between them. (2) Lightly press the front surface of the glass to ensure that the glass is securely fit to the vehicle body. (3) Using a scraper, remove any excess or protruding adhesive. HINT: Apply adhesive on the glass rim. NOTICE: Do not drive the vehicle for the amount of time described in the table below. Minimum time: Adhesive B73131 Temperature Minimum time prior to driving vehicle 35°C (95°F) 1 hour 30 minutes 20°C (68°F) 5 hours 5°C (41°F) 24 hours 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3561 70-8 WINDSHIELD/WINDOWGLASS/MIRROR - 26. (a) 27. (a) (b) WINDSHIELD GLASS INSTALL WINDSHIELD MOULDING OUTER UPPER Place a new moulding onto the vehicle body and tap it by hand. CHECK FOR LEAKS AND REPAIR Conduct a leak test after the adhesive has completely hardened. Seal any leaks with auto glass sealer. 28. INSTALL WINDSHIELD OUTSIDE MOULDING CLIP NO.1 Protective (a) Using an air riveter or hand riveter with nose piece, strike Tape rivets into the body panel to install the windshield outside moulding clip No. 1 to the body panel. NOTICE:
If the rivet is not positioned perpendicularly, it will bend the mandrel.
When trigger is then pulled, it may damage the rivet’s mandrel. B63761 Riveter INCORRECT NOTICE:
Do not prize a riveter, because the riveter will be damaged and the mandrel will be bent. Mandrel B76594
Riveter INCORRECT Riveter INCORRECT Do not tilt the riveter when removing the rivet, because the materials are not tightened firmly. B76595 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3562 70-9 WINDSHIELD/WINDOWGLASS/MIRROR -
Riveter WINDSHIELD GLASS Install the rivet while attaching the materials, because they are not tightened firmly. INCORRECT B76596 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3563 70-17 WINDSHIELD/WINDOWGLASS/MIRROR - BACK DOOR GLASS BACK DOOR GLASS 700AF-03 COMPONENTS w/ Rear Spoiler: Rear Spoiler Back Window Panel Trim Upper
Spacer Back Door Glass
Back Window Moulding Outside Back Door Trim Cover RH
Spacer Back Door Trim Cover LH Rear Wiper Arm Assy 6.0 (61, 53 in.⋅lbf) Back Door Trim Panel Assy Assist Strap Hole Cover Assist Strap Assy RH N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part B74624 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3571 70-18 WINDSHIELD/WINDOWGLASS/MIRROR - BACK DOOR GLASS 7012W-01 REPLACEMENT HINT:

1. 2. 3. 4. 5. 6. 7. 8. The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). REMOVE ASSIST STRAP HOLE COVER (See page 75-20 ) REMOVE ASSIST STRAP ASSY RH (See page 75-20 ) REMOVE BACK DOOR TRIM PANEL ASSY (See page 75-20 ) REMOVE BACK WINDOW PANEL TRIM UPPER (See page 75-20 ) REMOVE BACK DOOR TRIM COVER RH (See page 75-20 ) REMOVE BACK DOOR TRIM COVER LH (See page 75-20 ) REMOVE REAR WIPER ARM ASSY (See page 66-12 ) REMOVE REAR SPOILER (W/ REAR SPOILER) (See page 76-8 ) 9. (a) (b) Piano Wire (c) Spacer REMOVE BACK DOOR GLASS Disconnect the connector. From the interior, insert piano wires between the vehicle body and glass, as shown in the illustration. Tie objects that can serve as handles (for example, wooden blocks) to all wire ends. Spacer B76598 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3572 70-19 WINDSHIELD/WINDOWGLASS/MIRROR - Protective Tape B65166 BACK DOOR GLASS HINT: Apply protective tape to the outer surface of the vehicle body to prevent its surface from being scratched. NOTICE:
When separating the glass from the vehicle, be careful not to damage the vehicle’s paint or interior/exterior ornaments.
To prevent the safety pad from being scratched when removing the glass, place a plastic sheet between the piano wire and safety pad. (d) Cut through the adhesive by pulling the piano wire around the glass. (e) Using a suction cup, remove the glass. NOTICE: Leave as much adhesive on the vehicle body as possible when removing the glass. 10. (a) B73128 CLEAN BACK DOOR GLASS Using a scraper, remove the damaged spacers, moulding and adhesive sticking to the glass. (b) Clean the outer circumference of the glass with white gasoline. NOTICE:
Do not touch the glass surface after cleaning it.
Even if using new glass, clean the glass with white gasoline. B76577 11. INSTALL BACK DOOR GLASS SPACER NO.1 (a) Coat the installation part of the spacers with Primer G. NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Throw away any leftover Primer G.
Do not apply too much Primer G. (b) Install 2 new spacers onto the glass, as shown in the illustration. 12. INSTALL BACK WINDOW GLASS SPACER NO.2 Backside Spacer Ceramic Line 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3573 70-20 WINDSHIELD/WINDOWGLASS/MIRROR - BACK DOOR GLASS 13. (a) INSTALL BACK WINDOW MOULDING OUTSIDE Coat the installation part of the back window moulding outside with Primer G. NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Throw away any leftover Primer G.
Do not apply too much Primer G. (b) Install a new back window moulding outside, as shown in the illustration. Specification: Center A Moulding a Area Measurement a 2 mm (0.08 in.) Moulding End Glass Adhesive B51738 14. (a) Adhesive Vehicle Body B73084 INSTALL BACK DOOR GLASS Clean and shape the contact surface of the vehicle body. (1) Using a knife, cut away any rough adhesive on the contact surface of the vehicle body to ensure the appropriate surface shape. NOTICE: Be careful not to damage the vehicle body. HINT: Leave as much of the adhesive on vehicle body as possible. (2) Clean the contact surface of the vehicle body with a piece of shop rag saturated with cleaner. HINT: Even if all the adhesive has been removed, clean the vehicle body. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3574 70-21 WINDSHIELD/WINDOWGLASS/MIRROR - BACK DOOR GLASS (b) Primer M Primer M Adhesive (d) B76576 Using a brush, coat the exposed part of the vehicle body with Primer M. NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Do not coat the adhesive with Primer M.
Throw away any leftover Primer M.
Do not apply too much Primer M. (c) Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G. HINT: If the area other than that specified is coated by accident, wipe off the primer with a clean shop rag before it dries NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Throw away any leftover Primer G.
Do not apply too much Primer G. Apply adhesive. Adhesive: Part No. 08850-00801 or equivalent Backside c c a a A A-A C-C A B B D C B-B b b c D a C D-D b a b B74625 (1) Cut off the tip of the cartridge nozzle, as shown in the illustration. HINT: After cutting off the tip, use all adhesive within the time described in the table below. Usage timeframe: Temperature Usage Timeframe 35C (95F) 15 minutes 20C (68F) 1 hour 40 minutes 5C (41F) 8 hours (2) Load the sealer gun with the cartridge. (3) Coat the glass with adhesive, as shown in the illustration. Specification: Area Measurement a 12 mm (0.47 in.) b 8 mm (0.31 in.) c 12 mm (0.47 in.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3575 70-22 WINDSHIELD/WINDOWGLASS/MIRROR - BACK DOOR GLASS (e) Install the back window glass to the vehicle body. (1) Hold the back window glass in place securely with protective tape or equivalent until the adhesive hardens. NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Check that the spacers are attached to the vehicle body correctly.
Check that the vehicle body and glass have a small gap between them. (2) Lightly press the front surface of the glass to ensure that the glass is securely fit to the vehicle body. NOTICE: Do not drive the vehicle for the amount of time described in the table below. Minimum time: Temperature Minimum time prior to driving vehicle 35°C (95°F) 1 hour 30 minutes 20°C (68°F) 5 hours 5°C (41°F) 24 hours (3) Hold the glass in place securely with a protective tape or equivalent until the adhesive hardens. B51457 15. (a) (b) CHECK FOR LEAKS AND REPAIR Conduct a leak test after the adhesive has completely hardened. Seal any leaks with auto glass sealer. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3576 70-25 WINDSHIELD/WINDOWGLASS/MIRROR - POWER WINDOW CONTROL SYSTEM 7002R-03 INSPECTION 1. (a) INSPECT POWER WINDOW REGULATOR SWITCH ASSY Check continuity. (1) Check the continuity between the terminals when battery voltage is applied to terminals 1 and 8. B31305 Standard: Switch operation Measurement condition Specified condition UP Battery positive - Terminal 8 Battery negative - Terminal 1 Continuity between terminals 3 - 7 Continuity between terminals 1 - 6 DOWN Battery positive - Terminal 8 Battery negative - Terminal 1 Continuity between terminals 1 - 3 Continuity between terminals 6 - 7 If the continuity is not as specified, replace the switch. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3579 70-23 WINDSHIELD/WINDOWGLASS/MIRROR - POWER WINDOW CONTROL SYSTEM POWER WINDOW CONTROL SYSTEM 7002Q-03 ON-VEHICLE INSPECTION 1. INSPECT POWER WINDOW NOTICE: The initial condition that the customizing function is not chosen by the hand-held tester is shown. (a) Check the basic function (Manual operation function). (1) Turn the ignition switch ON. (2) Check that the door glass move up when the power window regulator master switch is pulled UP halfway and moves down when the switch is pushed DOWN halfway. (3) Check that the door glass moves up when the power window regulator switch of each door is pulled UP, and moves down when the switch is pushed DOWN. (4) Check that the door glasses other than the driver side door glass do not operate when the window lock switch is turned to LOCK. (b) Check the automatic operation function (Only driver side door glass). (1) Turn the ignition switch ON. (2) Check that the AUTO UP function operates to fully close the door glass when the power window regulator master switch is pulled UP fully. (3) Check that the AUTO DOWN function operates to fully open the door glass when the power window regulator master switch is pushed DOWN fully. (4) Check that the door glass will stops when the applicable window switch is pulled UP during the AUTO DOWN operation side, (However, if the UP and DOWN operations are continued, it will change is pushed to manual operation). (5) Check that the door glass stop when the applicable window switch change is pushed DOWN during AUTO UP operation (However, if the UP and DOWN operations are continued, it will change is pushed to manual operation). (c) Check the operation function after key-off. (1) After turning the ignition switch from ON to OFF, check that each door glass can be operated via the power window regulator master switch. Also, check that operation is disabled after the driver door is opened then closed once. (2) After turning the ignition switch from ON to OFF, check that the power window regulator master switch is unable to operate the door glass approximately 45 seconds later. (3) After turning the ignition switch from ON to OFF with the driver side door open, check that AUTO UP or AUTO DOWN function keeps operating until the door is fully open or fully closed even when the door is closed in the middle of the middle of operation. Also check that power window operation is disabled after operation has ended. (d) Check the operation function by driver side door key operation (Operation interlocked with key). (1) Check that the driver side door glass moves down when the door lock cylinder is held in the UNLOCK position for 2 seconds or more by key operation. Also, check that the door glass stops when the door lock cylinder is turned back to the original position. (2) Check that the driver side door glass moves up when the door lock cylinder is held in the LOCK position for 2 seconds or more by key operation. Also, check that the door glass stops when the door lock cylinder is turned back to the original position. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3577 70-24 WINDSHIELD/WINDOWGLASS/MIRROR - POWER WINDOW CONTROL SYSTEM (e) Check the jam protection function (Only driver side door glass). NOTICE:
Do not check this function using a part of your body such as a hand. Also, pay thorough attention that nothing gets caught by accident in this process.
If the power window regulator motor assembly has just been reset, raise and lower the door glass several times using AUTO operation before preforming check. HINT: The jam protection function works during the following UP operations; AUTO UP, UP after key-OFF, AUTO UP after key-OFF, UP interlocked with key. (1) (2) Hammer Handle (3) B51853 Fully open the door glass. Insert the handle of the hammer when the door glass is almost in the fully closed position. Try to fully close the door glass with AUTO UP operation, and check that the door glass moves down about 200 mm (7.87 in.) and stops there, so that hammer handle is not caught. HINT: The window goes down by about 50 mm or for 1 second. However, when the opening between the glass and body is less than 200 mm, the door glass goes down by 200 mm or keeps going down for 5 seconds, and then stops. (4) During DOWN operation, check that the door glass does not move up even when the applicable window switch is pulled UP. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3578 70-28 WINDSHIELD/WINDOWGLASS/MIRROR - POWER MIRROR CONTROL SYSTEM 70025-04 INSPECTION 1. (a) Left/Right Adjustment Switch Mirror Switch 10 INSPECT OUTER MIRROR SWITCH ASSY Inspect the mirror switch continuity. (1) Turn to the left/right adjustment switch to the L position. Inspect the left side mirror switch continuity. Tester connection Switch position Specified condition - OFF No continuity 4⇔8 6⇔7 UP Continuity 4⇔7 6⇔8 DOWN Continuity 5⇔8 6⇔7 LEFT Continuity 5⇔7 6⇔8 RIGHT Continuity If the continuity is not as specified, replace the switch. (2) Turn to the left/right adjustment switch to the R position. Inspect the right side mirror switch continuity. 1 B50553 Tester connection Switch position Specified condition - OFF No continuity 3⇔8 6⇔7 UP Continuity 3⇔7 6⇔8 DOWN Continuity 2⇔8 6⇔7 LEFT Continuity 2⇔7 6⇔8 RIGHT Continuity If the continuity is not as specified, replace the switch. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3582 70-29 WINDSHIELD/WINDOWGLASS/MIRROR - 2. (a) B64823 POWER MIRROR CONTROL SYSTEM INSPECT OUTER REAR VIEW MIRROR ASSY RH Inspect operation of the mirror motor. Battery connection Mirror operation Positive (+) - 6 Negative (-) - 5 Upward Positive (+) - 5 Negative (-) - 6 Downward Positive (+) - 4 Negative (-) - 5 Left Positive (+) - 5 Negative (-) - 4 Right (b) Check operation of the mirror heater. (1) Check the mirror between terminals 7 and 8 of the connector. Standard: continuity (2) Check that the mirror is warmed up when connecting the battery positive (+) to terminal 7 and the battery negative (-) to terminal 8 of the connector. 3. (a) INSPECT OUTER REAR VIEW MIRROR ASSY LH Inspect operation of the mirror motor. B64823 (b) Battery connection Mirror position Positive (+) - 6 Negative (-) - 5 Turn upward Positive (+) - 5 Negative (-) - 6 Turn downward Positive (+) - 4 Negative (-) - 5 Turn left Positive (+) - 5 Negative (-) - 4 Turn right Check operation of the mirror heater. (1) Check the mirror between terminals 7 and 8 of the connector. Standard: continuity (2) Check that the mirror is warmed up when connecting the battery positive (+) to terminal 7 and the battery negative (-) to terminal 8 of the connector. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3583 70-26 WINDSHIELD/WINDOWGLASS/MIRROR - POWER MIRROR CONTROL SYSTEM POWER MIRROR CONTROL SYSTEM 70023-04 LOCATION Outer Rear View Mirror Assembly RH Outer Rear View Mirror Assembly LH Outer Mirror Switch Assembly B51419 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3580 70-27 WINDSHIELD/WINDOWGLASS/MIRROR - POWER MIRROR CONTROL SYSTEM 70024-04 PROBLEM SYMPTOMS TABLE Symptom Suspected Area Mirror does not operate. 1. 2. 3. 4. Mirror operates abnormally. 1. Mirror switch 2. Mirror motor 3. Wire harness See Page CIG fuse (I/P J/B) Mirror switch Mirror motor Wire harness 70-28 70-28 70-28 70-28 - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3581 70-32 WINDSHIELD/WINDOWGLASS/MIRROR - DEFOGGER SYSTEM 7019F-01 INSPECTION 1. (a) INSPECT DEFOGGER RELAY Inspect the defogger relay (Marking: DEF) continuity. Condition Tester connection Specified condition Constant 1-2 3-4 Continuity Apply B+ between terminals 1 and 2. 3-5 Continuity If the continuity is not as specified, replace the relay. B50610 2. INSPECT AIR CONDITONER CONTROL ASSY (SEE PAGE 55-7 ) Defogger Wire Tester Probe Tin Foil B66134 3. INSPECT BACK WINDOW (DEFOGGER WIRE) NOTICE:
When cleaning the glass, wipe the glass along the wire using a soft and dry cloth. Take care not to damage the wires.
Do not use detergents or glass cleaners including abrasive ingredients.
When measuring voltage, wrap a piece of tin foil around the tip of the negative tester probe and press the foil against the wire with your finger, as shown in the illustration. (a) (b) (c) At Center Turn the ignition switch ON. Turn the defogger switch ON. Check the voltage at the center of each defogger wire, as shown in the illustration. Standard: Voltage Criteria Approx. 5 V Okay, wire is not broken Approx. 10 V or 0 V Wire is broken B63720 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3586 70-33 WINDSHIELD/WINDOWGLASS/MIRROR - Foil Strip 0V Less than 10 V Broken Wire V
Ground Side Battery Side  B63721 HINT: If there is approx 10 V, the wire may be broken between the center of the wire and the end on the battery side. If there is no voltage, the wire may be broken between the center of the wire and the end on the ground side. (d) Place the voltmeter positive (+) lead against the defogger wire on the battery side. (e) Place the voltmeter negative (-) lead with the foil strip against the wire on the ground side. (f) Slide the positive (+) lead from the battery side to the ground side. (g) The point where the voltmeter deflects from approx 10 V to 0 V is the place where the defogger wire is broken. HINT: If the defogger wire is not broken, the voltmeter indicates 0 V at the positive (+) end of the defogger wire but gradually increases to approx 12 V as the meter probe moves to the other end. (h) Repair Point Masking Tape Broken Wire DEFOGGER SYSTEM If necessary, repair the defogger wire. (1) Clean the broken wire tips with grease, wax and silicone remover. (2) Place the masking tape along both sides of the wire. (3) Thoroughly mix the repair agent (Dupont paste No. 4817). B63722 (4) Using a fine tip brush, apply a small amount of the agent to the wire. After a few minutes, remove the masking tape. (5) NOTICE: Do not repair the defogger wire again for at least 24 hours. B63723 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3587 70-30 WINDSHIELD/WINDOWGLASS/MIRROR - DEFOGGER SYSTEM DEFOGGER SYSTEM 7002G-06 LOCATION Defogger Wire (w/ TV Antenna) Rear Window Defogger Switch Defogger Wire Network GateWay Computer (w/ EMV) Air Conditioner Amplifier Assembly (w/ EMV) Air Conditioner Amplifier Assembly (w/o EMV) B51618 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3584 70-31 WINDSHIELD/WINDOWGLASS/MIRROR - DEFOGGER SYSTEM 7002F-07 PROBLEM SYMPTOMS TABLE Symptom Suspected Area See Page Rear window defogger does not operate (Indicator lamp On) 1. 2. 3. 4. 5. 6. Communication Function RR DEF 30 A Fuse Defogger Relay Rear Window Defogger Wire Wire Harness A/C ECU 70-32 05-1123 Rear window defogger does not operate (Indicator lamp OFF) 1. 2. 3. 4. 5. 6. Heater 15A Fuse A/C Control Panel Defogger Switch(A/C Panel Switch) A/C ECU Wire Harness Gateway Computer 05-1114 05-1114 05-1123 05-1123 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3585 70-10 WINDSHIELD/WINDOWGLASS/MIRROR - QUARTER WINDOW ASSY LH QUARTER WINDOW ASSY LH 7012U-01 COMPONENTS w/ Rear No. 2 Seat Rear Floor Finish Plate Deck Board Sub-assy No. 2 w/ Tonneau Cover: Tonneau Cover Deck Side Trim Box RH Deck Board Sub-assy Deck Board Bracket Reinforcement Deck Board Sub-assy No. 3 Deck Side Trim Box LH Rear No. 2 Seat Assy 37 (377, 27) Deck Floor Box Rear Rear Combination Lamp Service Cover LH 42, (428, 31) Rear No. 2 Seat Belt Assy Outer LH Roof Side Garnish Assy Inner Roof Side Rail Garnish Sub-assy Quarter Pillar Garnish LH Rear Seat Track Cover LH
Spacer
Quarter Window Assy LH Rear Side Trim Cover LH Rear Door Opening Trim Weatherstrip LH Deck Side Trim Cover FR 42, (428, 31) Rear Door Scuff Plate LH Deck Side Trim Cover FR N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part Rear No. 1 Seat Belt Assy Outer LH Rope Hook Deck Trim Side Panel Assy LH B74622 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3564 70-1 1 WINDSHIELD/WINDOWGLASS/MIRROR - QUARTER WINDOW ASSY LH w/o Rear No. 2 Seat Deck Board Sub-assy No. 2 Rear Floor Finish Plate w/ Tonneau Cover: Tonneau Cover Deck Board Sub-assy Deck Side Trim Box RH Deck Board Sub-assy No. 3 Deck Floor Box Rear Deck Floor Box Front Deck Side Trim Box LH Rear No. 1 Seat Assy
Quarter Window Assy LH 37 (377, 27) Rear Combination Lamp Service Cover LH Roof Side Rail Garnish Sub-assy Quarter Pillar Garnish LH
Spacer Rear Seat Track Bracket Cover Outer Roof Side Garnish Assy Inner Rear Side Trim Cover LH Rear Seat Track Bracket Cover Inner 42, (428, 31) Rear Door Opening Trim Weatherstrip LH Rear Door Scuff Plate LH Deck Side Trim Cover FR Rear No. 1 Seat Belt Assy Outer LH N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part Deck Trim Side Panel Assy LH Rope Hook B74623 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3565 70-12 WINDSHIELD/WINDOWGLASS/MIRROR - QUARTER WINDOW ASSY LH 7012V-01 REPLACEMENT HINT:



1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. The procedures listed below are for the LH side. Use the same procedures for the LH side and RH side. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). REMOVE REAR NO. 1 SEAT ASSY (W/O REAR NO.2 SEAT) (See page 72-28 ) REMOVE REAR DOOR SCUFF PLATE LH (See page 76-21 ) REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH (See page 76-21 ) REMOVE TONNEAU COVER ASSY (W/ TONNEAU COVER) (See page 76-21 ) REMOVE DECK BOARD SUB-ASSY NO.2 (See page 76-21 ) REMOVE DECK BOARD SUB-ASSY NO.3 (See page 76-21 ) REMOVE DECK BOARD SUB-ASSY (See page 76-21 ) REMOVE DECK FLOOR BOX REAR (See page 76-21 ) REMOVE DECK SIDE TRIM BOX LH (See page 76-21 ) REMOVE DECK SIDE TRIM BOX RH (See page 76-21 ) REMOVE DECK FLOOR BOX FRONT (W/O REAR NO.2 SEAT) (See page 76-21 ) REMOVE REAR FLOOR FINISH PLATE (See page 76-21 ) REMOVE DECK BOARD BRACKET REINFORCEMENT (W/ REAR NO.2 SEAT) (See page 76-21 ) REMOVE REAR NO. 2 SEAT ASSY (W/ REAR NO.2 SEAT) (See page 72-61 ) REMOVE REAR NO.1 SEAT BELT ASSY OUTER LH (See page 61-15 ) REMOVE REAR NO.2 SEAT BELT ASSY OUTER LH (W/ REAR NO.2 SEAT) (See page 61-22 ) REMOVE DECK SIDE TRIM COVER LH (See page 76-21 ) REMOVE REAR COMBINATION LAMP SERVICE COVER LH (See page 76-21 ) REMOVE ROPE HOOK (See page 76-21 ) REMOVE REAR SEAT TRACK COVER LH (W/ REAR NO.2 SEAT) (See page 72-44 ) REMOVE DECK TRIM SIDE PANEL ASSY LH (See page 76-21 ) REMOVE QUARTER PILLAR GARNISH LH (See page 76-21 ) REMOVE ROOF SIDE RAIL GARNISH SUB-ASSY LH (See page 76-21 ) REMOVE ROOF SIDE GARNISH ASSY INNER LH (See page 76-21 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3566 70-13 WINDSHIELD/WINDOWGLASS/MIRROR - 25. (a) A A B B D D C A -A C B-B QUARTER WINDOW ASSY LH REMOVE QUARTER WINDOW ASSY LH Using a knife, cut off the moulding, as shown in the illustration. NOTICE: Be careful not to damage the vehicle body with the knife. (b) Disconnect the connector. (c) Remove the remaining moulding. HINT: Make a partial cut in the moulding. Then, pull and remove it by hand. C -C D -D B51739 (d) Retainer (e) Piano Wire From the interior, insert piano wires between the vehicle body and glass, as shown in the illustration. Tie object that can serve as handles (for example, wooden blocks) to all wire ends. HINT: Apply protective tape to the outer surface of the vehicle body to prevent its surface from being scratched. NOTICE: When separating the glass from the vehicle, be careful not to damage the vehicle’s paint or interior/exterior ornaments. (f) Cut through the adhesive by pulling the piano wire around the glass. (g) Using a suction cup, remove the glass. NOTICE: Leave as much adhesive on the vehicle body as possible when removing the glass. Spacer Spacer Spacer Spacer Retainer B76597 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3567 70-14 WINDSHIELD/WINDOWGLASS/MIRROR - 26. (a) (b) QUARTER WINDOW ASSY LH INSTALL QUARTER WINDOW GLASS SPACER Clean the installation area. Install new spacers onto the glass. 27. (a) Adhesive Adhesive Vehicle Body B73084 INSTALL QUARTER WINDOW ASSY LH Clean and shape the contact surface of the vehicle body. (1) Using a knife, cut away any rough adhesive on the contact surface of the vehicle body to ensure the appropriate surface shape. NOTICE: Be careful not to damage the vehicle body. HINT: Leave as much adhesive on the vehicle body as possible. (2) Clean the contact surface of the vehicle body with a piece of shop rag saturated with cleaner. HINT: Even if all the adhesive has been removed, clean the vehicle body. (b) Primer M Primer M Adhesive B76576 Using a brush, coat the exposed part of the vehicle body on the vehicle side with Primer M. NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Do not coat the adhesive with Primer M.
Throw away any leftover Primer M.
Do not apply too much Primer M. (c) Using brush or sponge, coat the edge of the glass and the contact surface with Primer G. HINT: If an area other than that specified is coated by accident, wipe off the primer with a clean shop rag before it dries. NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Throw away any leftover Primer G.
Do not apply too much Primer G. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3568 70-15 WINDSHIELD/WINDOWGLASS/MIRROR - (d) QUARTER WINDOW ASSY LH Apply adhesive. Adhesive: Part No. 08850-00801 or equivalent Backside A -A Marking C-C a a A B -B B b b A B d c D D C D -D a a b C e a b b B78004 (1) Cut off the tip of the cartridge nozzle, as shown in the illustration. HINT: After cutting off the tip, use all adhesive within the time described in the table below. Usage timeframe: Temperature Usage Timeframe 35C (95F) 15 minutes 20C (68F) 1 hour 40 minutes 5C (41F) 8 hours (2) Load the sealer gun with the cartridge. (3) Coat the glass with adhesive, as shown in the illustration. Specification: Area Measurement a 8 mm (0.31 in.) b 6 mm (0.24 in.) c 5 mm (0.20 in.) d 2 mm (0.08 in.) e 4 mm (0.16 in.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3569 70-16 WINDSHIELD/WINDOWGLASS/MIRROR - QUARTER WINDOW ASSY LH (e) Install the quarter window to the vehicle body. (1) Hold the quarter window in place securely with protective tape or equivalent until the adhesive hardens. NOTICE:
Allow the primer coating to dry for 3 minutes or more.
Check that the spacers are attached to the vehicle body correctly.
Check that the vehicle body and glass have a small gap between them. (2) Lightly press the front surface of the glass to ensure that the glass is securely fit to the vehicle body. NOTICE: Do not drive the vehicle for the amount of time described in the table below. Minimum time: 28. (a) (b) Temperature Minimum time prior to driving vehicle 35°C (95°F) 1 hour 30 minutes 20C (68F) 5 hours 5°C (41°F) 24 hours CHECK FOR LEAKS AND REPAIR Conduct a leak test after the adhesive has completely hardened. Seal any leaks with auto glass sealer. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3570 70-37 WINDSHIELD/WINDOWGLASS/MIRROR - INNER REAR VIEW MIRROR ASSY 7012Z-01 INSPECTION HINT: EC mirror stands for electrochromic mirror. 1. 6 7 Battery w/ EC mirror: INSPECT INNER REAR VIEW MIRROR ASSY (a) Inspect operation of the electrochromic inner rear view mirror. (1) Connect the battery’s positive (+) lead to terminal 6 and the battery’s negative (-) lead to terminal 7. (2) Attach black colored tape to the forward sensor to prevent it from sensing. (3) Light up the mirror with an electric light, and check that the mirror surface changes from bright to dark. If the result is not as specified, replace the mirror assy. Black Colored Tape Forward Sensor Bright Dark B57086 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3591 70-35 WINDSHIELD/WINDOWGLASS/MIRROR - INNER REAR VIEW MIRROR ASSY 7012Y-01 PRE-CHECK 1. (a) 2. (a) 3. (a) 4. (a) 5. SELECT COMPASS DISPLAY MODE The COMP switch allows you to select the ”Display” or ”Non-display” mode of the compass. SET ZONE The location of magnetic north and true north differs depending on the location. Adjustment of the compass’s magnetism is required to correct possible compass deviations from true north. Each user must set a zone (refer to the Compass Zone Map). This will automatically adjust the compass to the magnetic conditions in the zone selected. The zone setting can be changed using the inner rear view mirror COMP switch. PERFORM CALIBRATION Because each vehicle has its own magnetic field, calibration should be performed for each vehicle. This compass function is used when storing information about the vehicle’s magnetic field. WHEN COMPASS IS MAGNETIZED: A compass may become magnetized during shipping by vessels or freight cars. Make sure to perform calibration and ensure that calibration is performed properly before delivery. If calibration cannot be completed despite driving the vehicle in a circle several times, the vehicle’s magnetic field may be interfering with the calibration. Demagnetize the vehicle using a demagnetizer and perform calibration again. SET COMPASS COMP Switch On Duration Normal Mode Ignition switch ON Pressed Compass Non-display Mode Pressed for 3 seconds 6. Zone Setting Mode Pressed for 6 seconds COMP Switch ON Zone area +1 7. Calibration Mode Leaving it untouched for a while Normal Mode 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3589 70-36 WINDSHIELD/WINDOWGLASS/MIRROR - 6. (a) INNER REAR VIEW MIRROR ASSY ZONE SETTING MODE Pressing the COMP switch for 3 seconds in the normal mode will activate the zone setting mode. A number (1 to 15) is displayed on the compass display. HINT: In the initial state, ”8” is displayed. (b) The displayed number increases by 1 every time the COMP switch is pressed. Referring to the map, check the number for the area where the vehicle will be used and set the zone number. (c) Do not touch the compass for several seconds after setting the zone. Check that the compass display shows an azimuthal direction (N, NE, E, SE, S, SW, W, or NW) or ”C”. 7. CALIBRATION SETTING MODE (a) Pressing the COMP switch for 6 seconds in the normal mode will activate the calibration setting mode. (b) Drive the vehicle at 8 km/h (5 mph) or less in a circle. (c) Driving in a circle 1 to 3 times will display the azimuthal direction on the display, completing the calibration. HINT: After the calibration is completed, it is not necessary to perform the above procedures unless the magnetic field strength of the vehicle drastically changes. If this happens, the azimuthal display will change to ”C”. B77945 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3590 70-34 WINDSHIELD/WINDOWGLASS/MIRROR - INNER REAR VIEW MIRROR ASSY INNER REAR VIEW MIRROR ASSY 7012X-01 REPLACEMENT HINT:

The installation procedures are the removal procedures in reverse order. EC mirror stands for electrochromic mirror. 1. (a) (b) (a) Cover w/o EC mirror: REMOVE INNER REAR VIEW MIRROR ASSY Push the cover in the direction indicated by the arrows (a) and remove it. While holding down the claw in the direction of the block arrow (b), slide the inner rear view mirror assy in the direction of the while arrow (c) and remove it. (a) Claw (b) (c) B64964 2. Slide (a) (b) (c) (d) w/ EC mirror: REMOVE INNER REAR VIEW MIRROR ASSY Remove the mirror cover. Disconnect the connector. Using a torx socket wrench (T20), remove the screw. Slide the mirror in the direction indicated by the arrow in the illustration, and remove the mirror. B77943 3. Slide (a) (b) (c) (d) w/ EC mirror and compass: REMOVE INNER REAR VIEW MIRROR ASSY Remove the mirror cover. Disconnect the connector. Using a torx socket wrench (T20), remove the screw. Slide the mirror in the direction indicated by the arrow in the illustration, and remove the mirror. B77942 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3588 71-3 INSTRUMENT PANEL/METER - COMBINATION METER 710LK-02 ON-VEHICLE INSPECTION 1. (a) INSPECT SPEEDOMETER Check the operation. (1) Using a speedometer tester, inspect the speedometer for acceptable indication error and check the operation of the odometer. Reference: km/h (Canada) Standard indication Acceptable range 20 km/h 18.0 to 23.0 km/h 40 km/h 40.0 to 44.0 km/h 60 km/h 60.0 to 64.5 km/h 80 km/h 80.0 to 85.0 km/h 100 km/h 100.0 to 105.0 km/h 120 km/h 120.0 to 125.5 km/h 140 km/h 140.0 to 146.0 km/h 160 km/h 160.0 to 167.0 km/h 180 km/h 180.0 to 188.0 km/h 200 km/h 200.0 to 209.0 km/h Reference: mph (U.S.) Standard indication Acceptable range 20 MPH 20.0 to 23.0 MPH 40 MPH 40.0 to 43.5 MPH 60 MPH 60.0 to 64.0 MPH 80 MPH 80.0 to 84.5 MPH 100 MPH 100.0 to 105.0 MPH 120 MPH 120.0 to 125.5 MPH NOTICE: Tire wear and over or under tire pressure will affect the indication error. (2) Check the deflection width of the speedmeter indicator. Reference: Below 0.5 km/h (0.3 mph) 2. (a) Wire Harness View: C12-13 I30440 INSPECT OUTPUT SIGNAL OF VEHICLE SPEED Check the output signal waveform. (1) Remove the combination meter assy. (2) Connect the oscilloscope to the terminals C12-13 and body ground. (3) Start the engine. (4) Check the signal waveform according to the condition (s) in the table below. Item Condition Tool setting 5 V/DIV, 20 ms/DIV Vehicle condition Driving at approx. 20Km/h HINT: As the vehicle speed increases, the cycle of the signal waveform narrows. GND A05135 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3594 71-4 INSTRUMENT PANEL/METER - COMBINATION METER 3. (a) INSPECT TACHOMETER Check operation (1) Connect the tune-up test tachometer and start the engine. NOTICE:
Reversing the connection of the tachometer will damage the transistors and the insides of the diodes.
When removing or installing the tachometer, be careful not to drop or subject it to heavy shocks. (2) Compare the result of the test with the standard indication. DC 13.5 V, 25C (77F) Acceptable range (r/min) Data in ( ) are for reference Standard indication (r/min) 700 630 to 770 1,000 (900 to 1100) 2,000 (1850 to 2150) 3,000 2800 to 3200 4,000 (3800 to 4200) 5,000 4800 to 5200 6,000 (5750 to 6250) 7,000 6700 to 7300 4. (a) (b) Fuel Sender Gauge Connector Front View: (c) I30899 (d) (e) 5. (a) (b) 6. (a) (b) (c) INSPECT FUEL RECEIVER GAUGE Disconnect the connector from the sender gauge. Connect terminals 1 and 2 on the wire harness side connector of the fuel sender gauge. Turn the ignition switch to the ON position, then check the position of the receiver gauge needle. OK: Needle position is on (EMPTY). Connect terminals 2 and 3 on the wire harness side connector of the fuel sender gauge. Turn the ignition switch to the ON position, then check the position of the receiver gauge needle. OK: Needle position is on (FULL). INSPECT FUEL LEVEL WARNING Disconnect the connector from the sender gauge. Turn the ignition switch to the ON position, then check that the fuel level needle indicates EMPTY and the fuel level warning light comes on. OK: Fuel level warning light comes on. INSPECT LOW OIL PRESSURE WARNING LIGHT Disconnect the connector from the low oil pressure switch. Turn the ignition switch to the ON position. Ground the terminal of the wire harness side connector, then check the low oil pressure warning light. OK: Low oil pressure warning light comes on. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3595 71-5 INSTRUMENT PANEL/METER - COMBINATION METER 7. (a) INSPECT BRAKE WARNING LIGHT Inspect the parking brake warning light. (1) Disconnect the connector from the parking brake switch. (2) Turn the ignition switch to the ON position. (3) Ground the terminal of the wire harness side connector, then check the parking brake warning light. OK: Brake warning light comes on. (b) Inspect the brake fluid level warning light. (1) Disconnect the connector from the brake fluid level warning switch. (2) Turn the ignition switch to the ON position. (3) Connect a terminal to the other terminal of the wire harness side connector, then check the brake fluid level warning switch. OK: Brake warning light comes on. 8. INSPECT BRAKE FLUID LEVEL WARNING SWITCH (a) Remove the reservoir tank cap and strainer. (b) Disconnect the connector. (c) Measure the resistance between the terminals. Standard: Float up (switch off): 10 kΩ or higher (d) Use a syphon, etc. to take fluid out of the reservoir tank. (e) Measure the resistance between the terminals. Standard: Float down (switch on): Below 1 Ω (f) Pour the fluid back in the reservoir tank. 9. INSPECT WASHER LEVEL WARNING SWITCH (a) Disconnect the connector from the washer level warning switch. (b) Turn the ignition switch to the ON position. (c) Ground the terminal of the wire harness side connector, then check the washer level warning light. OK: Washer level warning light comes on. 10. MAINTENANCE LIQUID RESETTING PROCEDURE Indicator Condition: (a) (b) (c) (d) HINT:

State Condition Specified State Blinking The vehicle runs 4,500 miles after the previous setting The indicator blinks for 15 seconds after the ignition switch on (including 3 seconds for a valve check). Continuously Illuminated The vehicle runs 5,000 miles after the previous setting The indicator is continuously illuminated after the ignition switch on. Set the display window to ODO. Turn the ignition switch off. Pressing the reset switch, turn the ignition switch to the ON position (keep pressing for at least 5 seconds). Reset procedure is completed. If the ignition switch is turned off during reset procedure, reset mode is canceled. If the reset switch is turned off during the reset procedure, reset mode is canceled and the display shows the condition prior to the reset procedure. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3596 71-1 INSTRUMENT PANEL/METER - COMBINATION METER COMBINATION METER 7101E-06 PROBLEM SYMPTOMS TABLE Warning Lights: Symptom Suspect Area See page 7. ECM Check Engine warning light does not come on. 05-5 05-366 71-18 8. Wire Harness or Connector 9. Combination Meter Assy 1. ECM 2. Wire Harness or Connector 3. Combination Meter Assy 05-5 05-366 71-18 Brake warning light does not come on. 1. Skid control ECU 2. Wire Harness or Connector 3. Combination Meter Assy 05-761 71-18 ABS warning light does not come on. 1. ABS ECU 2. Wire Harness or Connector 3. Combination Meter Assy 05-761 71-18 SRS warning light does not come on. 1. Airbag Sensor Assy Center 2. Wire Harness or Connector 3. Combination Meter Assy 05-1200 71-18 Open Door warning light does not come on. 1. Refer to troubleshooting 2. Wire Harness or Connector 3. Combination Meter Assy 05-1601 71-18 Fuel Level warning light does not come on. 1. Refer to troubleshooting 2. Wire Harness or Connector 3. Combination Meter Assy 05-1893 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 Assy Driver’s seat belt warning light does not come on. 1. Refer to troubleshooting 2. Wire Harness or Connector 3. Combination Meter Assy 05-1898 71-18 1. Low Oil Level Sensor 4. Combination Meter Assy 05-5 05-366 05-5 05-366 71-18 1. Wire Harness or Connector 2. Skid Control ECU 3. Combination Meter Assy 05-761 71-18 Discharge warning light does not come on. ”OIL LEVEL” warning light does not come on. ”TIRE AIR PRESS” warning light does not come on. 71-3 71-18 2. Wire Harness or Connector 3. ECM Indicator Lights: Symptom Suspect Area See page Turn indicator light does not come on. 1. Turn Signal and Hazard Warning System 2. Wire Harness or Connector 3. Combination Meter Assy 05-1533 71-18 High Beam indicator light does not come on. 1. Headlight Dimmer Switch 2. Wire Harness or Connector 3. Combination Meter Assy 05-1533 71-18 Washer level indicator light does not come on. 1. Washer Level Warning Switch 2. Wire Harness or Connector 3. Combination Meter Assy Author
: 71-18 Date
: 3592 71-2 INSTRUMENT PANEL/METER - COMBINATION METER MAINT REQD indicator ia blinking or cotinuously illuminated. 1. Resetting procedure 2. Combination Meter Assy 71-3 71-18 All buzzer (key reminder, tail cancel, Seat belt) does not operate. 1. Refer to troubleshooting 2. Combination Meter Assy 05-1879 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 1. Wire Harness or Connector 2. Automatic transmission 05-883 05-993 71-18 A/T OIL TEMP indicator light does not come on. 3. Combination Meter Assy ECT SNOW indicator light does not come on. 1. Wire Harness or Connector 2. ECM 05-5 05-366 71-18 3. Combination Meter Assy 1. Park Neutral Position Switch A/T shift indicator light does not come on. 05-883 05-993 05-5 05-366 71-18 2. Wire Harness or Connector 3. ECM 4. Combination Meter Assy ”CRUISE” indicator light does not come on. 1. Wire Harness or Connector 2. ECM 05-5 05-366 71-18 3. Combination Meter Assy Meter Gauges: Symptom Suspect Area See page Speedometer does not operate. 1. Refer to troubleshooting 05-1885 Tachometer does not operate. 1. Refer to troubleshooting 05-1889 Fuel Gauge does not operate or operates abnormally. 1. Refer to troubleshooting 05-1893 Water temperature does not operate. 1. Refer to troubleshooting 05-1896 Clock: Symptom Suspect Area See page 1. Power source or ground 05-1170 05-1173 05-1175 71-6 Clock will not operate Clock loses or gains time 2. Integration control & panel assy Author
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: 3593 71-9 INSTRUMENT PANEL/METER - INSTRUMENT PANEL SAFETY PAD SUB-ASSY INSTRUMENT PANEL SAFETY PAD SUB-ASSY 7101I-02 PRECAUTION 1. (a) PRECAUTION FOR VEHICLE WITH SRS AIRBAG AND SEAT BELT PRETENSIONER Some operations in this section may affect the SRS airbags. Prior to performing the corresponding operations, read the SRS airbag NOTICE (see page 60-1 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3600 71-10 INSTRUMENT PANEL/METER - INSTRUMENT PANEL SAFETY PAD SUB-ASSY 710LI-02 REPLACEMENT HINT: COMPONENTS: SEE PAGE 71-6 1. TABLE OF BOLT, SCREW AND NUT HINT: The bolts, screws and nuts necessary for installation and removal of the instrument panel, are illustrated below and alphabetically coded. mm (in.) (L = Length) Code Shape Code φ=5 (0.20) L = 16 (0.63) φ=6 (0.24) L = 25 (0.98) φ=8 (0.32) L = 20 (0.79) φ=5 (0.20) L = 18.5 (0.73) Shape Code φ = 5.22 (0.21) L = 16 (0.63) Shape φ=6 (0.24) L = 16 (0.63) φ=6 (0.24) L = 20 (0.79) φ=6 (0.24) L = 20 (0.79) φ=6 (0.24) L = 20 (0.79) φ=6 (0.24) φ=6 (0.24) L = 18 (0.71) φ=6 (0.24) L = 16 (0.63) B78418 2. 3. 4. 5. 6. DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60-1 ) PLACE FRONT WHEELS FACING STRAIGHT AHEAD REMOVE STEERING WHEEL COVER LOWER NO.2 REMOVE STEERING WHEEL COVER LOWER NO.3 REMOVE HORN BUTTON ASSY (SEE PAGE 60-17 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3601 71-1 1 INSTRUMENT PANEL/METER 7. 8. 9. 10. 11. - INSTRUMENT PANEL SAFETY PAD SUB-ASSY REMOVE STEERING WHEEL ASSY (SEE PAGE 50-8 ) SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021) REMOVE STEERING COLUMN COVER LWR (SEE PAGE 50-8 ) REMOVE STEERING COLUMN COVER UPR (SEE PAGE 50-8 ) REMOVE HEADLAMP DIMMER SWITCH ASSY (SEE PAGE 65-25 ) REMOVE WINDSHIELD WIPER SWITCH ASSY (SEE PAGE 66-16 ) 12. (a) (b) REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY CENTER Using a moulding remover, disengage the 8 clips. Disconnect the connectors, then remove the instrument cluster finish panel sub-assy center. HINT: Set the shift lever in the N position. 8 Clips 13. 14. B51309 REMOVE INTEGRATION CONTROL & PANEL ASSY (W/O NAVIGATION SYSTEM) (SEE PAGE 55-26 ) REMOVE MULTI-DISPLA Y (CRT DISPLAY) DISPLAY (W/ NAVIGATION SYSTEM) (SEE PAGE 67-8 ) 15. (a) (b) 5 Clips REMOVE INSTRUMENT PANEL FINISH PANEL LOWER Using a moulding remover, disengage the 5 clips. Disconnect the connectors, then remove the instrument panel finish panel lower. B51316 16. (a) REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSY Using a moulding remover, disengage the 5 clips, then remove the instrument cluster finish panel assy. 5 Clips B51317 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3602 71-12 INSTRUMENT PANEL/METER 17. (a) (b) - INSTRUMENT PANEL SAFETY PAD SUB-ASSY REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH Remove the 4 screws . Disengage the claw, then remove the instrument cluster finish panel garnish. B51318 18. (a) (b) REMOVE COMBINATION METER ASSY Remove the 3 screws , then pull the combination meter assy. Disconnect the connectors, then remove the combination meter assy. B51319 19. (a) (b) (c) (d) 3 Clips REMOVE INSTRUMENT PANEL FINISH PANEL SUB-ASSY LOWER Remove the 2 bolts . Disengage the 3 clips. Disconnect the connectors. Disconnect the hood lock control cable, then remove the instrument panel finish panel sub-assy lower. B51321 20. (a) REMOVE INSTRUMENT PNL INSERT SUB- ASSY LWR LH Remove the 3 bolts and the instrument panel insert sub-assy LWR LH. B75540 21. (a) (b) 2 Claws 4 Clips REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSY CENTER Using a moulding remover, disengage the 4 clips and the 2 claws. Disconnect the connectors, then remove the instrument cluster finish panel assy center. HINT: Set the shift lever in the N position. B75537 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3603 71-13 INSTRUMENT PANEL/METER 22. (a) - INSTRUMENT PANEL SAFETY PAD SUB-ASSY REMOVE FLOOR CARPET COVER CENTER LH Remove the 2 clips and the floor carpet cover center LH. B77066 23. REMOVE FLOOR CARPET COVER CENTER RH Claw 24. (a) REMOVE FRONT SEAT ARMREST ASSY CENTER Using a screwdriver, disengage the 2 claws and remove the seat armrest cover LH. HINT: Tape the screwdriver tip, before use. (b) Remove the bolt and front seat armrest assy center. B76439 25. (a) Protective Tape REMOVE CONSOLE BOX ASSY Cover the parts indicated in the illustration with protective tape to prevent them from being damaged. (b) Remove the 3 screws . (c) Remove the 2 console caps and the 2 screws . (d) Remove the 2 bolts . (e) Pull the console box assy towards the rear of the vehicle and disengage the 2 clips, and then remove the console box assy. NOTICE: Be careful not to damage the bottom of the instrument panel safety pad when removing the console box assy. 2 Clips B78445 26. (a) REMOVE GLOVE COMPARTMENT DOOR ASSY Remove the glove compartment door damper clip. B51994 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3604 71-14 INSTRUMENT PANEL/METER - INSTRUMENT PANEL SAFETY PAD SUB-ASSY (b) Remove the 2 clips and the glove compartment door assy. 27. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER NO.2 Remove the 7 screws and the instrument panel finish panel lower No. 2. B51312 (a) B51322 28. 29. 30. 31. 32. 33. 34. DISCONNECT PASSENGER AIRBAG CONNECTOR (SEE PAGE 60-29 ) REMOVE FRONT PILLAR GARNISH LH (SEE PAGE 76-21 ) REMOVE FRONT PILLAR GARNISH RH (SEE PAGE 76-21 ) REMOVE FRONT DOOR SCUFF PLATE LH (SEE PAGE 76-21 ) REMOVE FRONT DOOR SCUFF PLATE RH (SEE PAGE 76-21 ) REMOVE COWL SIDE TRIM SUB-ASSY LH (SEE PAGE 76-21 ) REMOVE COWL SIDE TRIM SUB-ASSY RH (SEE PAGE 76-21 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3605 71-15 INSTRUMENT PANEL/METER 35. (a) - INSTRUMENT PANEL SAFETY PAD SUB-ASSY REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY W/PASSENGER AIR BAG ASSY Disconnect the connectors. B51328 (b) (c) Remove the 7 bolts and the nut . Disengage the 3 pins, then remove the instrument panel safety pad sub-assy. B51323 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3606 71-16 INSTRUMENT PANEL/METER - INSTRUMENT PANEL SAFETY PAD SUB-ASSY 36. REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH NO.2 (a) Disengage the 4 clips, then remove the instrument cluster finish panel garnish No. 2. 37. REMOVE AUTOMATIC LIGHT CONTROL SENSOR (a) Disconnect the connector. (b) Remove the automatic light control sensor. 38. REMOVE COOLER (SOLAR SENSOR) THERMISTOR (a) Disconnect the connector. (b) Remove the cooler (solar sensor) thermistor. NOTICE: Do not pry the cooler (solar sensor) thermistor off from the upper position. 39. REMOVE INSTRUMENT PANEL PIN NO.1 (a) Remove the 3 screws and the 3 instrument panel pin No.1. 40. REMOVE DEFROSTER NOZZLE ASSY (a) Remove the 7 screws and the defroster nozzle assy. 41. REMOVE SIDE DEFROSTER NOZZLE DUCT NO.1 (a) Remove the screw and the defroster nozzle duct No. 1. 42. REMOVE SIDE DEFROSTER NOZZLE DUCT NO.2 (a) Remove the screw and the side defroster nozzle duct No. 2. 43. REMOVE HEATER TO REGISTER DUCT NO.1 (a) Remove the clip. (b) Remove the 3 screws and the heater to register duct No. 1. 44. REMOVE HEATER TO REGISTER DUCT NO.4 (a) Remove the clip. (b) Remove the 3 screws and the heater to register duct No. 4. 45. REMOVE HEATER TO REGISTER CENTER SUB DUCT (a) Remove the 4 screws and the heater to register center sub duct. 46. REMOVE INSTRUMENT PANEL REGISTER ASSY LOWER NO.1 (a) Remove the 2 screws and the instrument panel register assy lower No. 1. 47. REMOVE INSTRUMENT PANEL REGISTER ASSY NO.1 (a) Remove the 2 screws and the instrument panel register assy No. 1. 48. REMOVE INSTRUMENT PANEL BRACKET SUB-ASSY CENTER (a) Remove the 3 screws and the instrument panel bracket sub-assy center. 49. REMOVE NAVIGATION ANTENNA ASSY (W/ NAVIGATION SYSTEM) (SEE PAGE 67-19 ) 50. REMOVE INSTRUMENT PANEL WIRE 51. REMOVE INSTRUMENT PANEL PASSENGER AIR BAG ASSY (SEE PAGE 60-29 ) 52. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3607 71-17 INSTRUMENT PANEL/METER 53. 54. (a) - INSTRUMENT PANEL SAFETY PAD SUB-ASSY INSTALL INSTRUMENT PANEL PASSENGER AIR BAG ASSY (SEE PAGE 60-29 ) INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY W/PASSENGER AIR BAG ASSY Install the 7 bolts , nut with the instrument panel safety pad sub-assy. Torque: Bolt : 20 N⋅m (204 kgf⋅cm, 15 ft⋅lbf) B51323 55. 56. 57. 58. 59. 60. 61. 62. INSTALL FRONT SEAT ARMREST ASSY CENTER CENTER SPIRAL CABLE (SEE PAGE 60-26 ) INSTALL STEERING WHEEL ASSY (SEE PAGE 50-8 ) INSPECT STEERING WHEEL CENTER POINT INSTALL HORN BUTTON ASSY (SEE PAGE 60-17 ) CONNECT BATTERY NEGATIVE TERMINAL INSPECT HORN BUTTON ASSY (SEE PAGE 60-1 1) INSPECT SRS WARNING LIGHT (SEE PAGE 05-1207 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3608 71-18 INSTRUMENT PANEL/METER - COMBINATION METER ASSY COMBINATION METER ASSY 7101K-05 OVERHAUL HINT: The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated. 1. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY CENTER (SEE PAGE 71-10 ) 2. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER (SEE PAGE 71-10 ) 3. REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSY (SEE PAGE 71-10 ) 4. REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH (SEE PAGE 71-10 ) 5. REMOVE COMBINATION METER ASSY (SEE PAGE 71-10 ) 6. (a) (b) REMOVE COMBINATION METER GLASS Remove the 2 screws. Disengage the 6 claws and remove the combination meter glass. 6 Claws B78425 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3609 71-6 INSTRUMENT PANEL/METER - INSTRUMENT PANEL/METER INSTRUMENT PANEL/METER 7101H-02 COMPONENTS Front Pillar Garnish LH Front Pillar Garnish RH C C I C 20 (204, 15) E G G G G G G G G G G G Instrument Cluster Finish Panel Garnish Combination Meter Assy B B B B G B G G G G Instrument Panel Finish Panel Lower No.2 w/o Navigation System: Integration Control & Panel Assy w/ Navigation System: Multi-Display (CRT Display) Display G E G C B B B B B B G Instrument Cluster Finish Panel Sub-assy Center Steering Column Windshield Wiper Cover UPR B Switch Assy Glove Compartment Door Assy Cowl Side Trim Sub-assy RH Front Door Scuff Plate RH B B Instrument Panel Finish Panel Lower Instrument Panel Insert Sub-assy LWR LH Instrument Cluster Finish Panel Assy Headlamp Dimmer Switch Assy Steering Column Cover LWR Steering Wheel F Cover Lower No.3 F Steering Wheel Cover Lower No.2 50 (510, 37) F B D Floor Carpet Cover Floor Carpet Cover Center RH Center LH B K K Instrument Panel Finish Panel Sub-assy Lower Console Box Assy Front Door Scuff Plate LH B J D Cowl Side Trim Sub-assy LH Horn Button Assy Instrument Cluster Finish Panel Assy Center 8.8 (90, 78 in.⋅lbf) J Front Seat Armrest Assy 37 (378, 27) N⋅m (kgf⋅cm, ft⋅lbf) Front Seat Armrest Cover : Specified torque B75538 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3597 71-7 INSTRUMENT PANEL/METER - INSTRUMENT PANEL/METER Instrument Panel Pin No.1 Instrument Panel Wire A A A A A A A A Instrument Panel Passenger Airbag Assy w/ Navigation System: Navigation Antenna 5.6 (57, 49 in.⋅lbf) Instrument Panel Safety Pad Sub-assy A Cooler Thermistor A Automatic Light Control Sensor Instrument Panel Register Assy No.1 A A A Instrument Panel Register Assy Lower No.1 A A Instrument Cluster Finish Panel Garnish No.2 A A A A Defroster Nozzle Duct No.2 A A A A Defroster Nozzle Assy A Defroster Nozzle Duct No.1 A A Heater To Register Instrument Finish Duct No.4 Panel Retainer Lower No.2 A A A A A Heater To Register Center Sub Duct Heater To Register Duct No.1 Instrument Finish Panel Retainer Lower No.1 A A A I Instrument Panel Bracket Sub-assy Center I L L Instrument Panel Finish Panel Retainer Lower No.3 N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque B75539 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3598 71-8 INSTRUMENT PANEL/METER - INSTRUMENT PANEL/METER Instrument Cluster Finish Panel Garnish Instrument Cluster Finish Sub-assy Center Combination Meter Combination Meter Glass Instrument Cluster Finish Panel Assy Instrument Panel Finish Panel Lower B51335 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3599 61-3 SEAT BELT - FRONT SEAT BELT FRONT SEAT BELT 610JU-01 COMPONENTS Front Door Opening Trim Weatherstrip RH Rear Door Opening trim Weatherstrip RH 42 (428, 31) Shoulder Anchor Cover Rear Door Scuff Plate RH 42 (428, 31) Center Pillar Garnish Lower RH 7.5 (77, 66 in. ⋅lbf) 42 (428, 31) Front Door Scuff Plate RH Floor Anchor Cover Manual Seat Type Power Seat Type 42 (428, 31) 42 (428, 31) Front Seat Inner Belt Assy RH Front Seat Inner Belt Assy RH N⋅m (kgf⋅cm ft⋅lbf) : Specified torque B77526 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3457 61-8 SEAT BELT - FRONT SEAT BELT 610JW-01 DISPOSAL HINT: When scrapping vehicles equipped with a seat belt pretensioner or disposing of a front seat outer belt (with seat belt pretensioner), always first activate the seat belt pretensioner in accordance with the procedures described below. If any abnormality occurs during activation of the seat belt pretensioner, contact the SERVICE DEPARTMENT of TOYOTA MOTOR SALES, U.S.A., INC. When disposing of a front seat outer belt assy (with seat belt pretensioner) that was activated in a collision, start with step 1-(f) in this section. SST B50515 CAUTION:
Never dispose of a front seat outer belt assy that has an inactivated pretensioner.
The seat belt pretensioner produces a loud, exploding sound when it activates. Perform the operation where it will not be a nuisance to nearby residents.
When activating a front seat outer belt (with seat belt pretensioner), stand at least 10 m (33 ft) away from the front seat outer belt.
Use gloves and safety glasses when handling a front seat belt with an activated pretensioner.
Always wash your hands with water after completing activation.
Do not apply water to a front seat outer belt that has an activated pretensioner
When activating the seat belt pretensioner, always use the specified SST (SRS airbag deployment tool).
Perform operation in a place away from electrical interference. SST 09082-00700 1. DISPOSE OF FRONT SEAT OUTER BELT ASSY RH (WHEN INSTALLED IN VEHICLE) HINT: Prepare a battery to power activation of the seat belt pretensioner. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3462 61-9 SEAT BELT - FRONT SEAT BELT (a) Check if SST is functioning. CAUTION: When activating the seat belt pretensioner, always use the specified SST. SST 09082-00700, 09082-00770 SST B50515 (1) Connect SST red clip to the battery’s positive (+) terminal and the black clip to the negative (-) terminal. HINT: Do not connect the yellow connector. The yellow connector is used to connect to the seat belt pretensioner. Battery SST B50511 (2) SST B50514 Press SST activation switch and check that the LED of SST activation switch turn on. CAUTION: If the LED turns on when the activation switch is not being pressed, SST may be malfunctioning. Do not use SST. (b) Disconnect SST from the battery. (c) Disconnect the pretensioner connector. (1) Disconnect the battery’s negative (-) terminal. (2) Check the SRS airbag system (see page 60-53 ). (3) Remove the front door scuff plate RH (see page 76-21 ). (4) Remove the rear door scuff plate RH (see page 76-21 ). (5) Remove the front door opening trim weatherstrip RH (see page 76-21 ). (6) Remove the rear door opening trim weatherstrip RH (see page 76-21 ). (7) Remove the center pillar garnish lower RH (see page 76-21 ). (8) Remove the center pillar garnish upper RH (see page 76-21 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3463 61-10 SEAT BELT - FRONT SEAT BELT (9) (d) Disconnect the pretensioner connector, as shown in the illustration. Connect SST. (1) Install the floor anchor of the seat belt. B61489 B60414 (2) SST Connect 2 SSTs, then connect the yellow connector to the seat belt pretensioner. SST 09082-00700, 09082-00770 NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. SST B51763 (3) (4) 10 m or more B50513 Move SST at least 10 m (33 ft) away from the front of the vehicle. Close all the doors and windows of the vehicle. HINT: Do not close the windows fully. Leave a gap for inserting SST wire harness. NOTICE: Take care not to damage SST wire harness. (5) Connect SST red clip to the battery’s positive (+) terminal and the black clip to the negative (-) terminal. (e) Activate the seat belt pretensioner. (1) Confirm that no one is inside the vehicle or within 10 m (33 ft) of the vehicle. (2) Press SST activation switch and activate the seat belt pretensioner. HINT: The seat belt pretensioner operates simultaneously with the LED light for SST activation switch. (f) Dispose of the outer belt (with the seat belt pretensioner). CAUTION:
Do not touch the outer belt for at least 30 minutes after the seat belt pretensioner has been activated. It is very hot.
Use gloves and safety glasses when handling an outer belt with a pretensioner that has been activated.
Always wash your hands with water after completing the operation.
Do not apply water to a front seat outer belt that has an activated pretensioner 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3464 61-1 1 SEAT BELT - FRONT SEAT BELT HINT: When scrapping a vehicle, activate the seat belt pretensioner, and then scrap the vehicle with the activated outer belt installed. 2. DISPOSE OF FRONT SEAT OUTER BELT ASSY RH (WHEN NOT INSTALLED IN VEHICLE) NOTICE:
When disposing of the front seat outer belt (with the seat belt pretensioner) only, never use the customer’s vehicle to activate the seat belt pretensioner.
Be sure to follow the procedures listed below when activating the seat belt pretensioner. HINT: Prepare a battery as the power source to activate the seat belt pretensioner. (a) Cut Here B79201 Remove the outer belt (see page 61-4 ). (1) Wind the seat belt with the retractor. (2) When the seat belt is sufficiently wound, cut the seat belt approximately 10 cm from the retractor, as shown in the illustration HINT: The seat belt is designed so that winding the seat belt as much as possible before pretensioner activation will decrease the pulling power of the seat belt during pretensioner activation. (b) Check if SST is functioning (see step 1-(a)). CAUTION: When activating the seat belt pretensioner, always use the specified SST. SST 09082-00700, 09082-00770 Battery SST B50511 (c) SST Connect SST. (1) Connect SST, then connect them to the seat belt pretensioner. NOTICE: To avoid damaging SST connector and wire harness, do not lock the secondary lock of the twin lock. SST B51763 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3465 61-12 SEAT BELT (2) - FRONT SEAT BELT Place the outer belt on the ground and cover it with a tire with a wheel attached. NOTICE: Set up the front seat outer belt assy as shown in the illustration. SST SST B69491 (3) 10 m or More B50541 Move the SST at least 10 m (33 ft) away from the wheel. NOTICE: Take care not to damage the SST wire harness. (d) Activate the seat belt pretensioner. (1) Connect SST red clip to the battery’s positive (+) terminal and the black clip to the battery’s negative (-) terminal. (2) Check that no one is within 10 m (33 ft) of the wheel. (3) Press SST activation switch and activate the seat belt pretensioner. HINT: The seat belt pretensioner operates simultaneously with the LED light for SST activation switch. (e) Dispose of the outer belt (with the seat belt pretensioner). CAUTION:
Do not touch the outer belt for at least 30 minutes after the seat belt pretensioner has been activated. It is very hot.
Use gloves and safety glasses when handling an outer belt assy with a pretensioner that has been activated.
Always wash your hands with water after completing operation.
Do not apply water to an outer belt assy that has an activated pretensioner. (1) Remove the wheel and SST. (2) Place the outer belt in a plastic bag, tie the end tightly and dispose of it in the same way as other general parts. B60422 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3466 61-4 SEAT BELT - FRONT SEAT BELT 610JV-03 REPLACEMENT HINT:



The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. Use the same procedures for the RH side and LH side. The procedures listed below are for the RH side. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). 1. Manual seat type: REMOVE FRONT SEAT INNER BELT ASSY RH CAUTION:
Removal of the seat belt pretensioner must be started at least 90 seconds after the ignition switch is turned OFF and the negative (-) terminal cable is disconnected from the battery.
Carefully read the notices for the ”pretensioner” in the SRS airbag system section and the front seat outer belt section (see page 60-1 ). (a) Remove the front seat RH (see page 72-1 1). (b) Remove the front seat cushion shield inner RH (see page 72-1 1). (c) Remove the front seat inner belt RH. (1) Disconnect the connector and clamp. (2) Remove the nut and belt. (d) Protruding Part B78495 Install the front seat inner belt RH. (1) Install the belt with the nut. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) NOTICE: Do not allow the anchor part of the front belt and the protruding part of the floor panel to overlap. (e) Connect the clamp and connector. (f) Connect the battery’s negative battery terminal. (g) Initialize the occupant classification sensor (see page 72-1 1 or 72-19 ). (h) Check the SRS warning lamp (see page 60-1 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3458 61-5 SEAT BELT - FRONT SEAT BELT 2. Power seat type: REMOVE FRONT SEAT INNER BELT ASSY RH CAUTION:
Removal of the seat belt pretensioner must be started at least 90 seconds after the ignition switch is turned OFF and the negative (-) terminal cable is disconnected from the battery.
Carefully read the notices for the ”pretensioner” in the SRS airbag system section and the front seat outer belt section (see page 60-1 ). (a) Remove the front seat assy RH (see page 72-1 1). (b) Remove the power seat switch knobs (see page 72-1 1). (c) Disconnect the connector and clamp. (d) Remove the nut and belt. (e) Protruding Part B77530 Install the belt with the nut. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) NOTICE: Do not allow the anchor part of the front belt and the protruding part of the floor panel to overlap. (f) Connect the clamp and connector. (g) Connect the battery’s negative battery terminal. (h) Initialize the occupant classification sensor (see page 72-1 1 or 72-19 ). (i) Check the SRS warning lamp (see page 60-1 ). 3. REMOVE FRONT SEAT OUTER BELT ASSY RH CAUTION:
Removal of the seat belt pretensioner must be started at least 90 seconds after the ignition switch is turned OFF and the negative (-) terminal cable is disconnected from the battery.
Carefully read the notices for the ”pretensioner” in the SRS airbag system section and the front seat outer belt section (see page 60-1 ). (a) Remove the front door scuff plate RH (see page 76-21 ). (b) Remove the rear door scuff plate RH (see page 76-21 ). (c) Remove the front door opening trim weatherstrip (see page 76-21 ). (d) Remove the rear door opening trim weatherstrip (see page 76-21 ). (e) Remove the center pillar garnish lower RH (see page 76-21 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3459 61-6 SEAT BELT (f) - FRONT SEAT BELT Remove the front seat outer belt assy RH. (1) Using a screwdriver, disengage the 4 claws and remove the shoulder belt anchor cover. HINT: Tape the screwdriver tip before use. (2) Remove the bolt and shoulder anchor. Claw Protective Tape B78496 (3) Claw Using a screwdriver, disengage the 2 claws and remove the floor belt anchor cover. HINT: Tape the screwdriver tip before use. B77537 (4) (5) B61489 B60414 Unlock (g) 45 Lock B60413 Disconnect the pretensioner connector, as shown in the illustration. Remove the 2 bolts and outer belt. B61488 Install the front seat outer belt assy RH. (1) Check the amount of inclination required to lock the retractor.
When the inclination of the retractor is 15 or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45, check that the belt locks. NOTICE: Do not disassemble the retractor. If operation is not as specified, replace the outer belt assy. (2) Install the front seat outer belt assy RH. Torque: 7.5 N⋅m (77 kgf⋅cm, 66 in.⋅lbf) for upper bolt 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) for lower bolt 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3460 61-7 SEAT BELT - FRONT SEAT BELT (3) (h) (i) B78597 (j) (k) (l) (m) (n) (o) (p) Connect the pretensioner connector, as shown in the illustration. (4) Install the shoulder belt anchor to the shoulder belt anchor adjuster with the bolt. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) Install the center pillar garnish lower. Install the floor anchor to the front seat with the bolt. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) Install the front door scuff plate. Install the rear door scuff plate. Install the front door opening trim weatherstrip. Install the rear door opening trim weatherstrip. Connect the battery’s negative battery terminal. Initialize the occupant classification sensor (see page 72-1 1 or 72-19 ). Check the SRS warning lamp (see page 60-1 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3461 61-13 SEAT BELT - REAR NO.1 SEAT BELT REAR NO.1 SEAT BELT 610JX-01 COMPONENTS 7.5 (77, 66 in. ⋅lbf) 42 (428, 31) Rear Seat Inner Belt Assy LH 42 (428, 31) 42 (428, 31) 42 (428, 31) 42 (428, 31) 42 (428, 31) Rear No. 1 Seat Outer Belt Assy RH Rear Seat Inner Belt Assy RH 42 (428, 31) Rear Seat Inner Belt Assy N⋅m (kgf⋅cm ft⋅lbf) : Specified torque B78506 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3467 61-14 SEAT BELT - REAR NO.1 SEAT BELT Rear Door Opening Trim Weatherstrip RH Quarter Pillar Garnish RH Tonneau Cover Back Door Weather Strip Deck Trim Side Panel RH Deck Board No. 2 Rope Hook Rear Floor Finish Plate Deck Board Cover Rear Door Scuff Plate RH Deck Board No. 3 Deck Side Trim Box RH Deck Floor Box RR Deck Floor Box FR Deck Side Trim Box LH w/ Rear No. 2 Seat Deck Trim Foot Air Duct Deck Board Rear Seat Reclining Cover RH Rear Door Scuff Plate RH Rear Floor Silencer Floor Carpet B78297 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3468 61-15 SEAT BELT - REAR NO.1 SEAT BELT 610JY-02 REPLACEMENT HINT:



1. (a) (b) (c) (d) 2. (a) (b) (c) (d) The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. Use the same procedures for the RH side and LH side. The procedures listed below are for the RH side. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). REMOVE REAR SEAT INNER BELT ASSY RH w/o Rear No. 2 seat: Remove the deck board (see page 76-21 ). Remove the rear No.1 seat RH (see page 72-35 or 72-54 ). Remove the rear seat belt assy inner RH. (1) Remove the bolt and belt. Install the rear seat belt assy inner RH. (1) Install the belt with the bolt. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) REMOVE REAR SEAT OUTER BELT ASSY CENTER w/o Rear No. 2 seat: Remove the deck board (see page 76-21 ). Remove the rear No. 1 seat RH (see page 72-35 or 72-54 ). Remove the rear seatback cover (see page 72-35 or 72-54 ). Remove the rear seat outer belt assy center. (1) Remove the nut, bolt and belt. (e) Unlock 45 Lock B77535 Install the rear seat outer belt assy center. (1) Check the degree of tilt when the belt begins to lock the ELR. NOTICE: Do not disassemble the retractor.
When the inclination of the retractor is 15 or less, check that the belt can be pulled from the retractor. When the inclination of the inclination of the retractor is over 45 check that the belt locks. If operation is not as specified, replace the belt assy. (2) Install the seat belt with bolt and nut. Torque: 7.5 N⋅m (77 kgf⋅cm, 66 in.⋅lbf) for bolt 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) for nut (3) Install the seatback cover (see page 72-35 or 72-54 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3469 61-16 SEAT BELT Protruding Part B76375 - REAR NO.1 SEAT BELT (4) Install the floor anchor with the bolt. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) NOTICE: Do not allow the anchor part of the rear belt and the protruding parts of the seat cushion frame to overlap.
With the belt installed, check that the belt locks when it is pulled out quickly. If operation is not as specified, replace the seat belt assy. (5) Check the ELR lock. NOTICE: The check should be performed with the assembly installed.
With the belt installed, check that the belt locks when it is pulled out quickly. If operation is not as specified, replace the belt assy. 3. (a) REMOVE REAR SEAT INNER BELT ASSY w/o Rear No. 2 seat: Remove the deck board (see page 76-21 ). (b) Remove the rear No. 1 seat LH (see page 72-35 or 72-54 ). (c) Remove the rear seat inner belt assy. (1) Remove the bolt and belt. (d) Install the rear seat inner belt assy. (1) Install the belt with the bolt. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) NOTICE: Do not allow the anchor part of the rear belt and the protruding parts of the floor panel to overlap. Protruding Part Protruding Part B77533 4. (a) (b) (c) (d) REMOVE REAR SEAT INNER BELT ASSY LH w/o Rear No. 2 seat: Remove the deck board (see page 76-21 ). Remove the rear No.1 seat LH (see page 72-35 or 72-54 ). Remove the rear seat inner belt assy LH. (1) Remove the bolt and belt. Install the rear seat inner belt assy LH. (1) Install the belt with the bolt. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3470 61-17 SEAT BELT 5. (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) (q) (r) (s) (t) (u) (v) - REAR NO.1 SEAT BELT REMOVE REAR SEAT OUTER BELT ASSY RH Remove the tonneau cover (see page 76-21 ). Remove the deck board cover (see page 76-21 ). Remove the deck board cover No. 2 (see page 76-21 ). Remove the deck board cover No. 3 (see page 76-21 ). w/ Rear No. 2 seat: Remove the rear seat reclining cover RH (see page 76-21 ). Remove the deck floor box RR (see page 76-21 ). w/o Rear No. 2 seat: Remove the deck floor box FR (see page 76-21 ). Remove the rear floor finish plate (see page 76-21 ). Remove the deck side trim box LH (see page 76-21 ). Remove the deck side trim box RH (see page 76-21 ). Remove the rear No. 1 seat LH (see page 76-21 ). Remove the rear No. 1 seat RH (see page 76-21 ). Remove the rear door scuff plate RH (see page 76-21 ). Remove the rear door opening trim weatherstrip RH (see page 76-21 ). Remove the back door weatherstrip (see page 76-21 ). Remove the rope hook (see page 76-21 ). Remove the deck trim side panel RH (see page 76-21 ). w/ Rear No. 2 seat: Remove the quarter pillar garnish RH (see page 76-21 ). w/ Rear No. 2 seat: Remove the 3 clips and turn over the front floor carpet. w/ Rear No. 2 seat: Remove the 2 clips and rear floor silencer LH and RH. w/ Rear A/C: Remove the 4 clips and foot air duct rear. Remove the rear seat outer belt assy RH. (1) Remove the bolt and shoulder anchor. (2) Remove the bolt and belt. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3471 61-18 SEAT BELT - REAR NO.1 SEAT BELT (w) Unlock 45 Lock B77535 Install the rear seat outer belt assy RH. (1) Check the degree of tilt when the belt begins to lock the ELR. NOTICE: Do not disassemble the retractor.
When the inclination of the retractor is 15 or less, check that the belt can be pulled from the retractor. When the inclination of the inclination of the retractor is over 45 check that the belt locks. If operation is not as specified, replace the belt assy. (2) Claw Claw Install the belt assy with the bolt, as shown in the illustration. B78498 Protruding Part Front Side Floor Anchor B78499 (3) Install the rear outer belt with the bolt. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) NOTICE: Do not allow the anchor part of the rear belt and the protruding parts of the floor panel to overlap.
With the belt installed, check that the belt locks when it is pulled out quickly. If operation is not as specified, replace the seat belt assy. (4) Check the ELR lock. NOTICE: The check should be performed with the outer belt assy installed.
With the belt installed, check that the belt locks when it is pulled out quickly. If operation is not as specified, replace the belt assy. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3472 61-19 SEAT BELT - (5) REAR NO.1 SEAT BELT Check the fastening function of the child restraint system. NOTICE: The check should be performed with the outer belt assy installed.
When the belt is pulled out fully, the belt should automatically try to retract.
After the belt has fully retracted, the belt should be able to be pulled out and retracted again. If operation is not as specified, replace the belt assy. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3473 61-20 SEAT BELT - REAR NO.2 SEAT BELT REAR NO.2 SEAT BELT 610JZ-01 COMPONENTS 42 (428, 31) Rear No. 2 Seat Outer Belt Assy RH 42 (428, 31) 42 (428, 31) 7.5 (77, 66 in. ⋅lbf) 42 (428, 31) 42 (428, 31) Rear Seat Lap Type Belt Assy RH Rear Seat Inner Belt Assy Rear Seat Lap Type Belt Assy LH N⋅m (kgf⋅cm ft⋅lbf) : Specified torque B77529 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3474 61-21 SEAT BELT - REAR NO.2 SEAT BELT Rear Door Opening Trim Weatherstrip RH Deck Trim Side Cover Deck Trim Side Panel RH Rear Seat Reclining Cover RH Rear Door Scuff Plate RH Tonneau Cover Back Door Weatherstrip Deck Board No. 2 Deck Board Cover Rear Floor Finish Plate Deck Board No. 3 Rear Floor Box RR Rear Floor Trim Box RH Deck Floor Box FR Deck Side Trim Box LH B78296 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3475 61-22 SEAT BELT - REAR NO.2 SEAT BELT 610K0-02 REPLACEMENT HINT:



1. (a) (b) (c) 2. (a) (b) The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. Use the same procedures for the RH side and LH side. The procedures listed below are for the RH side. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). REMOVE REAR SEAT LAP TYPE BELT RH Remove the rear No. 2 seat (see page 72-61 ). Remove the rear seat lap type belt assy RH. (1) Remove the bolt and belt. Install the rear seat lap type belt assy RH. (1) Remove the bolt and belt. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) REMOVE REAR SEAT INNER BELT ASSY Remove the rear No. 2 seat (see page 72-61 ). Remove the rear seat inner belt assy. (1) Remove the 2 bolts and 2 belts. (c) Protruding Part B77531 Install the rear seat inner belt assy. (1) Remove the 2 bolts and 2 belts. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) NOTICE: Do not allow the anchor part of the rear belt and the protruding parts of the floor panel to overlap. 3. REMOVE REAR NO.2 SEAT OUTER BELT ASSY RH (a) Remove the tonneau cover (see page 76-21 ). (b) Remove the deck board cover (see page 76-21 ). (c) Remove the deck board cover No. 2 (see page 76-21 ). (d) Remove the deck board cover No. 3 (see page 76-21 ). (e) Remove the rear seat reclining cover LH (see page 76-21 ). (f) Remove the rear seat reclining cover RH (see page 76-21 ). (g) Remove the deck floor box RR (see page 76-21 ). (h) Remove the rear floor finish plate (see page 76-21 ). (i) Remove the deck side trim box LH (see page 76-21 ). (j) Remove the deck side trim box RH (see page 76-21 ). (k) Remove the rear No. 1 seat LH (see page 76-21 ). (l) Remove the rear No. 1 seat RH (see page 76-21 ). (m) Remove the rear No. 2 seat RH (see page 76-21 ). (n) Remove the rear door opening trim weatherstrip RH (see page 76-21 ). (o) Remove the back door weatherstrip (see page 76-21 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3476 61-23 SEAT BELT (p) (q) (r) (s) Seat Belt Anchor Cover (t) - REAR NO.2 SEAT BELT Remove the rope hook (see page 76-21 ). Remove the rear door scuff plate RH (see page 76-21 ). Remove the deck trim side panel RH (see page 76-21 ). Remove the quarter pillar garnish RH (see page 76-21 ). Remove the rear No. 2 seat belt assy outer RH. (1) Using a screwdriver, open the seat belt anchor cover HINT: Tape the screwdriver tip before use. (2) Remove the bolt and shoulder anchor. (3) Remove the 2 bolts and belt. Protective Tape Claw B77538 (u) Unlock 45 Lock B77534 Install the rear No. 2 seat belt assy outer RH. (1) Check the amount of inclination required to lock the retractor.
When the inclination of the retractor is 15 or less, check that the belt can be pulled from the retractor. When the inclination of the retractor is over 45, check that the belt locks. NOTICE: Do not disassemble the retractor. If operation is not as specified, replace the outer belt assy. (2) Install the belt with the 2 bolts. Torque: 7.5 N⋅m (77 kgf⋅cm, 66 in.⋅lbf) for upper bolt 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) for lower bolt (3) Install the shoulder anchor with the bolt. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3477 61-1 SEAT BELT - SEAT BELT WARNING SYSTEM SEAT BELT WARNING SYSTEM 610JS-01 LOCATION Passenger Seat Occupant Classification Sensor Rear Occupant Classification Sensor Front A/C Control Assy
Passenger Side Seat Belt Warning Lamp Combination Meter Assy
Driver Side Seat Belt Warning Lamp Occupant Classification ECU Instrument Panel J/B
AM1 M-fuse
IG1 Fuse
RAD NO. 2 Fuse Front Seat Inner Belt Assy RH Airbag Sensor Assy Front Seat Inner Belt Assy LH B79063 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3455 61-2 SEAT BELT - SEAT BELT WARNING SYSTEM 610JT-01 PROBLEM SYMPTOMS TABLE Symptom Suspected Area See Page Driver side seat belt warning lamp does not flash 1. 2. 3. 4. 5. 6. 7. IG1 fuse AM1 M-fuse RAD NO. 2 fuse Combination meter Front seat inner belt assy LH Airbag sensor assy Wire harness 61-1 61-1 61-1 05-1898 05-1228 05-1228 Passenger side seat belt warning lamp does not flash 1. 2. 3. 4. 5. 6. 7. 8. IG1 fuse AM1 M-fuse RAD NO. 2 fuse A/C control assy Front seat inner belt assy RH Occupant classification sensor Occupant classification ECU Wire harness 61-1 61-1 61-1 05-1228 05-1228 05-1228 05-1228 NOTICE: The front seat inner belt RH and LH cannot be inspected. When the front seat inner belt seems to be malfunctioning, use the hand-held tester to check for DTCs. HINT: The seat belt warning system is part of the large-scale multiplex communication system. This system features shared communication wiring that reduces the wiring complexity of the communication lines. The first step in any repair is to confirm the proper operation of the communication system. Proceed with troubleshooting after the communication has been verified (see multiplex communication system). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3456 72-6 SEAT - FRONT POWER SEAT CONTROL SYSTEM 720RG-01 INSPECTION 1. (a) Front Power Seat Switch LH Driver’s seat only: Front Vertical Switch Reclining Switch Slide Switch Driver’s seat only: Rear Vertical Switch B60011 INSPECT FRONT POWER SEAT SWITCH LH Check the resistance between the terminals when each switch is operated. Standard: Slide switch Tester Connection Switch Condition Specified Condition 1-9 FRONT Below 1 Ω 4-6 FRONT Below 1 Ω 4-6 OFF Below 1 Ω 4-9 OFF Below 1 Ω 1-6 REAR Below 1 Ω 4-9 REAR Below 1 Ω Tester Connection Switch Condition Specified Condition 1 - 10 UP Below 1 Ω 4 -5 UP Below 1 Ω 4 -5 OFF Below 1 Ω 4 - 10 OFF Below 1 Ω 1 -5 DOWN Below 1 Ω 4 - 10 DOWN Below 1 Ω Tester Connection Switch Condition Specified Condition 1-7 UP Below 1 Ω 4 -8 UP Below 1 Ω 4-7 OFF Below 1 Ω 4 -8 OFF Below 1 Ω 1 -8 DOWN Below 1 Ω 4 -7 DOWN Below 1 Ω Tester Connection Switch Condition Specified Condition 1 -3 FRONT Below 1 Ω 2 -4 FRONT Below 1 Ω 2-4 OFF Below 1 Ω 3 -4 OFF Below 1 Ω 1 -2 REAR Below 1 Ω 3 -4 REAR Below 1 Ω Driver’s seat only: Front vertical switch Driver’s seat only: Rear vertical switch Reclining switch If the result is not as specified, replace the switch. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3615 72-7 SEAT 2. (a) Front Power Seat Switch RH Reclining Switch Slide Switch - FRONT POWER SEAT CONTROL SYSTEM INSPECT FRONT POWER SEAT SWITCH RH Check the resistance between the terminals when each switch is operated. Standard: Slide switch Tester Connection Switch Condition Specified Condition 1-9 FRONT Below 1 Ω 4-6 FRONT Below 1 Ω 4-6 OFF Below 1 Ω 4-9 OFF Below 1 Ω 1-6 REAR Below 1 Ω 4-9 REAR Below 1 Ω Tester Connection Switch Condition Specified Condition 1 -3 FRONT Below 1 Ω Reclining switch B68207 2 -4 FRONT Below 1 Ω 2-4 OFF Below 1 Ω 3 -4 OFF Below 1 Ω 1 -2 REAR Below 1 Ω 3 -4 REAR Below 1 Ω If the result is not as specified, replace the switch. 3. Power Seat Switch Assy (Lumbar Support) (a) Hold Release Driver’s seat only: INSPECT POWER SEAT SWITCH ASSY (LUMBAR SUPPORT) Check the resistance between the terminals when the switch is operated. Standard: Tester Connection Switch Condition Specified Condition 1 -2 HOLD Below 1 Ω 3 -4 HOLD Below 1 Ω 1 -2 OFF Below 1 Ω 4 -5 OFF Below 1 Ω 1 -3 RELEASE Below 1 Ω 4 -5 RELEASE Below 1 Ω If the result is not as specified, replace the switch assy. B68208 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3616 72-8 SEAT 4. (a) Slide Motor Counterclockwise Clockwise 21 B35140 Driving Axis B57292 - FRONT POWER SEAT CONTROL SYSTEM INSPECT FRONT SEAT ADJUSTER ASSY Check operation of the slide motor. (1) Check if the motor rotates smoothly when the battery is connected to the slide motor connector terminals. Standard: Measurement Condition Operational Direction Battery positive (+) → 1 Battery negative (-) → 2 Clockwise Battery positive (+) → 2 Battery negative (-) → 1 Counterclockwise If the result is not as specified, replace the slide motor. (b) Front Vertical Motor Counterclockwise Clockwise 21 B35140 Driving Axis B57292 Driver’s seat only: Check operation of the front vertical motor. (1) Check if the motor rotates smoothly when the battery is connected to the front vertical motor connector terminals. Standard: Measurement Condition Operational Direction Battery positive (+) → 1 Battery negative (-) → 2 Clockwise Battery positive (+) → 2 Battery negative (-) → 1 Counterclockwise If the result is not as specified, replace the front vertical motor. (c) Rear Vertical Motor Counterclockwise B35140 Clockwise 21 Driving Axis B57292 Driver’s seat only: Check operation of the rear vertical motor. (1) Check if the motor rotates smoothly when the battery is connected to the rear vertical motor connector terminals. Standard: Measurement Condition Operational Direction Battery positive (+) → 1 Battery negative (-) → 2 Clockwise Battery positive (+) → 2 Battery negative (-) → 1 Counterclockwise If the result is not as specified, replace the rear vertical motor. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3617 72-9 SEAT (d) Reclining Motor Counterclockwise Clockwise 21 Driving Axis B35140 B57292 - FRONT POWER SEAT CONTROL SYSTEM Check operation of the reclining motor. (1) Check if the motor rotates smoothly when the battery is connected to the reclining motor connector terminals. Standard: Measurement Condition Operational Direction Battery positive (+) → 1 Battery negative (-) → 2 Clockwise Battery positive (+) → 2 Battery negative (-) → 1 Counterclockwise If the result is not as specified, replace the reclining motor. 5. Lumbar Support Adjuster Motor (a) Counterclockwise Clockwise Driving Axis B68209 Driver’s seat only: INSPECT LUMBAR SUPPORT ADJUSTER ASSY Check operation of the lumbar support adjuster motor. (1) Check if the motor rotates smoothly when the battery is connected to the lumbar support adjuster motor connector terminals. Standard: Measurement Condition Operational Direction Battery positive (+) → 1 Battery negative (-) → 2 Clockwise Battery positive (+) → 2 Battery negative (-) → 1 Counterclockwise If the result is not as specified, replace the adjuster motor. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3618 72-4 SEAT - FRONT POWER SEAT CONTROL SYSTEM 720RF-01 ON-VEHICLE INSPECTION 1. (a) Reclining Function Lumbar Support Function Rear Vertical Function Front Vertical Function 2. CHECK POWER SEAT FUNCTION Check the basic functions. (1) Operate the power seat switches and check to make sure each seat function works:
Sliding
Front vertical (driver’s seat only)
Rear vertical (driver’s seat only)
Reclining
Lumbar support (driver’s seat only) Sliding Function B76688 CHECK POWER SEAT MOTOR ASSY (SLIDING, FRONT VERTICAL, REAR VERTICAL AND RECLINING FUNCTIONS) HINT: The front vertical function and rear vertical function are only available for the driver’s seat. (a) Check the PTC operation inside the power seat motor. HINT: The PTC thermistor’s resistance increases when the power seat switch is held down even after the power seat has been moved to the maximum in one direction. After the resistance increases, current is shut off to prevent a short circuit. NOTICE: Perform steps (1) to (4) for the full range of motion for each power seat function. (1) Choose a power seat function. Operate the power seat switch and move the seat to the maximum in one direction. Keep the seat in that position for approximately 60 seconds. (2) Operate the power seat switch again and continue to try to move the seat in the same direction as in step (1). Measure the amount of time elapsed before the electrical current is automatically cut. Check if electrical current has shut off by making sure the sound of the motor has stopped. Standard: 4 to 90 seconds (3) After the current has stopped, release the power seat switch and wait for approximately 60 seconds. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3613 72-5 SEAT - FRONT POWER SEAT CONTROL SYSTEM (4) Operate the same power seat switch and move the seat to the opposite extreme of the direction in step (1). Check that the motor operates. (5) Repeat steps (1) to (4) for the remaining power seat functions. 3. Driver’s seat only: CHECK LUMBAR SUPPORT ADJUSTER ASSY LH (a) Check the PTC operation inside the power seat motor. NOTICE: The inspection should be performed with the seat installed in the vehicle. (1) Operate the lumbar support switch and move the lumbar support to either the foremost or rearmost position. Keep the seat in that position for approximately 60 seconds. (2) Operate the lumbar support switch again and continue to try to move the lumbar support in the same direction as in step (1). Measure the amount of time elapsed before the electrical current is automatically cut. Check if electrical current has shut off by making sure the sound of the motor has stopped. Standard: 4 to 90 seconds (3) After the current has stopped, release the lumbar support switch and wait for approximately 60 seconds. (4) Operate the lumbar support switch and move the seat to the opposite extreme of the direction in step (1). Check that the motor operates. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3614 72-1 SEAT - FRONT POWER SEAT CONTROL SYSTEM FRONT POWER SEAT CONTROL SYSTEM 720JM-02 LOCATION Instrument Panel J/B Assy
POWER M-fuse B78184 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3610 72-2 SEAT - FRONT POWER SEAT CONTROL SYSTEM Lumbar Support Motor Reclining Motor Reclining Motor Front Power Seat Switch RH Slide Motor Front Vertical Motor Rear Vertical Motor Slide Motor Power Seat Switch Assy (Lumbar Support) Front Power Seat Switch LH B76690 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3611 72-3 SEAT - FRONT POWER SEAT CONTROL SYSTEM 720JJ-02 PROBLEM SYMPTOMS TABLE Symptom Suspected Area See Page All power seat functions do not operate 1. POWER M-fuse 2. Wire harness 72-1 - Only slide operation function does not operate 1. Front power seat switch 2. Slide motor 3. Wire harness 72-6 72-6 - Only front vertical operation function does not operate (driver’s seat only) 1. Front power seat switch 2. Front vertical motor 3. Wire harness 72-6 72-6 - Only rear vertical operation function does not operate (driver’s seat only) 1. Front power seat switch 2. Rear vertical motor 3. Wire harness 72-6 72-6 - Only reclining operation function does not operate 1. Front power seat switch 2. Reclining motor 3. Wire harness 72-6 72-6 - Only lumbar support operation function does not operate (driver’s seat only) 1. Power seat switch assy (Lumbar support) 2. Lumbar support adjuster motor 3. Wire harness 72-6 72-6 - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3612 72-10 SEAT - FRONT SEAT ASSY LH (POWER SEAT TYPE) FRONT SEAT ASSY LH (POWER SEAT TYPE) 720JN-02 COMPONENTS Front Seat Headrest Assy Separate Type Front Seatback Pad Front Seat Headrest Support w/ Side Airbag: Separate Type Front Seatback Cover 5.6 (57, 49 in.⋅lbf) Seat Armrest Cover Front Seatback Board Sub-assy LH 37 (377, 27) Seat Armrest Assy LH
Hog Ring Front Seatback Board Cover Separate Type Front Seat Cushion Cover
Hog Ring Clip Separate Type Front Seat Cushion Pad Reclining Adjuster Inside Cover RH (Upper side) Diver’s Seat Only: Lumbar Support Adjuster Assy LH Front Seat Adjuster LH Reclining Adjuster Inside Cover RH (Lower side) Front Seat Inner Belt Assy LH Front Seat Cushion Shield Inner LH 36.7 (375, 27) Reclining Adjuster Inside Cover LH (Upper side) 42 (428, 31) 36.7 (375, 27) Passenger’s Seat Only: Reclining Adjuster Inside Cover LH (Lower side) Occupant Classification ECU Driver’s Seat Only: Front Seat Cushion Shield Inner No. 1 LH 8.0 (82, 71 in.⋅lbf) Driver’s Seat Only: Seat Slide Position Seat Position Protector Airbag Sensor Front Seat Cushion Shield LH Front Power Seat Switch LH Power Seat Switch Knob Driver’s Seat Only: Power Seat Switch Assy Seat Track Bracket Cover Inner Front LH Seat Track Bracket Cover Inner LH Seat Track Bracket Cover Outer LH Front Seat Cushion Shield Lower LH Front Seat Cushion Shield Lower RH N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque Seat Track Bracket Cover Outer Front LH
Non-reusable part Front Seat Wire LH B76689 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3619 72-1 1 SEAT - FRONT SEAT ASSY LH (POWER SEAT TYPE) 720RH-03 OVERHAUL CAUTION:
Wear safety gloves, because the cutting surfaces of the seatback frame and seat adjuster may injure your hand.
Work must be started at least 90 seconds after the ignition switch is turned to the LOCK position and 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 from disconnecting the negative (-) terminal cable of the battery, the SRS may deploy.) HINT:
The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.
Use the same procedures for the RH side and LH side.
The procedures listed below are for the LH side.
When removing/installing and overhauling the passenger seat, check the passenger occupant classification system and perform the zero point calibration (see page 05-1203 ).
A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). 1. (a) REMOVE SEAT TRACK BRACKET COVER OUTER FRONT LH Using a screwdriver, disengage the 3 claws and remove the bracket cover. HINT: Tape the screwdriver tip before use. 3 Claws B78036 2. (a) REMOVE SEAT TRACK BRACKET COVER INNER FRONT LH Using a screwdriver, disengage the 2 claws and remove the bracket cover. HINT: Tape the screwdriver tip before use. 2 Claws B78309 3. (a) REMOVE SEAT TRACK BRACKET COVER OUTER LH Using a screwdriver, disengage the 4 claws and remove the bracket cover. HINT: Tape the screwdriver tip before use. 4 Claws B78310 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3620 72-12 SEAT - FRONT SEAT ASSY LH (POWER SEAT TYPE) 4. REMOVE SEAT TRACK BRACKET COVER INNER LH HINT: Use the same procedures described for the bracket cover outer LH. 5. REMOVE FRONT SEAT ASSY LH (a) Remove the headrest. (b) Disconnect the connectors under the seat. (c) Remove the 4 bolts and seat. NOTICE: Be careful not to damage the vehicle body. 6. Passenger ’s seat only: REMOVE OCCUPANT CLASSIFICATION ECU (See page 60-64 ) 7. REMOVE FRONT SEAT CUSHION SHIELD LH (a) Remove the 2 rubber bands from the back of the front seatback board cover. (b) Using a screwdriver, pry out the 2 power seat switch knobs. HINT: Tape the screwdriver tip before use. (c) Remove the 7 screws. (d) Using a screwdriver, disengage the 4 claws and clip, and remove the cushion shield together with the cushion shield inner and cushion shield inner No. 1. HINT: Tape the screwdriver tip before use. Clip (e) (f) 4 Claws B78336 Disconnect the connector of the power seat switch. Remove the screw and disengage the claw using a screwdriver to remove the cushion shield from the cushion shield inner No. 1. HINT: Tape the screwdriver tip before use. 8. REMOVE FRONT SEAT CUSHION SHIELD INNER LH (a) Remove the screw. (b) Using a screwdriver, disengage the claw and remove the cushion shield inner from the cushion shield inner No. 1. 9. REMOVE FRONT POWER SEAT SWITCH LH (a) Disconnect the connectors. (b) Remove the 3 screws and seat switch. 10. Driver’s seat only: REMOVE POWER SEAT SWITCH ASSY (a) Remove the 2 screws and seat switch. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3621 72-13 SEAT 11. 12. (a) (b) (c) (d) - FRONT SEAT ASSY LH (POWER SEAT TYPE) REMOVE FRONT SEAT INNER BELT ASSY LH (See page 61-4 ) REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER Using a clip remover, remove the 2 clips on the cushion cover side. w/ Seat heater: Disconnect the seat heater connectors. Disengage the hook and remove the hog rings and seat cushion cover together with the pad. Remove the hog rings and cushion cover. 4 Claws 13. (a) (b) REMOVE FRONT SEATBACK BOARD SUB-ASSY LH Remove the 2 screws. Lower the seatback board in the direction indicated by the arrow in the illustration to disengage the 4 claws on the upper part. (c) Hold the seatback board on the upper right and lower left as shown in the illustration. (d) Turn the seatback board counterclockwise to disengage the claws and remove it. B78337 Hold Hold B78338 Counterclockwise B78339 14. (a) (b) REMOVE FRONT SEATBACK BOARD COVER SUB-ASSY Disengage the hook on the upper part of the seatback board cover. Remove the hog rings and seatback board cover. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3622 72-14 SEAT 15. (a) - FRONT SEAT ASSY LH (POWER SEAT TYPE) REMOVE SEAT ARMREST ASSY LH Using a screwdriver, disengage the 2 claws and remove the armrest cover. HINT: Tape the screwdriver tip before use. (b) Remove the bolt and armrest. 2 Claws B78965 16. (a) (b) (c) (d) REMOVE SEPARATE TYPE FRONT SEATBACK COVER Remove the 2 headrest supports. Remove the hog rings and seatback cover together with the pad. w/ Side airbag: Remove the nut and seatback cover bracket. Remove the hog rings and seatback cover. B60977 17. (a) (b) 18. (a) 19. (a) 20. (a) 21. (a) 22. (a) 23. (a) 24. (a) (b) (c) Driver’s seat only: REMOVE LUMBAR SUPPORT ADJUSTER ASSY LH Disconnect the connectors. Remove the 2 screws and lumbar support adjuster. REMOVE RECLINING ADJUSTER INSIDE COVER LH (UPPER SIDE) Remove the screw and reclining adjuster cover. REMOVE RECLINING ADJUSTER INSIDE COVER RH (UPPER SIDE) Remove the screw and reclining adjuster cover. REMOVE RECLINING ADJUSTER INSIDE COVER LH (LOWER SIDE) Remove the 2 screws and reclining adjuster cover. REMOVE RECLINING ADJUSTER INSIDE COVER RH (LOWER SIDE) Remove the 2 screws and reclining adjuster cover. REMOVE FRONT SEAT CUSHION SHIELD LOWER LH Remove the screw and cushion shield. REMOVE FRONT SEAT CUSHION SHIELD LOWER RH Remove the screw and cushion shield. Driver’s seat only: REMOVE SEAT POSITION AIRBAG SENSOR Disconnect the wire harness connector. Disengage the claw and remove the seat slide position protector. Using a torx socket wrench (T30), remove the torx bolt and airbag sensor. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3623 72-15 SEAT - FRONT SEAT ASSY LH (POWER SEAT TYPE) 25. Seat Position Airbag Sensor Slide Rail Feeler Gauge B76909 Driver’s seat only: INSTALL SEAT POSITION AIRBAG SENSOR (a) Temporarily install the seat position airbag sensor. (b) Install a 1 mm (0.04 in.) feeler gauge between the slide rail and sensor as shown in the illustration. NOTICE:
If the seat position airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace the seat position airbag sensor with a new one.
When installing the seat position airbag sensor, be careful that the SRS wiring does not interfere with other parts and is not pinched between other parts. HINT: Be sure to maintain a clearance between the seat position airbag sensor and the seat rail is within 0.6 mm (0.023 in.) to 2.0 mm (0.079 in.). (c) Push the top of the sensor. While holding the sensor, tighten the sensor using a torx socket wrench (T30). Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) (d) Install the seat slide position protector. (e) Connect the wire harness connector. 26. B50126 INSTALL SEPARATE TYPE FRONT SEATBACK COVER (a) Install the seatback pad. (b) Cover the top of the seatback pad with the seatback cover. (c) Using hog ring pliers, completely install the seatback cover with new hog rings. NOTICE:
Be careful not to damage the cover.
When installing the hog rings, take care to prevent wrinkles as much as possible. (d) Install the 2 headrest supports. (e) w/ Side airbag: Fully cover the airbag with the seatback cover bracket and tighten the nut. Torque: 5.6 N⋅m (57 kgf⋅cm, 49 in.⋅lbf) B80142 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3624 72-16 SEAT - FRONT SEAT ASSY LH (POWER SEAT TYPE) NOTICE:
For a vehicle with side airbag, the side airbag may not be activated normally unless the seatback cover is securely installed.
Check that the strap has no twist after installing the bracket.
Install the bracket securely. 27. INSTALL SEAT ARMREST ASSY LH (a) Install the armrest with the bolt. Torque: 37 N⋅m (377 kgf⋅cm, 27 ft⋅lbf) (b) Install the armrest cover. 28. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER (a) Install the seat cushion. (b) Using hog ring pliers, install the cushion cover to the cushion pad with new hog rings. NOTICE:
Be careful not to damage the cover.
When installing the hog rings, take care to prevent wrinkles as much as possible. B50126 (c) w/ Seat heater: Connect the seat heater connectors. (d) Install the clip. INSTALL FRONT SEAT INNER BELT ASSY LH (See page 61-4 ) INSTALL FRONT SEAT ASSY LH Place the seat in the cabin. Connect the connectors under the seat. Tighten the 2 bolts on the front side of the seat. Torque: 36.7 N⋅m (375 kgf⋅cm, 27 ft⋅lbf) Tighten the 2 bolts on the rear side of the seat. Torque: 36.7 N⋅m (375 kgf⋅cm, 27 ft⋅lbf) Install the 4 seat track covers. Install the headrest. Connect the negative battery’s terminal. INSPECT FUNCTION OF POWER SEAT OPERATION (See page 72-4 ) w/ Seat heater: CHECK SEAT HEATER OPERATION Hog Ring Pliers 29. 30. (a) (b) (c) (d) (e) (f) (g) 31. 32. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3625 72-17 SEAT 33. - FRONT SEAT ASSY LH (POWER SEAT TYPE) Passenger ’s seat only: CHECK FUNCTION OF FRONT PASSENGER OCCUPANT CLASSIFICATION SYSTEM HINT: Perform the zero point calibration and sensitivity check when any of the following conditions is met.
The occupant classification ECU is replaced.
Accessories (seatback tray and seat cover, etc.) are installed.
The passenger seat is removed from the vehicle.
Both the SRS warning lamp and the passenger airbag ON/OFF indicator lamp (”OFF”) turn on.
The vehicle is brought to the workshop for repair due to an accident or a collision. (a) Zero point calibration procedure: (1) Adjust the seat position according to the conditions below. Adjustment Component Position Slide Direction Rearmost position Reclining Angle Upright position Headrest Height Lowest position (2) (3) (4) Connect the hand-held tester to the DLC3. Turn the ignition switch ON. Perform the zero point calibration by following the prompts on the tester screen. HINT: Refer to the hand-held tester operator’s manual for further details. (b) Sensitivity check procedure. (1) Connect the hand-held tester to the DLC3. (2) Apply a 30 kg weight (for example, a 30 kg of lead mass) onto the passenger seat. (3) Turn the ignition switch to the ON position. (4) Using the hand-held tester, perform the sensitivity check and confirm that the sensitivity is within the standard value. Standard value: 27 to 33 kg HINT:
When performing the sensitivity check, use a solid weight made from metal. The check results may not be accurate if a weight made from liquid is used.
When the sensitivity deviates from the standard value, retighten the bolts of the passenger seat, taking care not to deform the seat rail. Perform the sensitivity check again. If the sensitivity still is not within the standard value, replace the front seat assembly RH. NOTICE: Do not place any objects on the seat. Perform the initialization by attaching a mass more than 2 kgs in the seatback pocket, seatback table installed by the user or other appropriate location. (c) Check the SRS warning lamp (see page 60-1 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3626 72-26 SEAT - REAR NO.1 SEAT ASSY LH (W/O REAR NO.2 SEAT) REAR NO.1 SEAT ASSY LH (W/O REAR NO.2 SEAT) 720RT-01 COMPONENTS Rear Seat Lock Control Lever Sub-assy LH Rear Seat Lock Control Lever Cover Rear Seat Headrest Assy Rear Seatback Board Carpet Assy LH Rear Seat Headrest Support
Hog Ring Rear Seatback Cover LH Separate Type Rear Seatback Cover Clip Separate Type Rear Seat Cushion Cover
Hog Ring Separate Type Rear Seatback Pad 21 (214, 15) Separate Type Rear Seat Cushion Pad 21 (214, 15) Rear Seat Reclining Control No. 2 Cable Rear Seat Cushion Frame Sub-assy LH N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part B78369 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3635 72-27 SEAT - REAR NO.1 SEAT ASSY LH (W/O REAR NO.2 SEAT) Rear Seatback Frame Sub-assy LH Tonneau Cover Hook Holder 42 (428, 31) 9.0 (92, 80 in.⋅lbf) Rear Seat Cushion Moulding Rear LH Fold Seat Stopper Band Assy No. 2 42 (428, 31) 42 (428, 31) Rear Seat Reclining Cover Inner LH 18 (184, 13) Rear Seat Belt Assy Inner Seat Track Stop Plate LH Fold Seat Cushion Frame No. 1 42 (428, 31) 42 (428, 31) Rear Seatback Frame Sub-assy Lower LH Reclining Control Link Sub-assy LH 42 (428, 31) Fold Seat Cushion Frame No. 2 18 (184, 13) 42 (428, 31)
E-Ring Seat Hinge Rod 42 (428, 31) 36.7 (374, 27) Rear Seat Cushion Moulding LH 36.7 (374, 27) Rear Seat Track Assy Inner LH 36.7 (374, 27) 36.7 (374, 27) Rear Seat Track Bracket Cover Inner Rear Seat Track Assy Outer LH Rear Seat Track Adjusting Handle Rear Seat Track Bracket Cover Outer N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part B78370 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3636 72-28 SEAT - REAR NO.1 SEAT ASSY LH (W/O REAR NO.2 SEAT) 720JQ-03 OVERHAUL HINT:

1. The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). REMOVE DECK BOARD SUB-ASSY (See page 76-21 ) 2. (a) REMOVE REAR SEAT TRACK BRACKET COVER OUTER Using a screwdriver, disengage the 4 claws and remove the bracket cover. HINT: Tape the screwdriver tip before use. 3. REMOVE REAR SEAT TRACK BRACKET COVER INNER 4 Claws HINT: B78372 Use the same procedures described for the bracket cover outer. REMOVE REAR NO.1 SEAT ASSY LH Using a clip remover, remove the 3 clips. 4. (a) HINT: Tape the clip remover tip before use. (b) Remove the bolt holding the fold seat stopper band on the vehicle side. (c) Remove the headrest. (d) Remove the 5 bolts and seat. Claw 5. (a) (b) REMOVE REAR SEAT CUSHION MOULDING LH Remove the 2 screws. Remove the moulding by pulling it out in the arrow mark direction shown in the illustration. 6. REMOVE REAR SEAT CUSHION MOULDING REAR LH Remove the 3 screws. Using a screwdriver, disengage the 3 claws and remove the moulding. B78376 (a) (b) HINT: Tape the screwdriver tip before use. 3 Claws B78377 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3637 72-29 SEAT 7. (a) (b) 8. (a) (b) 9. (a) - REAR NO.1 SEAT ASSY LH (W/O REAR NO.2 SEAT) REMOVE REAR SEAT CUSHION ASSY LH Using a torx socket wrench (T45), remove the 2 torx bolts. Remove the 2 bolts and cushion. REMOVE SEPARATE TYPE REAR SEAT CUSHION COVER Disengage the hook and remove the cushion cover together with the pad from the cushion. Remove the hog rings and seat cushion cover. REMOVE TONNEAU COVER HOOK HOLDER Remove the 2 screws and 2 holders. 10. (a) REMOVE REAR SEATBACK COVER LH Using a screwdriver, disengage the 4 claws and remove the seatback cover. HINT: Tape the screwdriver tip before use. 4 Claws B78655 11. (a) 4 Clips REMOVE REAR SEATBACK BOARD CARPET ASSY LH Remove the 4 clips and seatback board carpet. B78379 12. Control Lever Cover (a) B68217 REMOVE REAR SEAT LOCK CONTROL LEVER SUB-ASSY LH Using a screwdriver, disengage the 2 claws and remove the seat lock control lever cover. HINT: Tape the screwdriver tip before use. (b) Remove the 2 screws. (c) Disconnect the reclining remote control cable and remove the seat lock control lever. 13. (a) (b) (c) (d) REMOVE SEPARATE TYPE REAR SEATBACK COVER Remove the 2 headrest supports. Using a clip remover, remove the 2 clips. Disengage the hook and remove the seatback cover together with the pad from the seatback frame. Remove the hog rings and seatback cover. B60977 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3638 72-30 SEAT 14. (a) 15. 16. - REAR NO.1 SEAT ASSY LH (W/O REAR NO.2 SEAT) REMOVE FOLD SEAT STOPPER BAND ASSY NO.2 Remove the bolt and stopper band on the seat side. DISCONNECT REAR SEAT RECLINING CONTROL NO. 2 CABLE REMOVE REAR SEAT BELT ASSY INNER (See page 61-15 ) 17. (a) REMOVE REAR SEAT RECLINING COVER INNER LH Remove the screw and the reclining cover in the direction indicated by the arrow in the illustration. B76718 18. (a) 19. (a) 20. (a) 21. (a) (b) 22. (a) 23. (a) REMOVE REAR SEATBACK FRAME ASSY LH Using a torx socket wrench (T40), remove the 4 torx bolts and seatback frame. REMOVE RECLINING CONTROL LINK SUB-ASSY LH Remove the 4 nuts and control link. REMOVE SEAT TRACK STOP PLATE LH Remove the 2 nuts and stop plate. REMOVE REAR SEATBACK FRAME SUB-ASSY LOWER LH Outer side: Using a torx socket wrench (T40), remove the 3 torx bolts. Inner side: Using a torx socket wrench (T55), remove the 2 torx bolts and seatback frame. REMOVE FOLD SEAT CUSHION FRAME NO.1 Remove the 2 nuts and cushion frame. REMOVE FOLD SEAT CUSHION FRAME NO.2 Remove the 2 nuts and cushion frame. 24. REMOVE REAR SEAT TRACK ADJUSTING HANDLE Screwdriver (Less than 2.0 mm (0.079 in.)) (a) Using a screwdriver, push down the handle stopper to disengage the claw with the slide rail in the frontmost position. Remove the adjusting handle. Screwdriver Seat Track Handle Stopper Track Adjusting Handle B70385 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3639 72-31 SEAT 25. (a) 26. (a) 27. (a) (b) 28. (a) 29. (a) 30. (a) 31. 32. (a) - REAR NO.1 SEAT ASSY LH (W/O REAR NO.2 SEAT) INSTALL FOLD SEAT CUSHION FRAME NO.1 Install the cushion frame with the 2 nuts. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) INSTALL FOLD SEAT CUSHION FRAME NO.2 Install the cushion frame with the 2 nuts. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) INSTALL REAR SEATBACK FRAME SUB-ASSY LOWER LH Outer side: Using a torx socket wrench (T40), install the 3 torx bolts. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) Inner side: Using a torx socket wrench (T55), install the seatback frame with the 2 torx bolts. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) INSTALL REAR SEATBACK FRAME ASSY LH Using a torx socket wrench (T40), install the seatback frame with the 4 torx bolts. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) INSTALL SEAT TRACK STOP PLATE LH Install the stop plate with the 2 nuts. Torque: 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) INSTALL RECLINING CONTROL LINK SUB-ASSY LH Install the control link with the 4 nuts. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) INSTALL REAR SEAT BELT ASSY INNER (See page 61-15 ) INSTALL FOLD SEAT STOPPER BAND ASSY NO.2 Install the fold seat stopper band with the bolt. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) 33. (a) Hog Ring Pliers B50126 INSTALL SEPARATE TYPE REAR SEATBACK COVER Using hog ring pliers, install the seatback cover to the seatback pad with new hog rings. (b) Install the seatback cover to the seatback frame. NOTICE:
Be careful not to damage the cover.
When installing the hog rings, take care to prevent wrinkles as much as possible. (c) Install the 2 headrest supports. 34. INSTALL SEPARATE TYPE REAR SEAT CUSHION COVER (a) Using hog ring pliers, install the cushion cover to the cushion pad with new hog rings. (b) Install the cushion cover to the cushion frame. NOTICE:
Be careful not to damage the cover.
When installing the hog rings, take care to prevent wrinkles as much as possible. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3640 72-32 SEAT 35. (a) (b) 36. (a) (b) (c) - REAR NO.1 SEAT ASSY LH (W/O REAR NO.2 SEAT) INSTALL REAR SEAT CUSHION ASSY LH Hinge side: Using a torx socket wrench (T45), install the seat cushion with the 2 torx bolts. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) Cushion side: Install the seat cushion with the 2 bolts. Torque: 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) INSTALL REAR NO.1 SEAT ASSY LH Place the seat in the cabin. Install the seat with the 5 bolts. Torque: 36.7 N⋅m (375 kgf⋅cm, 27 ft⋅lbf) Install the fold seat stopper band with the bolt on the vehicle side. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) Install the headrest. When sliding the seat, check that both sides of the adjuster lock simultaneously. (d) (e) HINT: Check that the seat adjuster locks. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3641 72-33 SEAT - REAR NO.1 SEAT ASSY RH (W/O REAR NO.2 SEAT) REAR NO.1 SEAT ASSY RH (W/O REAR NO.2 SEAT) 720JR-02 COMPONENTS Rear Seat Lock Control Lever Sub-assy RH Rear Seat Headrest Assy RH Rear Seatback Lock Striker Cover RH Rear Seat Headrest Assy Center Rear Seat Headrest Support Rear Seatback Lock Bezel Upper No. 2 Center Seatback Cover Rear Seat Headrest Support
Hog Ring 21 (214, 15) Rear Seat Cushion Spring No. 2 Separate Type Rear Seatback Pad Center Seatback Frame Sub-assy 21 (214, 15) Separate Type Rear Seatback Cover 21 (214, 15) Reclining Cover Protector RH 21 (214, 15) Center Back Hinge Rear Seatback Moulding RH 21 (214, 15) 21 (214, 15) 21 (214, 15) Center Back Hinge Rear Seat Armrest Assy Center No. 1 Seatback Cover Rear Seatback Moulding LH Reclining Cover Protector LH Separate Type Rear Seat Cushion Cover Separate Type Rear Seat Cushion Pad
Hog Ring 21 (214, 15) 21 (214, 15) Rear Seat Cushion Frame Sub-assy N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part B78510 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3642 72-34 SEAT - REAR NO.1 SEAT ASSY RH (W/O REAR NO.2 SEAT) Rear Seatback Board Carpet Assy RH Tonneau Cover Hook Holder Rear Seat Shoulder Belt Cover Rear Seatback Cover RH Rear Seatback Frame Sub-assy RH 42 (428, 31) Clip 9.0 (92, 80 in.⋅lbf) 9.0 (92, 80 in.⋅lbf) 42 (428, 31) 42 (428, 31) Fold Seat Stopper Band Assy No. 1 55 (561, 41) Rear Seat Belt Assy Outer Center Rear Seat Belt Assy Inner Rear Seat Reclining Control Cable 42 (428, 31) 42 (428, 31) 18 (184, 13) 21 (214, 15) Reclining Control Link Sub-assy RH 42 (428, 31)
E-Ring Seat Track Stop Rear Seatback Frame Sub-assy Lower RH Plate RH Rear Seat Cushion Moulding RH 42 (428, 31) Center Seat Hinge Cover Upper LH 42 (428, 31) Fold Seat Cushion Frame No. 1 Rear Seat Reclining Cover Inner RH 18 (184, 13) 120 (1224, 89) 42 (428, 31) Seat Hinge Rod Rear Seat Track Assy Fold Seat Cushion Frame No. 2 36.7 (375, 27) Outer RH 36.7 (375, 27) 36.7 (375, 27) Rear Seat Track Bracket Cover Outer Rear Seat Cushion Moulding Rear RH 36.7 (375, 27) Rear Seat Track Assy Inner RH Rear Seat Track Bracket Cover Inner Rear Seat Track Adjusting Handle N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part B78511 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3643 72-35 SEAT - REAR NO.1 SEAT ASSY RH (W/O REAR NO.2 SEAT) 720JS-03 OVERHAUL HINT:

1. The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). REMOVE DECK BOARD SUB-ASSY (See page 76-21 ) 2. (a) REMOVE REAR SEAT TRACK BRACKET COVER OUTER Using a screwdriver, disengage the 4 claws remove the bracket cover. HINT: Tape the screwdriver tip before use. 3. REMOVE REAR SEAT TRACK BRACKET COVER INNER 4 Claws HINT: B78372 Use the same procedures described for the bracket cover outer. REMOVE REAR NO.1 SEAT ASSY RH Using a clip remover, remove the 5 clips. 4. (a) HINT: Tape the clip remover tip before use. (b) Remove the bolt holding the fold seat stopper band on the vehicle side. (c) Remove the 2 headrests. (d) Remove the 5 bolts and seat. 5. REMOVE TONNEAU COVER HOOK HOLDER (a) Remove the 2 screws and 2 holders. 6. (a) REMOVE REAR SEATBACK COVER RH Using a screwdriver, disengage the 4 claws and remove the seatback cover. HINT: Tape the screwdriver tip before use. 4 Claws B78655 7. (a) REMOVE REAR SEATBACK BOARD CARPET ASSY RH Remove the 6 clips and seatback board carpet. Clip 6 Clips B78487 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3644 72-36 SEAT - REAR NO.1 SEAT ASSY RH (W/O REAR NO.2 SEAT) 8. REMOVE RECLINING COVER PROTECTOR LH (a) Using a clip remover, remove the clip. HINT: Tape the clip remover tip before use. (b) Remove the screw and reclining cover protector by pulling out the protector in the direction indicated by the arrow in the illustration. B77393 Claw 9. (a) (b) REMOVE CENTER SEAT HINGE COVER UPPER LH Remove the screw. Using a screwdriver, remove the claw and hinge cover by pulling out the cover in the direction indicated by the arrow in the illustration. 10. (a) (b) REMOVE REAR SEATBACK ASSY CENTER Remove the screw. Using a torx socket wrench (T45), remove the torx bolt. Remove the 3 bolts and seatback. B78490 (c) B76711 11. REMOVE RECLINING COVER PROTECTOR RH (a) Using a clip remover, remove the clip. HINT: Tape the clip remover tip before use. (b) Remove the screw and reclining cover protector. 12. REMOVE REAR SEATBACK MOULDING LH (a) Using a torx socket wrench (T40), remove the torx bolt and center back hinge. (b) Using a torx socket wrench (T40), remove the torx bolt and rear seat cushion spring No. 2. (c) Remove the 3 screws and moulding. 13. REMOVE REAR SEATBACK MOULDING RH (a) Using a torx socket wrench (T40), remove the torx bolt and center back hinge. (b) Remove the 3 screws and moulding. 14. REMOVE REAR SEAT ARMREST ASSY CENTER (a) Using a torx socket wrench (T45), remove the 2 torx bolts and armrest. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3645 72-37 SEAT 15. (a) (b) - REAR NO.1 SEAT ASSY RH (W/O REAR NO.2 SEAT) REMOVE NO.1 SEATBACK COVER Remove the 2 headrest supports. Disengage the claws and remove the seatback cover. B60977 16. (a) REMOVE NO.2 CENTER SEATBACK COVER Remove the 2 screws and seatback cover. Claw 17. (a) (b) REMOVE REAR SEAT CUSHION MOULDING RH Remove the 2 screws. Remove the moulding by pulling it out in the direction indicated by the arrow in the illustration. 18. REMOVE REAR SEAT CUSHION MOULDING REAR RH Remove the 2 screws. Using a screwdriver, disengage the 3 claws and remove the moulding. B78491 (a) (b) HINT: Tape the screwdriver tip before use. 3 Claws 19. (a) (b) 20. (a) (b) B78492 REMOVE REAR SEAT CUSHION ASSY RH Using a torx socket wrench (T45), remove the 2 torx bolts. Remove the 2 bolts and seat cushion. REMOVE SEPARATE TYPE REAR SEAT CUSHION COVER Disengage the hook and remove the cushion cover together with the pad from the cushion frame. Remove the hog rings and cushion cover. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3646 72-38 SEAT 21. Control Lever Cover (a) B51234 REAR NO.1 SEAT ASSY RH (W/O REAR NO.2 SEAT) REMOVE REAR SEAT LOCK CONTROL LEVER SUB-ASSY RH Using a screwdriver, disengage the 2 claws and remove the control lever cover. HINT: Tape the screwdriver tip before use. (b) Remove the 2 screws. (c) Disconnect the reclining control cable and remove the control lever. 22. REMOVE REAR SEATBACK LOCK BEZEL UPPER (a) Using a screwdriver, disengage the 2 claws and 2 hooks. HINT: Tape the screwdriver tip before use. (b) Remove the shoulder belt cover by pulling it out in the direction indicated by the arrow in the illustration. Hook 2 Claws - B78493 23. (a) (b) (c) (d) REMOVE SEPARATE TYPE REAR SEATBACK COVER Remove the 2 headrest supports. Using a clip remover, remove the 2 clips. Disengage the hook and remove the seatback cover together with the pad from the seatback frame. Remove the hog rings and seatback cover. B60977 24. 25. (a) (b) REMOVE REAR SEAT BELT ASSY OUTER CENTER (See page 61-15 ) REMOVE REAR SEATBACK FRAME ASSY RH Using a torx socket wrench (T45), remove the 2 torx bolts. Remove the 2 bolts and seatback frame. 26. (a) 2 Claws 27. (a) 28. 29. REMOVE REAR SEAT SHOULDER BELT COVER Disengage the 2 claws and remove the belt cover by pulling it out in the direction indicated by the arrow in the illustration. B78986 REMOVE FOLD SEAT STOPPER BAND ASSY NO.1 Remove the bolt and stopper band. DISCONNECT REAR SEAT RECLINING CONTROL NO. 2 CABLE REMOVE REAR SEAT BELT ASSY INNER (See page 61-15 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3647 72-39 SEAT 30. (a) - REAR NO.1 SEAT ASSY RH (W/O REAR NO.2 SEAT) REMOVE REAR SEAT RECLINING COVER INNER RH Remove the screw and the reclining cover in the direction indicated by the arrow in the illustration. B76716 31. (a) 32. (a) 33. (a) (b) 34. (a) 35. (a) REMOVE SEAT TRACK STOP PLATE RH Remove the 2 nuts and the seat track stop plate. REMOVE RECLINING CONTROL LINK SUB-ASSY RH Remove the bolt, 4 nuts and reclining control link. REMOVE REAR SEATBACK FRAME SUB-ASSY LOWER RH Using a torx socket wrenches (T40), remove the 3 torx bolts. Using a torx socket wrenches (T55), remove the 2 torx bolts and seatback frame. REMOVE FOLD SEAT CUSHION FRAME NO.1 Remove the 2 nuts and cushion frame. REMOVE FOLD SEAT CUSHION FRAME NO.2 Remove the 2 nuts and cushion frame. 36. REMOVE REAR SEAT TRACK ADJUSTING HANDLE Screwdriver (Less than 2.0 mm (0.079 in.)) (a) Using a screwdriver, push down the handle stopper to disengage the claw with the slide rail in the frontmost position. Remove the track adjusting handle. Screwdriver Seat Track Handle Stopper Track Adjusting Handle B70385 37. (a) 38. (a) INSTALL FOLD SEAT CUSHION FRAME NO.1 Install the cushion frame with the 2 nuts. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) INSTALL FOLD SEAT CUSHION FRAME NO.2 Install the cushion frame with the 2 nuts. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3648 72-40 SEAT 39. (a) (b) 40. (a) 41. (a) 42. (a) 43. 44. 45. (a) - REAR NO.1 SEAT ASSY RH (W/O REAR NO.2 SEAT) INSTALL REAR SEATBACK FRAME SUB-ASSY LOWER RH Outer side: Using a torx socket wrench (T40), install the seatback frame lower to the fold seat cushion frame with the 3 torx bolts. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) Inner side: Using a torx socket wrench (T55), install the seatback frame lower to the fold seat cushion frame with the 2 torx bolts. Torque: 120 N⋅m (1224 kgf⋅cm, 89 ft⋅lbf) INSTALL SEAT TRACK STOP PLATE RH Install the seat track stop plate with the 2 nuts. Torque: 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) INSTALL RECLINING CONTROL LINK SUB-ASSY RH Install the control link with the bolt and 4 nuts. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) for bolt 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) for nut INSTALL REAR SEATBACK FRAME ASSY RH Install the seatback frame with the 4 bolts. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) for outside 55 N⋅m (561 kgf⋅cm, 41 ft⋅lbf) for inside INSTALL REAR SEAT BELT ASSY INNER (See page 61-15 ) INSTALL REAR SEAT BELT ASSY OUTER CENTER (See page 61-15 ) INSTALL FOLD SEAT STOPPER BAND ASSY NO.1 Install the stopper band with the bolt. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) 46. (a) Hog Ring Pliers B50126 INSTALL SEPARATE TYPE REAR SEATBACK COVER Using hog ring pliers, install the seatback cover to the seatback pad with new hog rings. (b) Install the seatback cover to the seatback frame. NOTICE:
Be careful not to damage the cover.
When installing the hog rings, take care to prevent wrinkles as much as possible. (c) Install the 2 headrest supports. 47. INSTALL SEPARATE TYPE REAR SEAT CUSHION COVER (a) Using hog ring pliers, install the cushion cover to the cushion pad with new hog rings. NOTICE:
Be careful not to damage the cover.
When installing the hog rings, take care to prevent wrinkles as much as possible. (b) Install the seat cushion cover to the seat cushion frame. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3649 72-41 SEAT 48. (a) (b) 49. (a) 50. (a) (b) (c) 51. (a) (b) 52. (a) (b) (c) 53. (a) (b) (c) - REAR NO.1 SEAT ASSY RH (W/O REAR NO.2 SEAT) INSTALL REAR SEAT CUSHION ASSY RH Using a torx socket wrench (T45), install the seat cushion with the 2 torx bolts. Torque:21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) for hinge side Install the seat cushion assy with the 2 bolts. Torque:18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) for cushion side INSTALL REAR SEAT ARMREST ASSY CENTER Using a torx socket wrench (T45), install the armrest assy with the 2 torx bolts. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) INSTALL REAR SEATBACK MOULDING LH Install the moulding with the 3 screws. Using a torx socket wrench (T40), install the center back hinge with the torx bolt. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) Using a torx socket wrench (T40), install the rear seat cushion spring No. 2 with the torx bolt. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) INSTALL REAR SEATBACK MOULDING RH Install the moulding with the 3 screws. Using a torx socket wrench (T40), install the center back hinge with the torx bolt. Torque:21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) INSTALL REAR SEATBACK ASSY CENTER Install the screw. Using a torx socket wrench (T45), install the seatback assy center with the torx bolt. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) Install the seatback assy with the 3 bolts. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) INSTALL REAR NO.1 SEAT ASSY RH Place the seat in the cabin. Install the seat with the 5 bolts. Torque: 36.7 N⋅m (375 kgf⋅cm, ft⋅lbf) Install the bolt onto the fold seat stopper band on the vehicle side. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) Install the 2 headrests. When sliding the seat, check that both sides of the adjuster lock simultaneously. (d) (e) HINT: Check that the seat adjuster locks. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3650 72-60 SEAT - REAR NO.2 SEAT ASSY REAR NO.2 SEAT ASSY 720RK-01 COMPONENTS Rear No. 2 Seat Headrest Support Assy Rear Side Seat Band Sub-assy No. 2 No. 2 Seat Headrest Assy Rear Seat Cover Bezel No. 1 Handle 3rd Seat No. 2 Seatback Board Assy No. 2 Seatback Pad No. 2 Seatback Cover Assy
Hog Ring No. 2 Seatback Frame Sub-assy Rear Seat Reclining Cover Inner RH Rear Seat Reclining Cover No. 2 RH Rear Seat Reclining Cover Inner LH Rear No. 1 Seat Lock Cable Assy Rear Seat Reclining Cover No. 2 LH No. 2 Seat CushionPad No. 2 Seat Leg RH Reclining Pedal Cover RH Reclining Pedal Cover LH
Hog Ring 37 (377, 27) No. 2 Seat Cushion Cover Sub-assy 42 (428, 31) No. 2 Seat Cushion Frame Sub-assy N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque 21 (214, 15)
Non-reusable part 18 (184, 13) No. 2 Seat Leg LH B74631 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3669 72-61 SEAT - REAR NO.2 SEAT ASSY 720RL-02 OVERHAUL HINT:

The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). REMOVE TONNEAU COVER ASSY (W/ TONNEAU COVER) (See page 76-21 ) REMOVE DECK BOARD SUB-ASSY NO.2 (See page 76-21 ) REMOVE DECK BOARD SUB-ASSY NO.3 (See page 76-21 ) REMOVE DECK BOARD SUB-ASSY (See page 76-21 ) REMOVE DECK FLOOR BOX REAR (See page 76-21 ) REMOVE DECK SIDE TRIM BOX LH (See page 76-21 ) REMOVE DECK SIDE TRIM BOX RH (See page 76-21 ) REMOVE DECK BOARD BRACKET REINFORCEMENT (See page 76-21 ) REMOVE RECLINING PEDAL COVER LH Remove the screw and reclining pedal cover LH. REMOVE RECLINING PEDAL COVER RH 1. 2. 3. 4. 5. 6. 7. 8. 9. (a) 10. HINT: Use the same procedures described for the LH side. 11. REMOVE REAR SEAT RECLINING COVER NO.2 LH (a) Remove the 2 screws and rear seat reclining cover No. 2 LH. 12. REMOVE REAR SEAT RECLINING COVER NO.2 RH HINT: Use the same procedures described for the LH side. 13. REMOVE REAR SEAT RECLINING COVER INNER LH (a) Remove the screw and rear seat reclining cover inner LH. 14. REMOVE REAR SEAT RECLINING COVER INNER RH HINT: Use the same procedures described for the LH side. LH Side 15. (a) REMOVE REAR NO.2 SEAT ASSY Remove the 4 bolts and rear No. 2 seat. 16. (a) REMOVE REAR NO.2 SEAT LEG LH Using a torx socket wrench (T45), remove the sub seat bolt. Remove the 4 bolts and rear No. 2 seat leg LH. REMOVE REAR NO.2 SEAT LEG RH B74633 LH Side (a) (b) (b) (b) (b) 17. HINT: Use the same procedures described for the LH side. (b) B76592 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3670 72-62 SEAT 18. (a) (b) Hook (c) A - REAR NO.2 SEAT ASSY REMOVE NO.2 SEAT CUSHION COVER SUB-ASSY Remove the 4 clips and hook. Remove the hog rings and seat cushion cover together with the pad from the seat cushion frame. Remove the hog rings and seat cushion cover from the seat cushion pad. A A Clip B75783 19. REMOVE REAR SEAT HEADREST ASSY 20. (a) (b) (c) 2 Claws REMOVE HANDLE 3RD SEAT Remove the 2 screws. Disengage the 2 claws. Disconnect the rear No. 1 seat cable and remove the handle 3rd seat. B74635 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3671 72-63 SEAT 21. (a) (b) - REAR NO.2 SEAT ASSY REMOVE NO.2 SEATBACK BOARD ASSY Remove the 7 clips. Disengage the 3 claws and remove the seatback board. 2nd 1st 3 Claws 7 Clips B75784 22. (a) (b) (c) 23. 24. 25. 26. 27. 28. REMOVE NO.2 SEATBACK COVER ASSY Remove the 2 headrest supports. Remove the hog rings and seatback cover together with the pad from the seatback frame. Remove the hog rings and seatback cover from the seatback pad. REMOVE REAR SIDE SEAT BAND SUB-ASSY NO.2 REMOVE REAR SEAT COVER BEZEL NO.1 REMOVE REAR NO.1 SEAT LOCK CABLE ASSY INSTALL REAR NO.1 SEAT LOCK CABLE ASSY INSTALL REAR SEAT COVER BEZEL NO.1 INSTALL REAR SIDE SEAT BAND SUB-ASSY NO.2 29. INSTALL NO.2 SEATBACK COVER ASSY (a) Install the seatback cover to the seatback pad with new hog rings. (b) Install the seatback cover with the pad to the seatback frame with new hog rings. HINT: When installing hog rings, take care to prevent wrinkles as little as possible. B50126 30. 31. 32. INSTALL NO.2 SEATBACK BOARD ASSY INSTALL HANDLE 3RD SEAT INSTALL REAR SEAT HEADREST ASSY 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3672 72-64 SEAT 33. (a) (b) - REAR NO.2 SEAT ASSY INSTALL NO.2 SEAT CUSHION COVER SUB-ASSY Install the seat cushion cover to the seat cushion pad with new hog rings. Install the seat cushion cover with the pad to the seat cushion frame with new hog rings. HINT: When installing the hog rings, take care to prevent wrinkles as much as possible. B50126 Hook (c) Install the 4 clips and hook. 34. (a) INSTALL REAR NO.2 SEAT LEG LH Install the rear No. 2 seat leg LH with the sub seat bolt and 4 bolts. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) for bolt A 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) for bolt B 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) for bolt C INSTALL REAR NO.2 SEAT LEG RH A A A Clip B75783 LH Side Sub Seat Bolt B B C A B76592 35. HINT: Use the same procedures described for the LH side. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3673 72-65 SEAT 36. (a) LH Side - REAR NO.2 SEAT ASSY INSTALL REAR NO.2 SEAT ASSY Install the rear No. 2 seat with the 4 bolts. Torque: 37 N⋅m (377 kgf⋅cm, 27 ft⋅lbf) B74633 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3674 72-18 SEAT - FRONT SEAT ASSY LH (MANUAL SEAT TYPE) FRONT SEAT ASSY LH (MANUAL SEAT TYPE) 720RI-01 COMPONENTS Front Seat Headrest Assy Front Seat Headrest Support Separate Type Front Seatback Cover Separate Type Front Seatback Pad w/ Side Airbag: 5.6 (57, 48 in.⋅lbf) Seat Armrest Cover 37 (377, 27) Front Seatback Board Sub-assy LH Seat Armrest Assy LH
Hog Ring Separate Type Front Seat Cushion Cover Clip
Hog Ring Front Seatback Board Cover Separate Type Front Seat Cushion Pad Front Seat Wire LH Front Seat Adjuster LH Front Seat Inner Belt Assy LH Reclining Adjuster Inside Cover RH (Upper side) Front Seat Cushion Shield Inner LH 42 (428, 31) Reclining Adjuster Inside Cover LH (Upper side) 36.7 (375, 27) Seat Track Bracket Cover Inner LH 36.7 (375, 27) Passenger’s Seat Only: Seat Track Bracket Cover Outer LH Occupant Classification ECU Reclining Adjuster Inside Cover RH (Lower side) 8.0 (82, 71 in.⋅lbf) Driver’s Seat Only: Driver’s Seat Only: Seat Slide Position Protector Seat Position Airbag Sensor Seat Track Bracket Cover Inner Front LH Seat Track Bracket Cover Outer Front LH Front Seat Cushion Shield LH Driver’s Seat Only: Vertical Adjuster Handle No. 2 Reclining Adjuster Release Handle LH Reclining Adjuster Inside Cover LH (Lower side) Front Seat Cushion Snap Ring Shield Lower RH Front Seat Cushion N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque Shield Lower LH
Non-reusable part Driver’s Seat Only: Vertical Seat Adjuster Knob LH Driver’s Seat Only: Vertical Adjuster Handle Cover LH B76692 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3627 72-19 SEAT - FRONT SEAT ASSY LH (MANUAL SEAT TYPE) 720RJ-02 OVERHAUL CAUTION:
Wear safety gloves, because the cutting surface of the seatback frame and seat adjuster may injure your hand.
Work must be at least 90 seconds after the ignition switch is turned to the LOCK position and 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 from disconnecting the negative (-) terminal cable of the battery, the SRS may deploy.) HINT:
The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included.
Use the same procedures for the RH side and LH side.
The procedures listed below are for the LH side.
When removing/installing and overhauling the passenger seat, check the passenger occupant classification system and perform the zero point calibration (see page 05-1203 ).
A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). 1. (a) REMOVE SEAT TRACK BRACKET COVER OUTER FRONT LH Using a screwdriver, disengage 2 claws and remove the bracket cover. HINT: Tape the screwdriver tip before use. 2 Claws B78351 2. (a) REMOVE SEAT TRACK BRACKET COVER INNER FRONT LH Using a screwdriver, disengage the 2 claws and remove the bracket cover. HINT: Tape the screwdriver tip before use. 2 Claws B78352 3. (a) REMOVE SEAT TRACK BRACKET COVER OUTER LH Using a screwdriver, disengage the 2 claws and remove the bracket cover. HINT: Tape the screwdriver tip before use. 2 Claws B78353 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3628 72-20 SEAT - FRONT SEAT ASSY LH (MANUAL SEAT TYPE) 4. REMOVE SEAT TRACK BRACKET COVER INNER LH HINT: Use the same procedures described for the bracket cover outer LH. Tape the screwdriver tip before use. 5. REMOVE FRONT SEAT ASSY LH (a) Remove the headrest. (b) Disconnect the connectors under the seat. (c) Remove the 4 bolts and seat. NOTICE: Be careful not to damage the body. 6. Passenger ’s seat only: REMOVE OCCUPANT CLASSIFICATION ECU (See page 60-64 ) 7. (a) Driver’s seat only: REMOVE VERTICAL SEAT ADJUSTER KNOB LH Using a cloth, remove the snap rings and vertical seat adjuster knob. B76691 8. (a) Driver’s seat only: REMOVE VERTICAL ADJUSTING HANDLE NO.2 Using a screwdriver, disengage the 3 claws and remove the vertical adjuster handle cover LH. HINT: Tape the screwdriver tip before use. (b) Remove the 2 screws and vertical adjusting handle. 3 Claws B78347 9. (a) REMOVE RECLINING ADJUSTER RELEASE HANDLE LH Using a screwdriver, pry out the reclining adjuster release handle. HINT: Tape the screwdriver tip before use. Claw B78348 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3629 72-21 SEAT 10. (a) (b) (c) - FRONT SEAT ASSY LH (MANUAL SEAT TYPE) REMOVE FRONT SEAT CUSHION SHIELD LH Remove the 2 rubber bands from the back of the seatback board cover. Remove the screw. Using a screwdriver, disengage the 2 claws and clip, and remove the cushion shield. HINT: Tape the screwdriver tip before use. 2 Claws Clip B78349 11. (a) (b) REMOVE FRONT SEAT CUSHION SHIELD INNER LH Remove the screw. Using a screwdriver, disengage the 2 claws and clip, and remove the cushion shield. HINT: Tape the screwdriver tip before use. 2 Claws Clip B78350 12. 13. (a) (b) (c) (d) REMOVE FRONT SEAT INNER BELT ASSY LH (See page 61-4 ) REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER Remove the 2 clips on the cushion cover side. w/ Seat heater: Disconnect the seat heater connectors. Disengage the hook and remove the hog rings and seat cushion cover together with the pad. Remove the hog rings and cushion cover. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3630 72-22 SEAT 4 Claws - FRONT SEAT ASSY LH (MANUAL SEAT TYPE) 14. (a) (b) REMOVE FRONT SEATBACK BOARD SUB-ASSY LH Remove the 2 screws. Lower the seatback board in the direction indicated by the arrow in the illustration to disengage the 4 claws on the upper part. (c) Hold the seatback board on the upper right and lower left as shown in the illustration. (d) Turn the seatback board counterclockwise to disengage the claws and remove it. B78337 Hold Hold B78338 Counterclockwise B78339 15. (a) (b) REMOVE FRONT SEATBACK BOARD COVER SUB-ASSY Disengage the hook on the upper part of the seatback board cover. Remove the hog rings and seatback board cover. 16. (a) REMOVE SEAT ARMREST ASSY LH Using a screwdriver, disengage the 2 claws and remove the armrest cover. HINT: Tape the screwdriver tip before use. (b) Remove the bolt and armrest. 2 Claws B78965 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3631 72-23 SEAT 17. (a) (b) (c) (d) - FRONT SEAT ASSY LH (MANUAL SEAT TYPE) REMOVE SEPARATE TYPE FRONT SEATBACK COVER Remove the 2 headrest supports. Remove the hog rings and seatback cover together with the pad. w/ Side airbag: Remove the nut and seatback cover bracket. Remove the hog rings and seatback cover. B60977 18. (a) 19. (a) 20. (a) 21. (a) 22. (a) 23. (a) 24. (a) (b) (c) REMOVE RECLINING ADJUSTER INSIDE COVER LH (UPPER SIDE) Remove the screw and cushion shield. REMOVE RECLINING ADJUSTER INSIDE COVER RH (UPPER SIDE) Remove the screw and cushion shield. REMOVE RECLINING ADJUSTER INSIDE COVER LH (LOWER SIDE) Remove the screw and cushion shield. REMOVE RECLINING ADJUSTER INSIDE COVER RH (LOWER SIDE) Remove the screw and cushion shield. REMOVE FRONT SEAT CUSHION SHIELD LOWER LH Disengage the claw and remove the cushion shield. REMOVE FRONT SEAT CUSHION SHIELD LOWER RH Disengage the claw and remove the cushion shield. Driver’s seat only: REMOVE SEAT POSITION AIRBAG SENSOR Disconnect the wire harness connector. Disengage the claw and remove the seat slide position protector. Using a torx socket wrench (T30), remove the torx bolt and airbag sensor. 25. (a) (b) Seat Position Airbag Sensor Slide Rail Feeler Gauge B76909 INSTALL SEAT POSITION AIRBAG SENSOR Temporarily install the seat position airbag sensor. Install a 1 mm (0.04 in.) feeler gauge between the slide rail and sensor as shown in the illustration. NOTICE:
If the seat position airbag sensor has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace the seat position airbag sensor with a new one.
When installing the seat position airbag sensor, be careful that the SRS wiring does not interfere with other parts and is not pinched between other parts. HINT: Be sure to that a clearance between the seat position airbag sensor and the seat rail is within 0.6 mm (0.023 in.) to 2 mm (0.079 in.). (c) Push the top of the sensor. While holding the sensor, tighten the sensor using a torx socket wrench (T30). Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3632 72-24 SEAT (d) - FRONT SEAT ASSY LH (MANUAL SEAT TYPE) Install the seat slide position protector. 26. Hog Ring Pliers B50126 INSTALL SEPARATE TYPE FRONT SEATBACK COVER (a) Install the seatback pad. (b) Cover the top of the seatback pad with the seatback cover. (c) Using hog ring pliers, completely install the seatback cover with new hog rings. NOTICE:
Be careful not to damage the cover.
When installing the hog rings, take care to prevent wrinkles as much as possible. (d) Install the 2 headrest supports. (e) B80142 Hog Ring Pliers B50126 29. w/ Side airbag: Fully cover the airbag with the seatback cover bracket and tighten the nut. Torque: 5.6 N⋅m (57 kgf⋅cm, 49 in.⋅lbf) NOTICE:
For a vehicle with side airbag, the side airbag may not be activated normally unless the seatback cover is securely installed.
Check that the strap has no twist after installing the bracket.
Install the bracket securely. 27. INSTALL SEAT ARMREST ASSY LH (a) Install the armrest with the bolt. Torque: 37 N⋅m (377 kgf⋅cm, 27 ft⋅lbf) (b) Install the armrest cover. 28. INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER (a) Install the seat cushion. (b) Using hog ring pliers, install the cushion cover to the cushion pad with new hog rings. NOTICE:
Be careful not to damage the cover.
When installing the hog rings, take care to prevent wrinkles as much as possible. (c) w/ Seat heater: Connect the seat heater connectors. (d) Install the clip. INSTALL FRONT SEAT INNER BELT ASSY LH (See page 61-4 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3633 72-25 SEAT 30. (a) (b) (c) (d) (e) (f) (g) 31. 32. - FRONT SEAT ASSY LH (MANUAL SEAT TYPE) INSTALL FRONT SEAT ASSY LH Place the seat in the cabin. Connect the connectors under the seat. Tighten the 2 bolts on the front side of the seat. Torque: 36.7 N⋅m (375 kgf⋅cm, 27 ft⋅lbf) Tighten the 2 bolts on the rear side of the seat. Torque: 36.7 N⋅m (375 kgf⋅cm, 27 ft⋅lbf) Install the 4 seat track covers. Install the headrest. Connect the battery’s negative terminal. w/ Seat heater: CHECK SEAT HEATER OPERATION Passenger ’s seat only: CHECK FUNCTION OF FRONT PASSENGER OCCUPANT CLASSIFICATION SYSTEM HINT: Perform the zero point calibration and sensitivity check when any of the following conditions is met.
The occupant classification ECU is replaced.
Accessories (seatback tray and seat cover, etc.) are installed.
The passenger seat is removed from the vehicle.
Both the SRS warning lamp and the passenger airbag ON/OFF indicator lamp (”OFF”) turn on.
The vehicle is brought to the workshop for repair due to an accident or a collision. (a) Zero point calibration procedure: (1) Adjust the seat position according to the table below. Adjustment Component Position Slide Direction Rearmost position Reclining Angle Upright position Headrest Height Lowest position (2) (3) (4) Connect the hand-held tester to the DLC3. Turn the ignition switch ON. Perform the zero point calibration by following the prompts on the tester screen. HINT: Refer to the hand-held tester operator’s manual for further details. (b) Sensitivity check procedure: (1) Connect the hand-held tester to the DLC3. (2) Apply a 30 kg weight (for example, a 30 kg of lead mass) onto the passenger seat. (3) Turn the ignition switch ON. (4) Using the hand-held tester, perform the sensitivity check and confirm that the sensitivity is within the standard value. Standard value: 27 to 33 kg HINT:
When performing the sensitivity check, use a solid weight made from metal. The check results may not be accurate if a weight made from liquid is used.
When the sensitivity deviates from the standard value, retighten the bolts of the passenger seat, taking care not to deform the seat rail. Perform the sensitivity check again. If the sensitivity still is not within the standard value, replace the front seat assembly RH. NOTICE: Do not place any objects on the seat. Perform the initialization by attaching a mass more than 2 kgs in the seatback pocket, seatback table installed by the user, or other appropriate location. (c) Check the SRS warning lamp (see page 60-1 ). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3634 72-42 SEAT - REAR NO.1 SEAT ASSY LH (W/REAR NO.2 SEAT) REAR NO.1 SEAT ASSY LH (W/REAR NO.2 SEAT) 720RR-01 COMPONENTS Rear Seat Headrest Support No.2 Center Seatback Cover Rear Seat Headrest Assy Center 21 (214, 15) Stopper Reclining Cover Protector RH Center Seatback Frame 21 (214, 15) 21 (214, 15) Center Back Hinge Rear Seatback Moulding LH Rear Seat Cushion Spring No. 2 Rear Seatback Moulding RH 21 (214, 15) Reclining cover Protector LH No. 1 Seatback Cover 21 (214, 15) Center Back Hinge Rear Seat Headrest Assy Rear Seat Lock Control Lever Sub-Assy LH Rear Seat Headrest Support Rear Seat Armrest Assy Center Rear Seatback Lock Bezel Upper
Hog Ring Separate Type Rear Seat Cushion Cover Rear Seatback Lock Striker Cover Separate Type Rear Seat Cushion Pad 21 (214, 15) Separate Type Rear Seatback Cover
Hog Ring 21 (214, 15) Separate Type Rear Seatback Pad Rear Seat Cushion Frame LH N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part Vertical Adjuster Bracket Cover Outer B76695 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3651 72-43 SEAT - REAR NO.1 SEAT ASSY LH (W/REAR NO.2 SEAT) Rear Seatback Cover LH Rear Seat Shoulder Belt Cover Rear Seatback Frame LH Tonneau Cover Hook Holder 55 (561, 41) 9.0 (92, 80 in.⋅lbf) Rear Seatback Board Carpet Assy LH 42 (428, 31) 42 (428, 31) 42 (428, 31) Rear Seat Belt Assy Rear Seatback Rear Seat Reclining Outer Center Frame LH Control Cable 42 (428, 31) Reclining Control Link 21 (214, 15) Sub-assy LH Seat Track Stop Plate LH 42 (428, 31) Center Seat Hinge Cover Upper RH 18 (184, 13) Rear Seat Cushion Seat Track Upper Rail Cover LH Moulding Rear LH
E-Ring 18 (184, 13) 42 (428, 31) 120 (1224, 89) Fold Seat Cushion Rear Seatback Frame 42 (428, 31) Sub-assy Lower LH Frame No. 2 Rear Seat Reclining Fold Seat Cushion Seat Hinge Rod Cover Inner LH Rear Seat Track Assy Frame No. 1 Rear Seat Track Bracket 36.7 (375, 27) 42 (428, 31) Rear Seat Belt Assy Inner Reclining Adjuster Inside Cover Inner LH Inner LH 36.7 (375, 27) Rear Seat Track Bracket Cover Inner 42 (428, 31) Cover LH Rear Seat Track Bracket 36.7 (375, 27) Rear Seat Track Adjusting Handle Cover Outer LH Rear Seat Track Bracket Reclining Hinge Cover Outer Cover LH Rear Seat Track Assy Rear Seat Cushion Outer LH Moulding LH N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part B78189 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3652 72-44 SEAT - REAR NO.1 SEAT ASSY LH (W/REAR NO.2 SEAT) 720RS-03 OVERHAUL HINT:

The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). 1. (a) 4 Claws 4 Clips B78988 REMOVE REAR SEAT TRACK BRACKET COVER OUTER Using a screwdriver, disengage the 4 claws and remove the bracket cover. HINT: Tape the screwdriver tip before use. 2. REMOVE REAR SEAT TRACK BRACKET COVER INNER HINT: Use the same procedures described for the bracket cover outer. 3. REMOVE REAR SEAT TRACK BRACKET COVER OUTER LH (a) Using a screwdriver, disengage the 4 clips and remove the cover. HINT: Tape the screwdriver tip before use. B78537 4. (a) REMOVE REAR SEAT TRACK BRACKET COVER INNER LH Using a screwdriver, disengage the 4 clips and remove the cover. HINT: Tape the screwdriver tip before use. 4 Clips 5. (a) (b) 6. (a) B78538 REMOVE REAR NO.1 SEAT ASSY LH Remove the 2 headrests. Remove the 5 bolts and seat. REMOVE TONNEAU COVER HOOK HOLDER Remove the 2 screws and 2 holders. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3653 72-45 SEAT 7. (a) - REAR NO.1 SEAT ASSY LH (W/REAR NO.2 SEAT) REMOVE REAR SEATBACK COVER LH Using a screwdriver, disengage the 4 claws and remove the seatback cover. HINT: Tape the screwdriver tip before use. 4 Claws B78655 8. (a) 11 Clips REMOVE REAR SEATBACK BOARD CARPET ASSY LH Using a clip remover, disengage the 11 clips and remove seatback board carpet. B78541 9. REMOVE RECLINING COVER PROTECTOR RH (a) Using a clip remover, remove the clip. HINT: Tape the clip remover tip before use. (b) Remove the screw and reclining cover protector by pulling out the protector in the direction indicated by the arrow in the illustration. B80295 10. (a) (b) REMOVE CENTER SEAT HINGE COVER UPPER RH Remove the screw. Using a screwdriver, disengage the claw and remove the hinge cover by pulling it out in the direction indicated by the arrow in the illustration. HINT: Tape the screwdriver tip before use. Claw B78543 11. (a) (b) REMOVE SEAT TRACK UPPER RAIL COVER LH Remove the 2 screws. Using a screwdriver, disengage the claw and remove the cover. HINT: Tape the screwdriver tip before use. Claw B78544 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3654 72-46 SEAT 12. (a) (b) (c) - REAR NO.1 SEAT ASSY LH (W/REAR NO.2 SEAT) REMOVE REAR SEATBACK ASSY CENTER Remove the screw. Using a torx socket wrench (T45), remove the torx bolt. Remove the 3 bolts and seatback. B78545 13. REMOVE RECLINING COVER PROTECTOR LH (a) Using a clip remover, remove the clip. HINT: Tape the clip remover tip before use. (b) Remove the screw and reclining cover protector. 14. REMOVE REAR SEATBACK MOULDING LH (a) Using a torx socket wrench (T40), remove the torx bolt and center back hinge. (b) Remove the 3 screws and moulding. 15. REMOVE REAR SEATBACK MOULDING RH (a) Using a torx socket wrench (T40), remove the torx bolt and center back hinge. (b) Using a torx socket wrench (T40), remove the torx bolt and rear seat cushion spring No. 2. (c) Remove the 3 screws and moulding. 16. REMOVE REAR SEAT ARMREST ASSY CENTER (a) Using a torx socket wrench (T45), remove the 2 torx bolts and armrest. 17. (a) (b) REMOVE NO.1 SEATBACK COVER Remove the 2 headrest supports. Disengage the claws and remove the seatback cover. B60977 18. (a) REMOVE NO.2 CENTER SEATBACK COVER Remove the 2 screws and seatback cover. 19. (a) (b) REMOVE REAR SEAT CUSHION MOULDING LH Remove the 2 screws. Using a screwdriver, disengage the 4 claws and remove the moulding by pulling out the moulding in the direction indicated by the arrow in the illustration. HINT: Tape the screwdriver tip before use. 4 Claws B78546 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3655 72-47 SEAT 20. (a) (b) - REAR NO.1 SEAT ASSY LH (W/REAR NO.2 SEAT) REMOVE VERTICAL ADJUSTER BRACKET COVER OUTER Remove the screw. Using a screwdriver, disengage the 2 claws and remove the bracket cover by pulling it out in the direction indicated by the arrow in the illustration. HINT: Tape the screwdriver tip before use. 2 Claws B78547 21. (a) REMOVE RECLINING HINGE COVER LH Using a screwdriver, disengage the 2 claws and 2 clips and remove the hinge cover by pulling it out in the direction indicated by the arrow in the illustration. HINT: Tape the screwdriver tip before use. 2 Claws 2 Clips B78548 22. (a) (b) REMOVE REAR SEAT CUSHION MOULDING REAR LH Remove the 2 screws. Using a screwdriver, disengage the 3 claws and remove the moulding. HINT: Tape the screwdriver tip before use. 3 Claws 23. (a) (b) 24. (a) (b) B78549 REMOVE REAR SEAT CUSHION ASSY LH Using a torx socket wrench (T45), remove the 2 torx bolts. Remove the 2 bolts and seat cushion. REMOVE SEPARATE TYPE REAR SEAT CUSHION COVER Disengage the hook and remove the cushion cover together with the pad from the cushion frame. Remove the hog rings and cushion cover. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3656 72-48 SEAT 25. Control Lever Cover (a) B68217 REAR NO.1 SEAT ASSY LH (W/REAR NO.2 SEAT) REMOVE REAR SEAT LOCK CONTROL LEVER SUB-ASSY LH Using a screwdriver, disengage the 2 claws and remove the control lever cover. HINT: Tape the screwdriver tip before use. (b) Remove the 2 screws. (c) Disconnect the reclining control cable and remove the control lever. 26. REMOVE REAR SEATBACK LOCK BEZEL UPPER (a) Using a screwdriver, disengage the 2 claws and 2 hooks. HINT: Tape the screwdriver tip before use. (b) Remove the shoulder belt cover by pulling it out in the direction indicated by the arrow in the illustration. 2 Hooks 2 Claws - B78493 27. (a) (b) (c) (d) REMOVE SEPARATE TYPE REAR SEATBACK COVER Remove the 2 headrest supports. Using a clip remover, remove the 2 clips. Disengage the hook and remove the seatback cover together with the pad from the seatback frame. Remove the hog rings and seatback cover. B60977 28. 29. (a) (b) REMOVE REAR SEAT BELT ASSY OUTER CENTER (See page 61-15 ) REMOVE REAR SEATBACK FRAME ASSY LH Using a torx socket wrench (T45), remove the 2 torx bolts. Remove the 2 bolts and seatback frame. 30. (a) 2 Claws 31. 32. REMOVE REAR SEAT SHOULDER BELT COVER Disengage the 2 claws and remove the belt cover by pulling it out in the direction indicated by the arrow in the illustration. B78494 DISCONNECT REAR SEAT RECLINING CONTROL NO. 2 CABLE REMOVE REAR SEAT BELT ASSY INNER (See page 61-15 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3657 72-49 SEAT 33. (a) (b) - REAR NO.1 SEAT ASSY LH (W/REAR NO.2 SEAT) REMOVE REAR SEAT RECLINING COVER INNER LH Remove the screw. Remove the reclining cover in the direction indicated by the arrow in the illustration. B78620 34. (a) 35. (a) 36. (a) 37. (a) (b) 38. (a) 39. (a) REMOVE RECLINING ADJUSTER INSIDE COVER LH Remove the screw and inside cover. REMOVE SEAT TRACK STOP PLATE LH Remove the 2 nuts and stop plate. REMOVE RECLINING CONTROL LINK SUB-ASSY LH Remove the bolt, 4 nuts and reclining control link. REMOVE REAR SEATBACK FRAME SUB-ASSY LOWER LH Using a torx socket wrench (T40), remove the 3 torx bolts. Using a torx socket wrench (T55), remove the 2 torx bolts and seatback frame. REMOVE FOLD SEAT CUSHION FRAME NO.1 Remove the 2 nuts and cushion frame. REMOVE FOLD SEAT CUSHION FRAME NO.2 Remove the 2 nuts and cushion frame. Screwdriver (Less than 2.0 mm (0.079 in.)) 40. (a) REMOVE REAR SEAT TRACK ADJUSTING HANDLE Using a screwdriver, push down the handle stopper to disengage the claw with the slide rail in the frontmost position. Remove the track adjusting handle. Screwdriver Seat Track Handle Stopper Track Adjusting Handle B70385 41. (a) INSTALL FOLD SEAT CUSHION FRAME NO.1 Install the cushion frame with the 2 nuts. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3658 72-50 SEAT 42. (a) 43. (a) (b) 44. (a) 45. (a) 46. (a) 47. 48. - REAR NO.1 SEAT ASSY LH (W/REAR NO.2 SEAT) INSTALL FOLD SEAT CUSHION FRAME NO.2 Install the cushion frame with the 2 nuts. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) INSTALL REAR SEATBACK FRAME SUB-ASSY LOWER LH Outer side side: Using a torx socket wrench (T40), install the seatback frame lower to the fold seat cushion frame with the 3 torx bolts. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) Inner side: Using a torx socket wrench (T55), install the seatback frame lower to the fold seat cushion frame with the 2 torx bolts. Torque: 120 N⋅m (1224 kgf⋅cm, 89 ft⋅lbf) INSTALL SEAT TRACK STOP PLATE LH Install the seat track stop plate with the 2 nuts. Torque: 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) INSTALL RECLINING CONTROL LINK SUB-ASSY LH Install the control link with the bolt and 4 nuts. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) for bolt 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) for nut INSTALL REAR SEATBACK FRAME ASSY LH Install the seatback frame with the 4 bolts. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) for outside 55 N⋅m (561 kgf⋅cm, 41 ft⋅lbf) for inside INSTALL REAR SEAT BELT ASSY INNER (See page 61-15 ) INSTALL REAR SEAT BELT ASSY OUTER CENTER (See page 61-15 ) 49. (a) Hog Ring Pliers B50126 INSTALL SEPARATE TYPE REAR SEATBACK COVER Using hog ring pliers, install the seatback cover to the seatback pad with new hog rings. (b) Install the seatback cover to the seatback frame. NOTICE:
Be careful not to damage the cover.
When installing the hog rings, take care to prevent wrinkles as much as possible. (c) Install the 2 headrest supports. 50. INSTALL SEPARATE TYPE REAR SEAT CUSHION COVER (a) Using hog ring pliers, install the cushion cover to the cushion pad with new hog rings. NOTICE:
Be careful not to damage the cover.
When installing the hog rings, take care to prevent wrinkles as much as possible. (b) Install the seat cushion cover to the seat cushion frame. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3659 72-51 SEAT 51. (a) (b) 52. (a) 53. (a) (b) 54. (a) (b) (c) 55. (a) (b) (c) 56. (a) (b) (c) - REAR NO.1 SEAT ASSY LH (W/REAR NO.2 SEAT) INSTALL REAR SEAT CUSHION ASSY LH Using a torx socket wrench (T45), install the seat cushion with the 2 torx bolts. Torque:21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) for hinge side Install the seat cushion with the 2 bolts. Torque:18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) for cushion side INSTALL REAR SEAT ARMREST ASSY CENTER Using a torx socket wrench (T45), install the armrest with the 2 torx bolts. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) INSTALL REAR SEATBACK MOULDING LH Install the moulding with the 3 screws. Using a torx socket wrench (T40), install the center back hinge with the torx bolt. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) INSTALL REAR SEATBACK MOULDING RH Install the moulding with the 3 screws. Using a torx socket wrench (T40), install the center back hinge with the torx bolt. Torque:21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) Using a torx socket wrench (T40), install the rear seat cushion spring No. 2 with the torx bolt. Torque:21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) INSTALL REAR SEATBACK ASSY CENTER Install the screw. Using a torx socket wrench (T45), install the seatback assy with the torx bolt. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) Install the seatback assy with the 3 bolts. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) INSTALL REAR NO.1 SEAT ASSY LH Place the seat in the cabin. Install the seat with the 5 bolts. Torque: 36.7 N⋅m (375 kgf⋅cm, 27 ft⋅lbf) Install the bolt onto the fold seat stopper band on the vehicle side. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) Install the 2 headrests. When sliding the seat, check that both sides of the adjuster lock simultaneously. (d) (e) HINT: Check that the seat adjuster locks. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3660 72-52 SEAT - REAR NO.1 SEAT ASSY RH (W/REAR NO.2 SEAT) REAR NO.1 SEAT ASSY RH (W/REAR NO.2 SEAT) 720RP-02 COMPONENTS Rear Seat Lock Control Lever Sub-Assy RH Rear Seat Headrest Assy Rear Seatback Lock Striker Cover Rear Seatback Cover RH Rear Seat Headrest Support
Hog Ring Cover Remote Control Lever Knob RH Cover Rear Seatback Board Carpet Assy RH Rear Seat Cover Bezel No. 1 Separate Type Rear Seatback Pad Separate Type Rear Seatback Cover
Hog Ring Separate Type Rear Seat Cushion Cover Rear Seat Reclining Control No. 2 Cable Separate Type Rear Seat Cushion Pad Vertical Adjuster Bracket Cover Outer 21 (214, 15) 21 (214, 15) Rear Seat Cushion Frame RH N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part B76693 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3661 72-53 SEAT - REAR NO.1 SEAT ASSY RH (W/REAR NO.2 SEAT) Rear Seatback Frame RH Tonneau Cover Hook Holder 42 (428, 31) Rear Seat Cushion Moulding RH 42 (428, 31) Rear Back Lock Control Lever Sub-Assy RH 18 (184, 13) 18 (184, 13) Reclining Adjuster Inside Cover RH 42 (428, 31) Seat Track Stop Plate RH Rear Seatback Frame Sub-Assy Lower Fold Seat Cushion Frame No. 1 Reclining Control Link Sub-Assy RH 42 (428, 31) Rear Seat Belt Assy Inner 42 (428, 31) Rear Seat Cushion Moulding Rear RH 42 (428, 31) Rear Seat Reclining Cover Inner RH 42 (428, 31) 18 (184, 13) Seat Track Upper Rail Cover RH 18 (184, 13) Seat Hinge Rod
E-Ring Rear Seat Track Assy Outer RH Fold Seat Cushion Frame No. 2 42 (428, 31) 36.7 (374, 27) Rear Seat Track Bracket Cover Outer RH Reclining Hinge Cover RH 36.7 (374, 27) 36.7 (374, 27) Rear Seat Track Bracket Cover Outer Rear Seat Track Bracket Cover Inner RH Rear Seat Track Assy Inner RH 36.7 (374, 27) Rear Seat Track Adjusting Handle Rear Seat Track Bracket Cover Inner N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque
Non-reusable part B76694 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3662 72-54 SEAT - REAR NO.1 SEAT ASSY RH (W/REAR NO.2 SEAT) 720RQ-03 OVERHAUL HINT:

The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). 1. (a) 4 Claws 4 Clips B78372 HINT: Tape the screwdriver tip before use. 2. REMOVE REAR SEAT TRACK BRACKET COVER INNER HINT: Use the same procedures described for the bracket cover outer. 3. REMOVE REAR SEAT TRACK BRACKET COVER OUTER RH (a) Using a screwdriver, disengage the 4 clips and remove the cover. HINT: Tape the screwdriver tip before use. B78621 4. (a) REMOVE REAR SEAT TRACK BRACKET COVER INNER RH Using a screwdriver, disengage the claw and 3 clips and remove the cover. HINT: Tape the screwdriver tip before use. Clip Claw 3 Clips 5. (a) (b) REMOVE REAR SEAT TRACK BRACKET COVER OUTER Using a screwdriver, disengage the 4 claws and remove the 2 covers. B78622 REMOVE REAR NO.1 SEAT ASSY RH Remove the headrest. Remove the 5 bolts and seat. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3663 72-55 SEAT 6. (a) (b) - REAR NO.1 SEAT ASSY RH (W/REAR NO.2 SEAT) REMOVE REAR SEAT CUSHION MOULDING REAR RH Remove the 2 screws. Using a screwdriver, disengage the 4 claws and remove the moulding by pulling it out in the arrow mark direction shown in the illustration. HINT: Tape the screwdriver tip before use. 4 Claws B78623 7. (a) (b) REMOVE REAR SEAT CUSHION MOULDING RH Remove the 2 screws. Using a screwdriver, disengage the 5 claws and remove the moulding by pulling it out in the arrow mark direction shown in the illustration. HINT: Tape the screwdriver tip before use. 5 Claws B78624 8. (a) (b) 2 Claws B78625 9. (a) 2 Claws 2 Clips 10. (a) (b) REMOVE VERTICAL ADJUSTER BRACKET COVER OUTER Remove the screw. Disengage the 2 claws and remove the bracket cover by pulling it out in the arrow mark direction shown in the illustration. REMOVE RECLINING HINGE COVER RH Disengage the 2 clips and 2 claws and remove the hinge cover by pulling it out in the arrow mark direction shown in the illustration. B78626 REMOVE REAR SEAT CUSHION ASSY RH Using a torx socket wrench (T45), remove the 2 bolts. Remove the 2 bolts and cushion. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3664 72-56 SEAT - REAR NO.1 SEAT ASSY RH (W/REAR NO.2 SEAT) 11. REMOVE SEPARATE TYPE REAR SEAT CUSHION COVER (a) Disengage the hook and remove the cushion cover together with the pad from the cushion frame. (b) Remove the hog rings and seat cushion cover. 12. REMOVE SEAT TRACK UPPER RAIL COVER RH (a) Remove the 2 screws and rail cover. 13. REMOVE REMOTE CONTROL LEVER KNOB RH (a) Remove the screw and control lever knob. 14. REMOVE REAR SEAT COVER BEZEL NO.1 (a) Using a screwdriver, disengage the 4 claws and remove the 2 covers. HINT: Tape the screwdriver tip before use. (b) Remove the 3 screws and seat cover bezel. 15. REMOVE TONNEAU COVER HOOK HOLDER (a) Remove the 2 screws and 2 holders. 16. (a) REMOVE REAR SEATBACK COVER RH Using a screwdriver, disengage the 4 claws and remove the seatback cover. HINT: Tape the screwdriver tip before use. : 4 Claws B78655 17. (a) 7 Clips REMOVE REAR SEATBACK BOARD CARPET ASSY RH Using a clip remover, disengage the 7 clips and remove seatback board carpet. B78627 18. Control Lever Cover (a) B51234 REMOVE REAR SEAT LOCK CONTROL LEVER SUB-ASSY RH Using a screwdriver, disengage the 2 claws and remove the seat lock control lever cover. HINT: Tape the screwdriver tip before use. (b) Remove the 2 screws. (c) Disconnect the reclining remote control cable and remove the seat lock control lever. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3665 72-57 SEAT 19. (a) (b) (c) (d) - REAR NO.1 SEAT ASSY RH (W/REAR NO.2 SEAT) REMOVE SEPARATE TYPE REAR SEATBACK COVER Remove the 2 headrest supports. Using a clip remover, remove the 2 clips. Disengage the hook and remove the seatback cover together with the pad from the seatback frame. Remove the hog rings and seatback cover. B60977 20. 21. DISCONNECT REAR SEAT RECLINING CONTROL NO. 2 CABLE REMOVE REAR SEAT BELT ASSY INNER (See page 61-15 ) 22. (a) REMOVE REAR SEAT RECLINING COVER INNER RH Remove the screw and reclining cover by pulling out the cover in the arrow mark direction shown in the illustration. B78628 23. (a) 24. (a) 25. (a) 26. (a) 27. (a) 28. (a) (b) 29. (a) 30. (a) REMOVE RECLINING ADJUSTER INSIDE COVER RH Remove the screw and inside cover. REMOVE REAR SEATBACK FRAME ASSY RH Using a torx socket wrench (T40), remove the 4 torx bolts and seatback frame. REMOVE RECLINING CONTROL LINK SUB-ASSY RH Remove the 4 nuts and control link. REMOVE SEAT TRACK STOP PLATE RH Remove the 2 nuts and stop plate. REMOVE REAR BACK LOCK CONTROL LEVER SUB-ASSY RH Remove the 3 nuts and control lever. REMOVE REAR SEATBACK FRAME SUB-ASSY LOWER LH Outer side: Using a torx socket wrench (T40), remove the 3 torx bolts. Inner side: Using a torx socket wrench (T55), remove the 2 torx bolts and seatback frame. REMOVE FOLD SEAT CUSHION FRAME NO.1 Remove the 2 nuts and cushion frame. REMOVE FOLD SEAT CUSHION FRAME NO.2 Remove the 2 nuts and cushion frame. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3666 72-58 SEAT Screwdriver (Less than 2.0 mm (0.079 in.)) 31. (a) - REAR NO.1 SEAT ASSY RH (W/REAR NO.2 SEAT) REMOVE REAR SEAT TRACK ADJUSTING HANDLE Using a screwdriver, push down the handle stopper to disengage the claw with the slide rail in the frontmost position. Remove the track adjusting handle. Screwdriver Seat Track Handle Stopper Track Adjusting Handle B70385 32. (a) 33. (a) 34. (a) (b) 35. (a) 36. (a) 37. (a) 38. (a) 39. INSTALL FOLD SEAT CUSHION FRAME NO.1 Install the cushion frame with the 2 nuts. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) INSTALL FOLD SEAT CUSHION FRAME NO.2 Install the cushion frame with the 2 nuts. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) INSTALL REAR SEATBACK FRAME SUB-ASSY LOWER LH Outer side: Using a torx socket wrench (T40), install the 3 torx bolts. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) Inner side: Using a torx socket wrench (T55), install the seatback frame with the 2 torx bolts. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) INSTALL REAR SEATBACK FRAME ASSY RH Using a torx socket wrench (T40), install the seatback frame with the 4 torx bolts. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) INSTALL REAR BACK LOCK CONTROL LEVER SUB-ASSY RH Install the control lever with the 3 nuts. Torque: 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) INSTALL SEAT TRACK STOP PLATE RH Install the stop plate with the 2 nuts. Torque: 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) INSTALL RECLINING CONTROL LINK SUB-ASSY RH Install the control link with the 4 nuts. Torque: 42 N⋅m (428 kgf⋅cm, 31 ft⋅lbf) INSTALL REAR SEAT BELT ASSY INNER (See page 61-15 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3667 72-59 SEAT - REAR NO.1 SEAT ASSY RH (W/REAR NO.2 SEAT) 40. (a) Hog Ring Pliers B50126 INSTALL SEPARATE TYPE REAR SEATBACK COVER Using hog ring pliers, install the seatback cover to the seatback pad with new hog rings. (b) Install the seatback cover to the seatback frame. NOTICE:
Be careful not to damage the cover.
When installing the hog rings, take care to prevent wrinkles as much as possible. (c) Install the 2 headrest supports. 41. INSTALL SEPARATE TYPE REAR SEAT CUSHION COVER (a) Using hog ring pliers, install the cushion cover to the cushion pad with new hog rings. NOTICE:
Be careful not to damage the cover.
When installing the hog rings, take care to prevent wrinkles as much as possible. (b) Install the cushion cover to the cushion frame. 42. INSTALL REAR SEAT CUSHION ASSY RH (a) Using a torx socket wrench (T45), install seat cushion with the 2 torx bolts. Torque: 21 N⋅m (214 kgf⋅cm, 15 ft⋅lbf) for hinge side (b) Install the seat cushion with the 2 bolts. Torque: 18 N⋅m (184 kgf⋅cm, 13 ft⋅lbf) for cushion side 43. INSTALL REAR NO.1 SEAT ASSY RH (a) Place the seat in the cabin. (b) Install the seat with the 4 bolts. Torque: 36.7 N⋅m (375 kgf⋅cm, 27 ft⋅lbf) (c) Install the fold seat stopper band with the bolt on the vehicle side. Torque: 9.0 N⋅m (92 kgf⋅cm, 80 in.⋅lbf) (d) Install the headrest. (e) When sliding the seat, check that both sides of the adjuster lock simultaneously. HINT: Check that the seat adjuster locks. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3668 72-68 SEAT - SEAT HEATER SYSTEM 720RO-01 INSPECTION 1. (a) Seat Heater (Front) Switch LH B51466 INSPECT SEAT HEATER (FRONT) SWITCH LH Check the resistance between the terminals when the switch is operated. Standard: Tester Connection Switch Condition Specified Condition 3-4 ON Below 1 Ω If the result is not as specified, replace the seat heater switch. (b) Push the seat heater switch ON and check that the seat heater switch indicator illuminates. Standard: Measurement Condition Switch Condition Specified Condition Battery positive (+) → Terminal 3 Battery negative (-) → Terminal 6 ON Illuminates If the result is not as specified, replace the switch or bulb. (c) Check that the seat heater switch indicator illuminates. Standard: Measurement Condition Specified Condition Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 2 Illuminates If the result is not as specified, replace the switch or bulb. 2. (a) Seat Heater (Front) Switch RH B51467 INSPECT SEAT HEATER (FRONT) SWITCH RH Check the resistance between the terminals when the switch is operated. Standard: Tester Connection Switch Condition Specified Condition 3-4 ON Below 1 Ω If the result is not as specified, replace the seat heater switch. (b) Push the seat heater switch ON and check that the seat heater switch indicator illuminates. Standard: Measurement Condition Switch Condition Specified Condition Battery positive (+) → Terminal 3 Battery negative (-) → Terminal 6 ON Illuminates If the result is not as specified, replace the switch or bulb. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3677 72-69 SEAT (c) - SEAT HEATER SYSTEM Check that the seat heater switch indicator illuminates Standard: Measurement Condition Specified Condition Battery positive (+) → Terminal 1 Battery negative (-) → Terminal 2 Illuminates If the result is not as specified, replace the switch or bulb. 1 3. (a) 5 3 5 2 3 1 2 INSPECT SEAT HEATER RELAY Check the resistance of the relay. Standard: Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (when battery voltage is applied to terminals 1 and 2) If the result is not as specified, replace the relay. B68834 4. A (a) INSPECT SEPARATE TYPE FRONT SEAT CUSHION COVER LH Apply battery voltage and check the seat cushion heater. (1) Check the seat cushion heater. Standard: Measurement Condition Specified Condition Battery positive (+) → Terminal A2 Battery negative (-) → Terminal B1 Seat cushion heater becomes warm If the result is not as specified, replace the seat cushion cover. NOTICE: After confirming that the seat heater is functioning normally, immediately remove the battery leads. Failing to do so will cause the seat heater to overheat. (2) Check the thermostat. (b) Apply battery voltage and check the seat cushion heater. (1) Check the thermostat. Standard: B B78186 Measurement Condition Specified Condition Battery positive (+) → Terminal A4 Battery negative (-) → Terminal B6 Seat cushion heater temperature below 44
C (111
F) If the temperature of the seat heater rises above the specified value, replace the seat cushion cover. NOTICE: After confirming that the seat heater is functioning normally, immediately remove the battery leads. Failing to do so will cause the seat heater to overheat. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3678 72-70 SEAT 5. A (a) - SEAT HEATER SYSTEM INSPECT SEPARATE TYPE FRONT SEAT CUSHION COVER RH Apply battery voltage and check the seat cushion heater. (1) Check the seat cushion heater. Standard: Measurement Condition Specified Condition Battery positive (+) → Terminal A2 Battery negative (-) → Terminal A1 Seat cushion heater becomes warm If the result is not as specified, replace the seat cushion cover. NOTICE: After confirming that the seat heater is functioning normally, immediately remove the battery leads. Failing to do so will cause the seat heater to overheat. (b) Apply battery voltage and check the seat cushion heater. (1) Check the thermostat. Standard: B B78186 Measurement Condition Specified Condition Battery positive (+) → Terminal B4 Battery negative (-) → Terminal B6 Seat cushion heater temperature below 44
C (111
F) If the temperature of the seat heater rises above the specified value, replace the seat cushion cover. NOTICE: After confirming that the seat heater is functioning normally, immediately remove the battery leads. Failing to do so will cause the seat heater to overheat. 6. INSPECT SEPARATE TYPE FRONT SEATBACK COVER (a) Apply battery voltage and check the seatback heater. Standard: Measurement Condition Specified Condition Battery positive (+) → Terminal 2 Battery negative (-) → Terminal 1 Seatback heater becomes warm If the result is not as specified, replace the seatback cover. NOTICE: After confirming that the seat heater is functioning normally, immediately remove the battery leads. Failing to do so will cause the seat heater to overheat. B78185 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3679 72-71 SEAT 7. (a) - SEAT HEATER SYSTEM INSPECT SEPARATE TYPE FRONT SEATBACK COVER Apply battery voltage and check the seat cushion heater. Standard: Measurement Condition Specified Condition Battery positive (+) → Terminal 2 Battery negative (-) → Terminal 1 Seat cushion heater becomes warm If the result is not as specified, replace the seatback cover. NOTICE: After confirming that the seat heater is functioning normally, immediately remove the battery leads. Failing to do so will cause the seat heater to overheat. B78185 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3680 72-66 SEAT - SEAT HEATER SYSTEM SEAT HEATER SYSTEM 720RM-01 LOCATION Seat Heater (Front) Switch RH Seat Heater (Front) Switch LH R/B Sub-assy
Seat Heater Relay Seatback Heater Assy RH Instrument Panel J/B Assy
SEAT HTR Fuse
IG1 Fuse Seat Cushion Heater Assy RH Seat Cushion Heater Assy LH Seatback Heater Assy LH B78187 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3675 72-67 SEAT - SEAT HEATER SYSTEM 720RN-01 PROBLEM SYMPTOMS TABLE Symptom Suspected Area See Page Driver’s and passenger’s seat heaters do not warm up 1. 2. 3. 4. 72-68 72-68 Only driver’s seat heater does not warm up 1. Seat heater (front) switch LH 2. Front seat cushion Cover LH (seat cushion heater assy LH) 3. Front seatback cover LH (seatback heater assy LH) 4. Wire harness 1. Seat heater (front) switch RH 2. Front seat cushion Cover RH (seat cushion heater assy RH) 3. Front seatback cover RH (seatback heater assy RH) 4. Wire harness 72-68 72-68 Only passenger’s seat heater does not warm up SEAT HTR fuse IG1 fuse Seat heater relay Wire harness 72-66 72-66 72-68 - 72-68 - 72-68 - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3676 73-3 THEFT DETERRENT & DOOR LOCK - POWER DOOR LOCK CONTROL SYSTEM 7302D-02 INSPECTION 1. (a) 2 1 6 5 4 3 INSPECT DOOR CONTROL SWITCH ASSY Inspect the door control switch continuity. Switch position Tester connection Lock 3-6 Specified condition Continuity OFF - No continuity Unlock 3-5 Continuity If the continuity is not as specified, replace the switch. B51554 2. (a) Unlock INSPECT FRONT DOOR LOCK ASSY RH Inspect the door lock assembly continuity. Switch position Tester connection Specified condition Lock 3-5 Continuity OFF - No continuity Unlock 4-5 Continuity If the continuity is not as specified, replace the door lock assembly. OFF Lock B51543 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3683 73-4 THEFT DETERRENT & DOOR LOCK (b) Unlock - POWER DOOR LOCK CONTROL SYSTEM Inspect operation of the door lock motor. Measurement condition Operation Battery positive - Terminal 1 Battery negative - Terminal 2 Lock Battery positive - Terminal 2 Battery negative - Terminal 1 Unlock If operation is not as specified, replace the door lock assembly. (c) Inspect the position switch continuity. Lock Measurement condition Tester connection Specified condition Battery positive Terminal 2 Battery negative Terminal 1 5-6 Continuity If the continuity is not as specified, replace the door lock assembly. B51544 3. (a) Unlock INSPECT FRONT DOOR LOCK ASSY LH Inspect the door lock assembly continuity. Switch position Tester connection Specified condition Lock 2-4 Continuity OFF - No continuity Unlock 2-3 Continuity If the continuity is not as specified, replace the door lock assembly. OFF Lock B51545 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3684 73-5 THEFT DETERRENT & DOOR LOCK (b) Unlock - POWER DOOR LOCK CONTROL SYSTEM Inspect operation of the door lock motor. Measurement condition Operation Battery positive - Terminal 5 Battery negative - Terminal 6 Lock Battery positive - Terminal 6 Battery negative - Terminal 5 Unlock If operation is not as specified, replace the door lock assembly. (c) Inspect the position switch continuity. Lock Measurement condition Tester connection Specified condition Battery positive Terminal 6 Battery negative Terminal 5 1-2 Continuity If the continuity is not as specified, replace the door lock assembly. B51546 4. (a) Unlock INSPECT REAR DOOR LOCK ASSY RH Inspect operation of the door lock motor. Measurement condition Operation Battery positive - Terminal 1 Battery negative - Terminal 2 Lock Battery positive - Terminal 2 Battery negative - Terminal 1 Unlock If operation is not as specified, replace the door lock assembly. (b) Inspect the position switch continuity. Lock Measurement condition Tester connection Specified condition Battery positive Terminal 2 Battery negative Terminal 1 3-4 Continuity If the continuity is not as specified, replace the door lock assembly. B51547 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3685 73-6 THEFT DETERRENT & DOOR LOCK 5. (a) Unlock Lock - POWER DOOR LOCK CONTROL SYSTEM INSPECT REAR DOOR LOCK ASSY LH Inspect the operation of door lock motor. Measurement condition Operation Battery positive - Terminal 1 Battery negative - Terminal 2 Lock Battery positive - Terminal 2 Battery negative - Terminal 1 Unlock If operation is not as specified, replace the door lock assembly. (b) Inspect the position switch continuity. Measurement condition Tester connection Specified condition Battery positive Terminal 2 Battery negative Terminal 1 1-2 Continuity If operation is not as specified, replace the door lock assembly. B51548 6. (a) Lock INSPECT BACK DOOR LOCK ASSY Inspect operation of the door lock motor. Measurement condition Operation Battery positive - Terminal 4 Battery negative - Terminal 3 Lock Battery positive - Terminal 3 Battery negative - Terminal 4 Unlock If operation is not as specified, replace the door lock assembly. (b) Inspect the back door courtesy switch continuity. Unlock Door lock latch position Door Lock Motor Specified condition Open or Half Lock Continuity Closed No continuity If the continuity is not as specified, replace the door lock assembly. Courtesy Switch 2 1 B51571 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3686 73-2 THEFT DETERRENT & DOOR LOCK - POWER DOOR LOCK CONTROL SYSTEM 7302C-02 ON-VEHICLE INSPECTION 1. (a) DOOR LOCK FAIL-SAFE When a malfunction in the door control switch (manual switch, operation interlocked with key) has been detected, door LOCK/UNLOCK operation become disabled. 2. CHECK ELECTRICAL DOOR LOCK OPERATION (a) Check the basic function. (1) Check that all doors lock when the door control switch (for manual operation) is turned to LOCK and all doors unlock when turned to UNLOCK. (2) Check that all doors lock when the driver side door lock key cylinder is turned to LOCK and all doors unlock when turned to UNLOCK from outside the vehicle. (b) Check the key confinement prevention function. NOTICE: In order to prevent the key from being locked-in, the inspection should be made with the driver side door glass open. (1) Insert the key into the ignition key cylinder. (2) With the driver side door open, check that all doors unlock immediately after the door lock knob for the driver side door is turned to LOCK. (3) With the driver side door open, check that all doors unlock immediately after the door control switch (for manual operation) is turned to LOCK. (4) With the driver side door open, turn the driver side door lock knob to LOCK and hold it for 2 seconds or more, and then close the driver side door. Then, check that all doors unlock. (c) Check the security function. (1) Close all doors with the driver side door glass open so that the door control switch can be operated from outside the vehicle. (2) Pull out the key, open the driver side door, and close and lock the door without using the key. Under this condition, check that all doors do not unlock when the door control switch (for manual operation) is turned to UNLOCK from outside the vehicle. (3) Pull out the key, close and lock the driver side door by key operation. Under this condition, check that all doors do not unlock when the door control switch (for manual operation) is turned to UNLOCK from outside the vehicle. (4) Pull out the key, close the driver side door and lock the door by wireless door lock operation. Under this condition, check that all doors do not unlock when the door control switch (for manual operation) is turned to UNLOCK from outside the vehicle. HINT: Check that the security function is canceled under the conditions below:
The ignition switch is turned ON.
The driver side door is unlocked using the key.
The door control switch (for manual operation) is turned to UNLOCK after the door control knob is turned to UNLOCK manually.
The doors are unlocked by wireless operation. (d) Check the illumination function. (1) Set the room light switch in the DOOR position. (2) With all doors locked, check that all doors unlock when the driver side door lock cylinder is turned to UNLOCK using the key. At the same time, the room light comes on. (3) The room light goes off in approximately 15 seconds if doors have not been opened for a while. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3682 73-1 THEFT DETERRENT & DOOR LOCK - POWER DOOR LOCK CONTROL SYSTEM POWER DOOR LOCK CONTROL SYSTEM 7302B-02 PRECAUTION 1. (a) NOTICES FOR REMOVAL AND INSTALLATION OPERATION When performing operation related to the door lock system and door lock key cylinder, be sure to disconnect the battery terminal or the connector of the window regulator motor. CAUTION: Operation is performed with the connectors being connected, the door control switch inside the door lock might be activated, which results in unexpected injury. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3681 73-8 THEFT DETERRENT & DOOR LOCK - WIRELESS DOOR LOCK CONTROL SYSTEM 7302F-02 ON-VEHICLE INSPECTION 1. (a) (b) (c) (d) (e) (f) (g) INSPECT WIRELESS DOOR LOCK CONTROL FUNCTION Check the basic function. (1) In the remote control operational area, check that all the doors lock or unlock when the switch has been pressed for approximately 1 second. However, this will not happen when the key is in the ignition key cylinder or any of the doors is open. Check the automatic locking function. (1) Check that all doors lock automatically as long as none of the doors have been opened or all doors have not been locked within approximately 30 seconds after all doors are unlocked by pressing the switch. (2) Under the above condition, check that the automatic locking function does not operate when any of the doors has been opened or all doors have been locked within approximately 30 seconds after all doors are unlocked by pressing the switch. Check the switch operation fail-safe function. (1) Check that doors can not be locked or unlocked by the switch while the key is in the ignition key cylinder. However, this does not apply when the system is in the recognition code registration mode. (2) Check that doors can not be locked or unlocked by the switch of an unregistered transmitter. Check the chattering prevention function. (1) Check that the corresponding operation occurs only once, and not repeated continuously while the switch is kept pressed. However, when the switch is operated repeatedly at one second intervals, check that the corresponding operation is carried out. Check the repeat function. (1) Check that all doors attempt to automatically lock once again, 2 second after the lock switch has been pressed while the movement of the driver side door control knob, which is in the unlocked state, is being restricted. Check the operation stop function when a door is open or not completely closed. (1) Check that doors are not locked or unlocked by the switch while the doors are open or not completely closed. Check the hazard flashing and buzzer sounding function (answer-back). (1) Check that the hazard lights flash and also the buzzer sounds once (when locked) or twice (when unlocked) simultaneously with locking or unlocking operation of all doors, when the switch is pressed. Check the room light on function. (h) HINT: Move the room light switch in the DOOR position befor the check. (1) Check that the room light will be on simultaneously with the unlocking operation when the switch has been pressed for 1 second (2) Check that the room light will be off in approximately 15 seconds if doors have not been opened after the unlocking operation. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3688 73-9 THEFT DETERRENT & DOOR LOCK 2. (a) - WIRELESS DOOR LOCK CONTROL SYSTEM CHECK WIRELESS CONTROL RECEIVER Disconnect the receiver connector and check that the connector on the wire harness side. B51174 Continuity and Voltage: Tester connection Condition Specified condition 1 - Body ground Constant Continuity 5 - Body ground Constant 10 - 14 V HINT: If the value is not as specified the vehicle’s side may be defective. (b) Connect the receiver connector and check that the voltage using an oscilloscope. Voltage: Tester connection 1 - Body ground Condition Specified condition All door is closed → Door control transmitter ON 0V→6V→0V HINT: If the result is not as specified, there may be a malfunction on the vehicle side. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3689 73-7 THEFT DETERRENT & DOOR LOCK - WIRELESS DOOR LOCK CONTROL SYSTEM WIRELESS DOOR LOCK CONTROL SYSTEM 7302E-02 PRECAUTION HINT: The switch described in this text indicates the switch for transmitting signals, which is built in the door control transmitter. 1. NOTE WHEN CHECKING (a) The wireless door lock remote control function operates only when the following 4 conditions are satisfied. (1) All the doors are closed. (2) No key is inserted in the ignition key cylinder. (3) The power door lock operates normally. (4) The receiving function is not cancelled by the security function. (b) The wireless door lock remote control function operational area. (1) The operational area differs depending on the operator and the way the transmitter is held. (2) In some places, the operational area will be reduced due to the vehicle body shape and the influence of the surrounding environment, or the remote control function will only operate partially. (3) Because the transmitter uses faint electric waves, strong electric waves or noise in the frequency used may reduce the operational area or the remote control may not function. (4) When the battery weakens, the operational area is reduced or the remote control may not be operated. HINT: If the door control transmitter has been left in a place that is exposed to the direct sunlight, such as on the instrument panel, it may cause the battery to weaken or other trouble. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3687 73-10 THEFT DETERRENT & DOOR LOCK - TRANSMITTER BATTERY TRANSMITTER BATTERY 730KH-01 REPLACEMENT 1. REMOVE TRANSMITTER BATTERY NOTICE: Special caution should be taken when handling each component as they are precise electronic components. (a) Using a coin or equivalent, open the transmitter case. NOTICE: Do not forcibly apart the cover. B79371 (b) B79372 2. Remove the discharged transmitter battery by ballpoint pen. Insert the tip of ballpoint pen at the guide groove and lift as shown in the left illustration. NOTICE:
Do not push the terminals with your finger.
Do not forcibly pry up the battery (lithium battery). The terminals may become damaged.
Do not touch the battery with wet hands. Water may cause rust.
Do not touch or move any components inside the transmitter, as it may cease to work. INSTALL TRANSMITTER BATTERY (a) Put a new transmitter battery with positive (+) side up. Close the transmitter case securely. NOTICE:
Be sure that the positive side and the negative side of the transmitter battery are matched up correctly.
Be careful not to bend the transmitter battery electrode during insertion.
Keep the transmitter case interior free of dust and oil. B79373 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3690 73-14 THEFT DETERRENT & DOOR LOCK - DOOR CONTROL TRANSMITTER 7302I-04 INSPECTION 1. (a) (b) B51553 INSPECT DOOR CONTROL TRANSMITTER Check operation of the registration of recognition code (See page 73-1 1). Inspect operation of the transmitter. (1) Using a screwdriver, remove the cover. (2) Remove the battery (lithium battery). (3) Install a new or normal battery (lithium battery). HINT: When a new or normal battery is not available, connect 2 new 1.5 V batteries in series, connect the battery positive (+) to the battery receptacle side terminal and battery negative (-) to the bottom terminal, and then apply 3 V to the transmitter. (4) In the location which is approximately 1 m away from the driver’s outside handle in the right direction, check transmitter operation when pressing transmission switch on the transmitter. Standard: Remote control of vehicle door lock can be operated. HINT:
The minimum operation distance differs depending on to the operator, the way the transmitter is held, and location.
Because the transmitter uses faint electric waves, strong electric waves or noise in the frequency used may reduce the operational area or the remote control may not function.
Install the battery (lithium battery).
Install the cover. (c) Check the battery capacity. HINT:
Make sure to use the TOYOTA electrical tester.
With the battery unloaded, whether the battery is available or not can not be judged by the test.
If the transmitter is faulty, the energy amount left in the battery might not be checked correctly.
On the lithium battery used for the transmitter, the voltage more than 2.5 V with the battery unloaded is shown on the tester until the energy is completely consumed. Therefore, when inspecting the energy amount left in the battery, it is necessary to measure the voltage when the battery is loaded (1.2 kΩ). (1) Using a screwdriver, remove the screw and cover. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3694 73-15 THEFT DETERRENT & DOOR LOCK - (2) (3) DOOR CONTROL TRANSMITTER Remove the battery (lithium battery) from the transmitter. Connect the lead to the negative (-) terminal of the transmitter and install the battery. B51551 (4) Connect the positive (+) tester to the positive (+) battery (lithium battery), and negative (-) tester to the lead respectively. (5) Press one of the transmission switches on the transmitter for approximately 1 second. (6) Press the transmission switch on the transmitter again to check the voltage. Standard: 2.1 V or more B51552 HINT:


When the temperature of the battery is low, the judgement can not be made correctly. When the outcome of the test is less than 2.1V, conduct the test again after leaving the battery in a place at 18°C for more than 30 minutes. By automatic power-off function, the voltage becomes no load voltage (more than 2.5 V) condition after 20 seconds from the switch has pressed. Make sure to read the voltage before it. High voltage might be shown 1 or 2 times after leaving the battery, judgement should be made with the voltage shown at the 3rd time or later. (7) Disconnect the lead. (8) Set the battery (lithium battery) in the transmitter. (9) Install the cover, so that the O-ring is not distorted or slipped off. (10) Using a screwdriver, tighten the screw. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3695 73-1 1 THEFT DETERRENT & DOOR LOCK - DOOR CONTROL TRANSMITTER DOOR CONTROL TRANSMITTER 7302H-02 REPLACEMENT 1. REGISTRATION OF RECOGNITION CODE HINT:
The add mode is used to register a new recognition codes while still retaining codes already registered. This mode is used to add a new transmitter. If the number of registered codes exceeds 4, the previously registered codes will be erased in order, starting from the first registered code.
The rewrite mode is used to erase all the previously registered codes in order to register all new recognition codes. This mode is used to exchange the transmitter or the door control receiver for a new one.
The prohibition mode is used to erase all the registered codes and disables the wireless door lock function. Use this mode when the transmitter is lost.
The confirmation mode is used to confirm how many recognition codes have already been registered before an additional registration of the recognition codes. (a) Make sure that the vehicle fulfills the following conditions. (1) No key is inserted in the ignition key cylinder. (2) The driver side door is opened (The other doors are closed). (3) The driver side door is unlocked. (b) Select a mode. (1) Insert the key into the ignition key cylinder, then pull it out (Perform this operation once again within 5 seconds). (2) Close and open the driver side door twice. (3) Insert the key into the ignition key cylinder, then pull it out. (4) Close and open the driver side door twice. (5) Insert the key into the ignition key cylinder, then close the door. (6) To select a mode, turn the ignition switch from ON to LOCK at approximately 1 second intervals according to the number of times shown below. Then remove the key from the ignition key cylinder. Add Mode ON-LOCK change 1 time Confirmation Mode 1 sec. 1 sec. 1 sec. ON ON LOCK LOCK Rewrite Mode ON-LOCK change 2 times Prohibition Mode ON-LOCK change 5 times 1 sec.1 sec. ON LOCK ON-LOCK change 3 times 1 sec.1 sec. ON LOCK B50826 NOTICE:
If the number of ON-LOCK operations of the ignition switch is 4 or more than 5, the registration will end without any signs. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3691 73-12 THEFT DETERRENT & DOOR LOCK (7) - DOOR CONTROL TRANSMITTER Within 3 seconds after a mode has been selected, the MPX ECU automatically performs LOCKUNLOCK operation to inform the operator which mode has been selected. HINT:

When the confirmation mode has been selected and 0 codes are registered, LOCK-UNLOCK operation is automatically performed 5 times. When the confirmation mode has been selected and LOCK-UNLOCK operation has been performed twice as shown in the illustration below, the number of the registered recognition codes is 2. Confirmation Mode Add Mode 1st time 1 sec. 2nd time 2sec. 2 sec. LOCK LOCK UNLOCK UNLOCK Rewrite Mode Prohibition Mode 1sec. 1 sec 1 sec.1 sec. LOCK LOCK UNLOCK UNLOCK B50827 HINT: When the prohibition mode or the confirmation mode is selected, the registration mode ends. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3692 73-13 THEFT DETERRENT & DOOR LOCK - DOOR CONTROL TRANSMITTER (c) Register the transmitter. (1) Within 40 seconds after the add mode or the rewrite mode has been selected, simultaneously press the LOCK and UNLOCK switches for 1.0 to 1.5 seconds. Then press either one of the switches for more than 1.0 second. NOTICE: Press and hold both switches for 1 second or more during each press. However, the time between the 1st press and the 2nd press must be under 3 seconds. (2) LOCK-UNLOCK operation is automatically performed once within 3 seconds after above operation (step 1), when the recognition code of the transmitter has been registered correctly. If the LOCK-UNLOCK operation is performed twice, the registration of the recognition code has failed. In this case, register the recognition code from the beginning of the registration procedures once again. LOCK-UNLOCK occurs once Registration has been completed Approx. 1 sec. LOCK-UNLOCK occurs twice Registration has failed Approx. Approx. 1 sec.1 sec. LOCK LOCK UNLOCK UNLOCK B50828 (3) In order to continue in registration mode, start the next registration within 40 seconds after the previous one. HINT: The maximum number of the recognition codes that can be registered is 4. (d) If even one of the following conditions is satisfied, the registration mode will end. (1) 40 seconds have elapsed under the condition that the registration mode is ready. (2) The driver side door is opened. (3) The key is inserted in the ignition key cylinder. (4) 4 recognition codes are registered at once. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3693 73-16 THEFT DETERRENT & DOOR LOCK - ENGINE IMMOBILIZER SYSTEM ENGINE IMMOBILIZER SYSTEM 730KG-01 REGISTRATION 1. (a) (b) DESCRIPTION OF CODE REGISTRATION When adding master keys and sub-keys (additional registration). (1) Register the key code (immobilizer code) in the transponder key ECU. See step Transponder key ECU 3 When replacing the transponder key ECU (new registration). (1) Register the key code (immobilizer code) in the transponder key ECU. (2) (c) Target ECU Target ECU See step Transponder key ECU 2 Register the ECU COMMUNICATION ID between the ECM and the transponder key ECU. Target ECU See step ECM 5 When replacing the ECM. (1) Register the ECU COMMUNICATION ID between the ECM and the transponder key ECU. Target ECU See step Transponder key ECU 5 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3696 73-17 THEFT DETERRENT & DOOR LOCK 2. (a) - ENGINE IMMOBILIZER SYSTEM KEY REGISTRATION IN AUTOMATIC REGISTRATION (NEW REGISTRATION) When an ignition key is inserted into the ignition cylinder, the key code (immobilizer code) registration is automatic. In this mode, a maximum of 4 key codes for 3 master keys and 1 sub-key can be registered. Any order of registration for the master keys and sub-keys is fine because the transponder key ECU can distinguish between different types of keys. HINT:

When a new transponder key ECU is installed, key codes (immobilizer codes) must be registered with ignition keys. New transponder key ECUs are automatically set to automatic key code registration mode. Automatic Key Code Registration (New Registration): Security Indicator START BLINKING (Until the first key is inserted.) Insert the key into the ignition key cylinder. OFF Registration begins. (Approx. 1 second) (The registration is completed approx. 1 second after the key is inserted.) Remove the key. ON (When the maximum number of key codes are registered, the security indicator re- Yes mains OFF until the last key registered is Register another key? removed. After it is removed, the security indicator starts blinking.) No END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3697 73-18 THEFT DETERRENT & DOOR LOCK - ENGINE IMMOBILIZER SYSTEM HINT:


When no key is inserted in the ignition key cylinder in automatic key code registration mode, the security indicator remains on. When the immobilizer system is operating normally and the key is pulled out, the security indicator blinks continuously. If the key code registration has failed in automatic key code registration mode, code 2-1 will be output from the security indicator. Trying to re-register an already registered key will cause code 2-2 to be output when the key is inserted. If the number of registered key codes exceeds the limit, code 2-3 will be output from the security indicator. The output details are shown below. Security Indicator: 0.2 sec. ON Normal (Immobilizer system is operating normally.) OFF 1.8 sec. 0.25 sec. 1 sec. ON Code 2-1 OFF 0.25 sec. 0.25 sec. 0.5 sec. 1 sec. ON Code 2-2 OFF 0.25 sec. 0.25 sec. 0.5 sec. 1 sec. ON Code 2-3 OFF 0.25 sec. (b) 0.5 sec. Finish the automatic key code registration mode. The automatic key code registration mode can be forced to end when at least 1 key code (immobiliser code) for the master key has been registered. (1) Turn the ignition switch ON and OFF 5 times within 10 seconds using the already registered master key. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3698 73-19 THEFT DETERRENT & DOOR LOCK - ENGINE IMMOBILIZER SYSTEM 3. REGISTRATION OF ADDITIONAL KEY (ADDITIONAL REGISTRATION) (a) Register an additional key by using the hand-held tester. HINT:
A maximum of 5 master key codes and 3 sub-key codes can be registered.
Registration mode will end if each step is not completed within the specified time.
When the ignition cylinder or the key cylinder set is replaced, remove the transmitter module from the original master key. Then install this transmitter module to a new key and use the new key as the master key. If necessary, use this master key to register other keys. NOTICE: When the ignition key cylinder has been replaced, locking and unlocking doors is possible with the new master key’s transmitter module (taken from the original master key). However, the new master key will not be able to lock and unlock doors through the door key cylinder. Keep the original master key. If the new master key’s transmitter module’s battery fails, the original master key can be used to lock and unlock doors through the door key cylinder. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3699 73-20 THEFT DETERRENT & DOOR LOCK - ENGINE IMMOBILIZER SYSTEM Additional Registration Security Indicator START BLINKING (Until the first key is inserted.) Insert the already registered master key in the ignition key cylinder and turn the ignition switch ON. OFF ON Hand-held tester operation: 1. Select HIGHLANDER from the menu. 2. Select IMMOBILISER. 3. Select ID UTILITY. 4. Select TRANSP CODE REG. After the above operation, proceed to the next step according to the prompts on the tester screen. Within 120 seconds Within 20 seconds after the tester instruction Remove the master key. Within 10 seconds Insert the key to be registered in the ignition key cylinder. BLINKING After 60 seconds, the key is registered. (The security indicator goes off.) OFF END 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3700 73-21 THEFT DETERRENT & DOOR LOCK - ENGINE IMMOBILIZER SYSTEM HINT:


A brief outline of procedures for key code registration is shown on the previous page. For more detailed information, please refer to the hand-held tester screen’s instructions. When the immobilizer system is operating normally and the key is pulled out, the security indicator blinks continuously. If the key code registration has failed in automatic key code registration mode, code 2-1 will be output from the security indicator. Trying to re-register an already registered key will cause code 2-2 to be output when the key is inserted. If the number of registered key codes exceeds the limit, code 2-3 will be output from the security indicator. The output details are shown in step 2 (new registration). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3701 73-22 THEFT DETERRENT & DOOR LOCK - ENGINE IMMOBILIZER SYSTEM 4. ERASURE OF KEY CODE (a) Erase key codes using the hand-held tester. HINT:
All key codes are erased except for the master key, which is used for erasing the key codes. In order to use a key whose code has been erased, a new key code must be registered.
Registration will be cancelled if each step is not completed within the specified time. Erasing Key Code Security Indicator START BLINKING (Until the first key is inserted.) OFF ON for 1 second then OFF Insert the already registered master key in the ignition key cylinder and turn the ignition switch ON. Hand-held tester operation: 1. Select HIGHLANDER from the menu. 2. Select IMMOBILISER. 3. Select ID UTILITY. 4. Select TRANSP CODE ERS. After the above operation, proceed to the next step in accordance with the tester screen’s instructions. Within 120 seconds Within 10 seconds after the tester Remove the master key. indicates BLINKING END HINT:

A brief outline of procedures for key code registration is shown on this page. For more detailed information, please refer to the hand-held tester screen’s instructions. When the immobilizer system is operating normally and the key is pulled out, the security indicator blinks continuously. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3702 73-23 THEFT DETERRENT & DOOR LOCK - ENGINE IMMOBILIZER SYSTEM 5. ECU COMMUNICATION ID REGISTRATION NOTICE:
The ECU communication ID should be registered when the transponder key ECU and/or the ECM is replaced in order to match the ECM COMMUNICATION ID.
The engine cannot be started unless the ECM COMMUNICATION ID matches. (a) Register the ECU communication ID. (1) Using SST, connect terminals TC and CG of the DLC3. (2) Turn the ignition switch ON (do not start the engine) and leave it as is for 30 minutes. (3) Turn the ignition switch OFF and disconnect terminals TC and CG. (4) Check that the engine starts. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3703 74-9 SLIDING ROOF/CONVERTIBLE - SLIDING ROOF SLIDING ROOF 740EF-01 COMPONENTS Rear Floor Finish Plate Tonneau Cover Assy Back Door Weatherstrip Deck Board Sub-assy No. 2 Rear Door Opening Trim Weatherstrip RH Quarter Pillar Garnish RH Front Door Opening Trim Weatherstrip RH Roof Side Rail Garnish Assy RH Deck Board Sub-assy No. 3 Deck Board Sub-assy Center Pillar Garnish RH Front Pillar Garnish RH Roof Side Garnish Assy Inner RH Deck Side Trim Box RH Deck Floor Box Rear Deck Trim Side Panel Assy RH Rear No. 1 Seat Outer Belt Assy RH 42 (420, 31) Front Door Scuff Plate RH Rear Door Scuff Plate RH Center Pillar Garnish Lower RH Front Seat Outer Belt Assy RH Deck Side Trim Box LH Roof Side Rail Garnish Assy LH Roof Side Garnish Assy Inner LH Rear No. 1 Seat Outer Belt Assy LH 42 (420, 31) Front Pillar Garnish LH Quarter Pillar Garnish LH Deck Floor Box Front Center Pillar Garnish LH Front Seat Outer Belt Assy LH Deck Trim Side Panel Assy LH Front Door Opening Trim Weatherstrip LH Rear Door Scuff Plate LH Front Door Scuff Plate LH Center Pillar Garnish Lower LH N⋅m (kgf⋅cm, ft⋅lbf) Rear Door Opening Trim Weatherstrip LH : Specified torque B77611 Author
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: 3712 74-10 SLIDING ROOF/CONVERTIBLE - SLIDING ROOF w/ Rear No. 2 Seat Rear Floor Finish Plate Deck Board Sub-assy No.2 Roof Side Rail Garnish Sub-assy RH Roof Side Garnish Assy Inner RH Rear No. 2 Seat Outer Belt Assy RH Deck Board Sub-assy Deck Side Trim Box RH Quarter Pillar Garnish RH Deck Board Sub-assy No.3 Deck Floor Box Rear 42 (420, 31) Roof Side Rail Garnish Sub-assy LH Rear No. 2 Seat Outer Belt Assy LH Deck Side Trim Box LH Deck Trim Side Panel Assy RH Roof Side Garnish Assy Inner LH Quarter Pillar Garnish LH Rear Door Scuff Plate RH Rear Door Scuff Plate LH N⋅m (kgf⋅cm, ft⋅lbf) Deck Trim Side Panel Assy LH : Specified torque B77612 Author
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: 3713 74-10-1 SLIDING ROOF/CONVERTIBLE - SLIDING ROOF Roof Silencer Pad No. 1 Sun Roof Opening Trim Moulding Roof Silencer Pad No. 4 Roof Silencer Pad No. 5 Room Lamp Assy No. 2 Assist Grip Sub-assembly Roof Headlining Assy RH Visor Assy Assist Grip Sub-assy Assist Grip Sub-assy Room Lamp Assy No. 1 Visor Holder Roof Console Box Assy Visor Holder LH Visor Assy B82237 Author
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: 3714 74-10-2 SLIDING ROOF/CONVERTIBLE - SLIDING ROOF Sliding Roof Side Garnish RH Sliding Roof Glass Sub-assy Sliding Roof Side Garnish LH 5.5 (56, 49 in.⋅lbf) Sunshade Trim Assy Sliding Roof Housing Center Mounting Bracket RH Sliding Roof Panel Stopper Sliding Roof Housing Front Mounting Bracket RH Drain Hose 8.0 (82, 71 in.⋅lbf) Sliding Roof Panel Stopper 8.0 (82, 71 in.⋅lbf) Drain Hose 5.5 (56, 49 in.⋅lbf) Sliding Roof Drive Gear Assy 8.0 (82, 71 in.⋅lbf) 5.5 (56, 49 in.⋅lbf) Sliding Roof Housing Center Mounting Bracket LH Drain Hose Sliding Roof Drive Gear Bracket N⋅m (kgf⋅cm, ft⋅lbf) 5.4 (55, 48 in.⋅lbf) : Specified torque Sliding Roof Housing Front Mounting Bracket LH 8.0 (82, 71 in.⋅lbf) B93084 Author
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: 3715 74-10-3 SLIDING ROOF/CONVERTIBLE - SLIDING ROOF Sliding Roof Drive Cable 5.5 (56, 49 in.⋅lbf) 5.5 (56, 49 in.⋅lbf) Sliding Roof Rail Roof Wind Deflector Panel Assy Sliding Roof Housing Panel N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque B93085 Author
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: 3716 74-10-4 SLIDING ROOF/CONVERTIBLE - SLIDING ROOF 740EG-01 OVERHAUL 1. 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL REMOVE ROOF HEADLINING ASSY (See page 76-21 ) 3. (a) REMOVE SLIDING ROOF SIDE GARNISH RH Using a screwdriver, detach the 4 claws and remove the garnish. HINT: Tape the screwdriver tip before use. B93086 4. REMOVE SLIDING ROOF SIDE GARNISH LH HINT: Use the same procedures described for the RH side. 5. REMOVE SLIDING ROOF GLASS SUB-ASSY (a) Using a T25 ”torx” driver, remove the 4 screws and glass. (b) Pull the glass upward to remove it. 6. (a) DISCONNECT SLIDING ROOF DRAIN HOSE Disconnect the 4 drain hoses. B93087 7. 8. REMOVE CURTAIN SHIELD AIRBAG RH (w/ Curtain Shield Airbag) (See page 60-38 ) REMOVE CURTAIN SHIELD AIRBAG LH (w/ Curtain Shield Airbag) (See page 60-38 ) 9. (a) REMOVE FRONT SIDE RAIL SPACER RH (w/o Curtain Shield Airbag) Detach the 3 claws and remove the rail spacer. B93088 Author
: Date
: 3717 74-10-5 SLIDING ROOF/CONVERTIBLE - SLIDING ROOF 10. REMOVE FRONT SIDE RAIL SPACER LH (w/o Curtain Shield Airbag) HINT: Use the same procedures described for the RH side. 11. (a) REMOVE REAR SIDE RAIL SPACER RH (w/o Curtain Shield Airbag) Detach the 4 claws and remove the rail spacer. B93089 12. REMOVE REAR SIDE RAIL SPACER LH (w/o Curtain Shield Airbag) HINT: Use the same procedures described for the RH side. 13. REMOVE SLIDING ROOF HOUSING FRONT MOUNTING BRACKET RH (a) Remove the 2 bolts and bracket. 14. REMOVE SLIDING ROOF HOUSING FRONT MOUNTING BRACKET LH HINT: Use the same procedures described for the RH side. 15. REMOVE SLIDING ROOF HOUSING CENTER MOUNTING BRACKET RH (a) Remove the 2 bolts and bracket. 16. REMOVE SLIDING ROOF HOUSING CENTER MOUNTING BRACKET LH HINT: Use the same procedures described for the RH side. 17. (a) (b) REMOVE SLIDING ROOF HOUSING SUB-ASSY Disconnect the drive gear connector. Remove the 8 nuts and roof housing. B93090 18. (a) (b) 19. (a) (b) REMOVE SLIDING ROOF DRIVE GEAR SUB-ASSY Remove the bracket. Remove the 2 bolts and drive gear. REMOVE SUNSHADE TRIM SUB-ASSY Remove the 2 stoppers. Slide and remove the sunshade trim. Author
: Date
: 3718 74-10-6 SLIDING ROOF/CONVERTIBLE 20. - SLIDING ROOF (a) REMOVE ROOF WIND DEFLECTOR SUB-ASSY Using a screwdriver, slide the drive cable. PANEL (b) Detach the claw, and remove the deflector panel. 21. (a) REMOVE SLIDING ROOF HOUSING PANEL Remove the screw and housing panel. B93091 B93092 B93093 22. REMOVE SLIDING ROOF DRIVE CABLE (a) Using a screwdriver, slide the drive cables backward and remove them. HINT: Tape the screwdriver tip before use. 23. INSTALL SLIDING ROOF DRIVE CABLE 24. ADJUST FULLY CLOSED POSITION (a) Using a screwdriver, slide the sliding roof drive cable LH and RH to align the matchmaks. Matchmark HINT:Tape the screwdriver tip before use. B93094 25. (a) (b) INSTALL SLIDING ROOF HOUSING PANEL Engage the 2 claws. Install the housing panel with the 2 screws. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) Author
: Date
: 3719 74-10-7 SLIDING ROOF/CONVERTIBLE 26. (a) 27. (a) (b) 28. (a) (b) 29. (a) (b) 30. (a) - SLIDING ROOF INSTALL ROOF WIND DEFLECTOR PANEL SUB-ASSY Engage the claw, and install the deflector panel. INSTALL SUNSHADE TRIM SUB-ASSY Insert the sunshade trim into the sliding roof housing. Install the 2 stoppers. INSTALL SLIDING ROOF DRIVE GEAR SUB-ASSY Install the drive gear with the 2 bolts. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) Install the bracket to the drive gear. INSTALL SLIDING ROOF HOUSING SUB-ASSY Install the roof housing with the 8 nuts. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) Connect the drive gear connector. INSTALL SLIDING ROOF HOUSING CENTER MOUNTING BRACKET RH Install the bracket with the 2 bolts. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) INSTALL SLIDING ROOF HOUSING CENTER MOUNTING BRACKET LH 31. HINT: Use the same procedures described for the RH side. 32. INSTALL SLIDING ROOF HOUSING FRONT MOUNTING BRACKET RH (a) Install the bracket with the 2 bolts. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 33. INSTALL SLIDING ROOF HOUSING FRONT MOUNTING BRACKET LH HINT: Use the same procedures described for the RH side. 34. CONNECT SLIDING ROOF DRAIN HOSE (a) Connect the 4 drain hoses. 35. (a) C A C B A D B (b) D a INSTALL SLIDING ROOF GLASS SUB-ASSY Using a T25 ”torx driver, temporarily install the sliding roof glass with the 4 screws.” Perform a level check. Check the difference in level for ”a” between the roof panel and the upper surface of the weatherstrip when the sliding roof glass is fully closed. Standard measurement Area Specified Condition A-A 0 + 1.00 - 2.0 mm 0 + 0.0039 - 0.0079 in. B-B 0 + 2.00 - 1.0 mm 0 + 0.0079 - 0.0039 in. C-C 0
1.5 mm 0
0.0059 in. D-D 0 + 1.50 - 1.0 mm 0 + 0.0059 - 0.0039 in. B93095 Author
: Date
: 3720 74-10-8 SLIDING ROOF/CONVERTIBLE - SLIDING ROOF (c) Perform a gap check. Check the gap between the roof panel and roof glass. NOTICE: The gap must be even all around. (d) Using a T25 ”torx” driver, install the sliding roof glass with the 4 screws. Even B93096 36. INSTALL SLIDING ROOF SIDE GARNISH RH (a) Attach the 4 claws to install the garnish. 37. INSTALL SLIDING ROOF SIDE GARNISH LH HINT: Use the same procedures described for the RH side. 38. CHECK FOR WATER LEAKS (a) Adjust the sliding roof glass, and check for water leaks. (b) If there are any leaks, readjust the sliding roof glass. 39. INSTALL REAR SIDE RAIL SPACER RH (w/o Curtain Shield Airbag) (a) Attach the 4 claws to install the rail spacer. 40. INSTALL REAR SIDE RAIL SPACER LH (w/o Curtain Shield Airbag) HINT: Use the same procedures described for the RH side. 41. INSTALL FRONT SIDE RAIL SPACER RH (w/o Curtain Shield Airbag) (a) Attach the 3 claws to install rail spacer. 42. INSTALL FRONT SIDE RAIL SPACER LH (w/o Curtain Shield Airbag) HINT: Use the same procedures described for the RH side. 43. INSTALL CURTAIN SHIELD AIRBAG RH (w/ Curtain Shield Airbag) (See page 60-38 ) 44. INSTALL CURTAIN SHIELD AIRBAG LH (w/ Curtain Shield Airbag) (See page 60-38 ) 45. INSTALL ROOF HEADLINING ASSY (See page 76-21 ) 46. CABLE TO NEGATIVE BATTERY TERMINAL Author
: Date
: 3721 74-5 SLIDING ROOF/CONVERTIBLE - SLIDING ROOF SYSTEM 740EC-01 DATA LIST/ACTIVE TEST 1. (a) (b) (c) CHECK USING INTELLIGENT TESTER Connect the intelligent tester to the DLC3. Select the DATA LIST mode on the intelligent tester. Sliding roof ECU: Item Switch condition Standard value OPEN SW Pressed → Unpressed ON/OFF CLOSE SW Pressed → Unpressed ON/OFF Position detection SW 1 Do sliding and tilting operation ON/OFF Position detection SW 2 Do sliding and tilting operation ON/OFF HALL IC condition Do sliding and tilting operation Normal/ Abnormal HALL IC out put Do sliding and tilting operation ON/OFF IG Ignition Switch ON → OFF ON/OFF IG line signal Ignition Switch ON → OFF ON/OFF Operation possible after key-OFF Ignition Switch ON → OFF ON/OFF The active test will indicate if the part is normal or malfunctioning. Sliding roof ECU: Item Condition Sliding Roof CLOSE/ UP Sliding Roof OPEN/DOWN Author
: Date
: 3708 74-2 SLIDING ROOF/CONVERTIBLE - SLIDING ROOF SYSTEM 740E9-01 HOW TO PROCEED WITH TROUBLESHOOTING HINT: Troubleshoot in accordance with the procedures on the following pages. 1 VEHICLE BROUGHT TO WORKSHOP 2 CUSTOMER PROBLEM ANALYSIS 3 PROBLEM SYMPTOM CONFIRMATION (a) (b) If the symptom does not occur, proceed to A. If the symptom occurs, proceed to B. A SYMPTOM SIMULATION B 4 PROBLEM SYMPTOM TABLE 5 CIRCUIT INSPECTION 6 IDENTIFICATION OF PROBLEM 7 REPAIR OR REPLACE 8 CONFIRMATION TEST END Author
: Date
: 3705 74-8 SLIDING ROOF/CONVERTIBLE - SLIDING ROOF SYSTEM 740EE-01 INSPECTION O5 1. (a) INSPECT SLIDING ROOF SWITCH ASSY Disconnect the sliding roof switch connector, and check the voltage or continuity of each terminal of the connector. B78737 Standard Symbols (Terminal No.) Wiring color Condition Specified condition UP (O5 - 6) ⇔ Body ground G⇔ - Each switch OFF Continuity DOWN (O5 - 4) ⇔ Body ground W⇔ - Each switch OFF Continuity UP (O5 - 6) ⇔ Body ground DOWN (O5 - 4) ⇔ Body ground G⇔ -
Ignition switch ON
Sliding roof fully closed
Slide open switch OFF → ON (Slide open side) 0 V → 10 to 14 V W⇔ -
Ignition switch ON
Sliding roof fully closed
Slide open switch OFF → ON (Slide open side) 0 V → 10 to 14 V IG (O5 - 9) ⇔ Body ground GR ⇔ - Ignition switch ON 0 V → 10 to 14 V GND (O5 - 1) ⇔ Body ground W-B⇔ - Constant Continuity Author
: Date
: 3711 74-6 SLIDING ROOF/CONVERTIBLE - SLIDING ROOF SYSTEM 740ED-01 ON-VEHICLE INSPECTION 1. CHECK AUTO OPERATION HINT: When pressing the switch for 0.3 seconds or less, the roof glass moves but auto operation does not operate. (a) Turn the ignition switch ON. (b) When the roof glass is fully closed, check that pressing the slide roof open side of the sliding roof switch for 0.3 seconds or more causes the roof glass to slide and stop at the fully open position. HINT: If the slide open side of the sliding roof switch is pressed again, the roof glass will move 45 mm beyond the stored fully open position. (c) When the roof glass is fully open, check that pressing the tilt up side of the sliding roof switch for 0.3 seconds or more causes the roof glass to slide to the fully closed position. (d) When the roof glass is for 0.3 seconds or more causes the roof glass to tilt to the fully tilted up position. fully closed, check that pressing the tilt up side of the sliding switch (e) When roof glass is fully tilted up, check that pressing the slide open side of the sliding roof switch for 0.3 seconds or more causes the roof glass to tilt to the fully tilted down position. (f) During auto function operation (slide open/ close, tilt up/down), check that operating the sliding roof switch stops the roof glass. 2. CHECK SLIDING ROOF OPERATION AFTER IGNITION SWITCH IS TURNED OFF (KEY-OFF OPERATION) (a) Turn the ignition switch from ON to OFF, and check that the sliding roof operates. Then open the driver side door once, and check that the sliding roof does not operate. (b) Turn the ignition switch from ON to OFF and wait for approximately 43 seconds. Check that the sliding roof does not operate. (c) Operate the auto (SLIDE OPEN or TILT UP) operation. While the roof glass is in motion, turn the ignition switch from ON to OFF. Check that the auto operation continues until the roof glass opens or closes fully. After the auto operation is completed, check that the sliding roof operation cannot be performed. 3. CHECK JAM PROTECTION FUNCTION (Overload Reverse Operation) CAUTION:
Do not use a part of your body, for example, your hand, to check the jam protection.
Do not allow anything to become caught in the sliding roof by accident in this procedure.
Perform the inspection from the inside of the vehicle. NOTICE:
Do not use hand objects, such as a hammer, to avoid damage to the roof.
If the jam protection does not operate, reset the sliding roof drive gear (motor). HINT: The jam protection function operates in any of the following condition:
AUTO operation
MANUAL operation
Sliding close or tiling down roof glass by AUTO operation after key-off operation Author
: Date
: 3709 74-7 SLIDING ROOF/CONVERTIBLE - SLIDING ROOF SYSTEM (a) When the sliding roof auto operation is operating and an object is caught between the vehicle body and glass, check that the roof glass opens a distance of 115 mm (4.53 in.) from the point of contact with the object, or opens fully if an opening distance of 115 mm (4.53 in.) is not available (the maximum operation duration: 20 seconds). (b) When the TILT UP DOWN function is operating, and an object is caught between the vehicle body and the roof glass, check that the sliding roof tilts up fully, or tilts up for 2 seconds. (c) After the jam protection function operates, check that the roof glass closes fully by the manual operation when the TILT UP switch is pressed for 10 seconds or more. B68295 B68296 Author
: Date
: 3710 74-1 SLIDING ROOF/CONVERTIBLE - SLIDING ROOF SYSTEM SLIDING ROOF SYSTEM 740E8-01 LOCATION Sliding Roof Housing Sliding Roof Drive Gear Sub-assy (Sliding Roof ECU) Sliding Roof Motor Switch B93077 Author
: Date
: 3704 74-3 SLIDING ROOF/CONVERTIBLE - SLIDING ROOF SYSTEM 740EA-01 PROBLEM SYMPTOMS TABLE Symptom Sliding roof system o operates erates abnormally. Suspected area See page 1. Slide roof control switch 74-8 2. Slide roof drive gear sub-assy 74-4 3. Wire harness Sliding roof system stops sto s operation o eration halftra ed in way. (No foreign materials are trapped motor assy) - 1. Slide roof control switch 74-8 2. Slide roof drive gear sub-assy 74-4 3. Wire harness - Author
: Date
: 3706 74-4 SLIDING ROOF/CONVERTIBLE - SLIDING ROOF SYSTEM 740EB-01 TERMINALS OF ECU S20 1. (a) CHECK SLIDING ROOF DRIVE GEAR SUB- ASSY (SLIDING ROOF ECU) Disconnect the sliding roof ECU connector, and check the voltage or continuity of each terminal of the wire harness side connector. B31361 Symbols (terminal No.) Wire color Condition Specified condition ECUB (S20 - 5) - Body ground B⇔ - Constant 10 to 14 V B (S20 - 7) - Body ground L⇔ - Constant 10 to 14 V E (S20 - 7) - Body ground W-B⇔ - Constant Continuity If the result is not as specified, there may be a malfunction on the wire harness. Author
: Date
: 3707 75-4 ENGINE HOOD/DOOR - FRONT DOOR 750GT-04 ADJUSTMENT HINT:


Before adjusting the door position for vehicles equipped with side airbags and curtain shield airbags, be sure to disconnect the battery. After adjustment, inspect the SRS warning lamp, the side airbag system and the curtain shield airbag system for normal operation. Then initialize both airbag systems. Use the same procedure for the RH side and LH side. The procedures listed below are for the LH side.

Centering Bolt Centering bolts are used to mount the door hinge to the vehicle body and door. The door cannot be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (w/ washers) when making adjustments. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). Standard Bolt B79352 1. (a) INSPECT FRONT DOOR PANEL SUB-ASSY LH Check that the value is within the standard value. Standard C B A: 3.0 to 6.0 mm (0.118 to 0.236 in.) B: 3.8 to 6.8 mm (0.150 to 0.268 in.) C: 3.8 to 6.8 mm (0.150 to 0.268 in.) D: 3.5 to 6.5 mm (0.138 to 0.256 in.) E: 3.5 to 6.5 mm (0.138 to 0.256 in.) D A E B51625 2. (a) ADJUST FRONT DOOR PANEL SUB-ASSY LH Disconnected the negative (-) terminal cable from the battery. CAUTION: Work must be started 90 seconds after the ignition switch is turned is the ”LOCK” position and the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds from disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3725 75-5 ENGINE HOOD/DOOR Body Side (b) Door Side (c) (d) (e) Body Side (a) - FRONT DOOR Using SST, adjust the door by loosening the body side hinge bolts. SST 09812-00010 Tighten the body side hinge bolts after the adjustment. Torque: 23 N⋅m (235 kgf⋅cm, 17 ft⋅lbf) Adjust the door by loosening the door side hinge bolts. Tighten the door side hinge bolts after the adjustment. Torque: 27 N⋅m (275 kgf⋅cm, 20 ft⋅lbf) Door Side (b) B51540 (f) (g) (h) (i) (j) Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a plastic hammer. Tighten the striker mounting screws again. Torque: 23 N⋅m (235 kgf⋅cm, 17 ft⋅lbf) Connect the negative (-) terminal cable th the battery. Initialize both airbag systems. Inspect the SRS warning lamp (see page 05-1207 ). B51396 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3726 75-3 ENGINE HOOD/DOOR - FRONT DOOR FRONT DOOR 7508N-04 COMPONENTS Front Door Glass Front Door Glass Run Front Door Outside Handle Front Door Outside Front Door Key Cylinder Handle Frame Front Door Outside Handle Cover Front Door Belt Moulding Front Door Outside Handle Rear Pad Front Door Outside Handle Pad Front Door Frame RR LWR 8.0 (82, 71 in.·lbf) 5.0 (51, 44 in.·lbf) Outer Rear View Mirror Front Door Lock Assy 23 (235, 17) 5.5 (56, 49 in.·lbf) Front Door Window Regulator 27 (275, 20)
Front Door Service Hole Cover 5.5 (56, 49 in.·lbf) Front Door Inside Handle Front Door Inside Handle Bezel Front Door Lower Frame Bracket Garnish Power Window Regulator Master Switch 11 (112, 8) 5.4 (54, 48 in.·lbf) Door Pull Handle Power Window Regulator Motor Front Door Trim Board B67989 B52498 N⋅m (kgf⋅cm, in.⋅lbf) : Specified torque
Non-reusable part B78827 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3724 75-6 ENGINE HOOD/DOOR - FRONT DOOR 750UG-03 OVERHAUL HINT:
The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ).


1. (a) Clip Claw REMOVE MULTIPLEX NETWORK MASTER SWITCH ASSY Using a screwdriver, disengage the 5 claws and clip, remove the power window regulator master switch. HINT: Tape the screwdriver tip before use. (b) Disconnect the connector. Claw B64830 Clip 2. (a) REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH Using a screwdriver, disengage the claw and clip, remove the front door lower frame bracket garnish. HINT: Tape the screwdriver tip before use. Claw B51384 3. (a) Clip REMOVE DOOR PULL HANDLE Using a screwdriver, disengage the 2 clips and remove the door pull handle. HINT: Tape the screwdriver tip before use. B51528 4. (a) (b) REMOVE FRONT DOOR INSIDE HANDLE BEZEL LH Remove the screw. Using a screwdriver, disengage the 3 claws and remove the door inside handle bezel. HINT: Tape the screwdriver tip before use. :Claw B52219 B78829 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3727 75-7 ENGINE HOOD/DOOR 5. (a) (b) - FRONT DOOR REMOVE FRONT DOOR TRIM BOARD SUB-ASSY LH Remove the clip and screw. Using a screwdriver, disengage the 7 clips and remove the trim board. HINT: Tape the screwdriver tip before use. B51380 6. (a) (b) REMOVE FRONT DOOR INSIDE HANDLE SUB-ASSY LH Remove the bolt and inside handle. Disconnect the 2 cables from the door lock. B51531 7. 8. (a) (b) 9. (a) (b) 10. 11. 12. 13. (a) REMOVE FRONT DOOR SERVICE HOLE COVER LH REMOVE FRONT NO. 2 SPEAKER ASSY Disconnect the connector. Remove the bolt and speaker. REMOVE OUTER REAR VIEW MIRROR ASSY LH Remove the 3 bolts. Disconnect the connector and remove the mirror. REMOVE FRONT NO. 1 SPEAKER ASSY REMOVE FRONT DOOR BELT MOULDING ASSY LH (See page 76-1 1) REMOVE FRONT DOOR GLASS RUN LH REMOVE FRONT DOOR FRAME SUB-ASSY REAR LOWER LH Remove the bolt and door frame rear lower. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) B51532 14. REMOVE FRONT DOOR GLASS SUB-ASSY LH HINT: Insert a shop rag inside the door panel to prevent scratching the glass. (a) Open the door glass until the bolts appear in the service hole. (b) Remove the 2 bolts and door glass. NOTICE: Do not damage the door glass. HINT: Pull the glass upward to remove it. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3728 75-8 ENGINE HOOD/DOOR 15. (a) (b) 16. (a) 17. (a) 18. 19. - FRONT DOOR REMOVE FRONT DOOR WINDOW REGULATOR SUB-ASSY LH Remove the 6 bolts. Disconnect the connector, and then remove the front door window regulator. REMOVE POWER WINDOW REGULATOR MOTOR ASSY LH FRONT Using a torx wrench (T25), remove the 3 screws and motor. APPLY BODY GREASE Apply MP grease to the sliding and rotating parts of the regulator. REMOVE FRONT DOOR LOCK ASSY LH APPLY BODY GREASE 20. (a) (b) (c) B51386 21. (a) A B B52376 (b) (c) (d) REMOVE FRONT DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH Using a torx wrench (T30), remove the 2 screws and door lock cylinder. Pushing the outside handle in the arrow mark direction as shown in the illustration, remove the outside handle and outside handle frame. Using a torx wrench (T30), remove the screw and frame. Torque: 4.0 N⋅m (41 kgf⋅cm, 36 in.⋅lbf) INSTALL FRONT DOOR LOCK ASSY LH Using a torx wrench (T30), install the door lock with the 4 screws. Torque: 5.0 N⋅m (50 kgf⋅cm, 45 in.⋅lbf) for A 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) for B Install the 2 bolts. Connect the links to the outside handle. Connect the connector. 22. INSTALL POWER WINDOW REGULATOR MOTOR ASSY LH FRONT (a) If the jam protection function does not operate properly, perform the following procedure. HINT: It is necessary to reset the power window motor (in the initial position for the limit switch) when separating the window regulator from the power window motor or operating the window regulator with the door glass not installed. (1) Remove the power window motor. HINT: Place the mactchmarks on the power window motor and window regulator gear. (2) Connect the power window motor and power window switch to the wire harness of the vehicle. (3) Turn the ignition switch ON and operate the power window motor in the power window up direction for more than 6 rotations or less than 10 rotations (4 seconds or more) using the power window switch. (4) Assemble the power window motor and regulator. HINT:
Install the motor when the regulator arm is below the middle point.
Align the matchmarks on the power window motor and window regulator gear when installing the power window motor. (5) Assemble the power window regulator and door glass. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3729 75-9 ENGINE HOOD/DOOR - FRONT DOOR HINT: Never rotate the motor in the power window’s down direction until the window glass is completely installed. 23. INSTALL FRONT DOOR WINDOW REGULATOR SUB-ASSY LH (a) Install the window regulator with the 4 bolts. Torque: 11.0 N⋅m (112 kgf⋅cm, 8 ft⋅lbf) 24. INSTALL FRONT DOOR SERVICE HOLE COVER LH (a) Install a new service hole cover to the door panel. HINT:
When installing the service hole cover, pull out the links and connectors through the service hole cover.
There should be no wrinkles or folds after installing the service hole cover.
After installing the service hole cover, check the sealing condition. B51534 25. (a) INSTALL OUTER REAR VIEW MIRROR ASSY LH Install the mirror with the 3 bolts. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3730 75-1 ENGINE HOOD/DOOR - HOOD HOOD 750GS-03 ADJUSTMENT HINT:


Standard Bolt Centering Bolt Use the same procedure for the RH side and LH side. Centering bolts are used to mount the door hinge to the vehicle body and door. The door cannot be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (w/ washers) when making adjustments. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). B77634 1. (a) INSPECT HOOD SUB-ASSY Check that the clearance is within the standard value. Standard A A: 4.0 (0.157) mm (in.) B52500 2. (a) ADJUST HOOD SUB-ASSY Horizontally and vertically adjust the hood. (1) Loosen the hood side hinge bolts. (2) Adjust the clearance so that it will be in the standard value, by moving the hood. (3) Tighten the hood side hinge bolts after the adjustment. Torque: 13 N⋅m (130 kgf⋅cm, 10 ft⋅lbf) B51373 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3722 75-2 ENGINE HOOD/DOOR (b) - HOOD Adjust the height of the hood front end using the cushion rubber. HINT: Raise and lower the cushion rubber by turning it. B51374 (c) Adjust the hood lock. (1) Using a screwdriver, disengage the clips and remove the hood lock release lever cover. HINT: Tape the screwdriver tip before use. Clip B51387 (2) (3) Loosen the 3 bolts. Adjust the hood lock position so that the lock will come in, by moving the lock. (4) Tighten the hood lock bolts after the adjustment. Torque: 7.0 N⋅m (71 kgf⋅cm, 62 in.⋅lbf) B51375 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3723 75-1 1 ENGINE HOOD/DOOR - REAR DOOR 750GU-04 ADJUSTMENT HINT:


Before adjusting the door position for vehicles equipped with side airbags and curtain shield airbags, be sure to disconnect the battery. After adjustment, inspect the SRS warning lamp, the side airbag system and the curtain shield airbag system for normal operation. Then initialize both airbag systems. Use the same procedure for the RH side and LH side. The procedures listed below are for the LH side.

Centering Bolt Centering bolts are used to mount the door hinge to the vehicle body and door. The door cannot be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (w/ washers) when making adjustments. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). Standard Bolt B79352 1. (a) INSPECT REAR DOOR PANEL SUB-ASSY LH Check that the clearance is within the standard value. Standard B C A: 3.5 to 6.5 mm (0.138 to 0.256 in.) B: 3.5 to 6.5 mm (0.130 to 0.256 in.) C: 3.8 to 6.8 mm (0.128 to 0.268 in.) D: 5.8 to 8.8 mm (0.228 to 0.346 in.) E: 3.5 to 6.5 mm (0.138 to 0.256 in.) D A E B51626 2. (a) ADJUST REAR DOOR PANEL SUB-ASSY LH Disconnected the negative (-) terminal cable from the battery. CAUTION: Work must be started 90 seconds after the ignition switch is turned is the ”LOCK” position and the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds from disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3732 75-12 ENGINE HOOD/DOOR Body Side (b) (c) Door Side (d) (e) Body Side (a) - REAR DOOR Adjust the door by loosening the body side hinge nuts. Tighten the body side hinge nuts after the adjustment. Torque: 26 N⋅m (272 kgf⋅cm, 18 ft⋅lbf) Adjust the door by loosening the door side hinge bolts. Tighten the door side hinge bolts after the adjustment. Torque: 27 N⋅m (275 kgf⋅cm, 20 ft⋅lbf) Door Side (b) B51541 (f) (g) (h) (i) (j) Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a plastic hammer. Tighten the striker mounting screws again. Torque: 23 N⋅m (235 kgf⋅cm, 17 ft⋅lbf) Connect the negative (-) terminal cable to the battery. Initialize both airbag systems. Check the SRS warning lamp (see page 05-1207 ). B51397 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3733 75-10 ENGINE HOOD/DOOR - REAR DOOR REAR DOOR 7508O-04 COMPONENTS Rear Door Glass Rear Door Quarter Rear Door Rear Door Outside Window Glass Outside Handle Handle Cover Rear Door Window Division Bar Rear Door Outside Handle Rear Pad Rear Door Outside Rear Door Outside Handle Frame Handle Pad Rear Door Inside Handle Rear Door Glass Run Rear Door Lock Assembly 5.0 (51, 44 in.·lbf) Rear Door Belt Moulding 5.5 (56, 49 in.⋅lbf) 23 (235, 17) Rear Door Window Regulator 27 (275, 20) 11 (112, 8) 26 (272, 18) 5.4 (54, 48 in.·lbf) 27 (275, 20) Rear Door Inside Handle Bezel Door Pull Handle Power Window Regulator Motor
Rear Door Service Hole Cover Rear Trim Board N⋅m (kgf⋅cm, in.⋅lbf) : Specified torque
Non-reusable part B52499 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3731 75-13 ENGINE HOOD/DOOR - REAR DOOR 7501X-05 OVERHAUL HINT:
The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ).


1. (a) Clip REMOVE DOOR PULL HANDLE Using a screwdriver, disengage the 2 clips and remove the door pull handle. HINT: Tape the screwdriver tip before use. B51528 2. (a) (b) REMOVE REAR DOOR INSIDE HANDLE BEZEL LH Remove the screw. Using a screwdriver, disengage the 3 claws and remove the door inside handle bezel. 3. (a) (b) REMOVE REAR DOOR TRIM BOARD SUB-ASSY LH Remove the screw. Using a screwdriver, disengage the 7 clips and remove the trim board, and then disconnect the connector. : Claw B78829 B52219 HINT: Tape the screwdriver tip before use. : Clip B51388 B78830 4. (a) (b) REMOVE REAR DOOR INSIDE HANDLE SUB-ASSY LH Remove the bolt. Remove the inside handle, and then disconnect the 2 cables from the rear door lock. Claw B51531 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3734 75-14 ENGINE HOOD/DOOR 5. 6. (a) (b) 7. 8. - REAR DOOR REMOVE REAR DOOR SERVICE HOLE COVER LH REMOVE REAR SPEAKER ASSY Remove the 3 bolts. Disconnect the connector and remove the rear speaker. REMOVE REAR DOOR BELT MOULDING ASSY LH (See page 76-12 ) REMOVE REAR DOOR GLASS RUN LH 9. (a) REMOVE REAR DOOR WINDOW DIVISION BAR SUB-ASSY LH Remove the 2 bolts, screw and division bar. B51530 10. REMOVE REAR DOOR QUARTER WINDOW GLASS LH B51435 12. (a) 13. (a) 14. (a) 11. REMOVE REAR DOOR GLASS SUB-ASSY LH HINT: Insert a shop rag inside the door panel to prevent scratching the glass. (a) Open the door glass. (b) Tilt the door glass and disconnect the roller of the regulator from the glass channel to remove the door glass. NOTICE: Do not damage the door glass. HINT: Pull the glass upward to remove it. REMOVE REAR DOOR WINDOW REGULATOR SUB-ASSY LH Remove the 4 bolts and window regulator. REMOVE POWER WINDOW REGULATOR MOTOR ASSY LH Using a torx driver (T25), remove the 3 screws and motor. APPLY BODY GREASE Apply MP grease to the sliding and rotating parts of the regulator. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3735 75-15 ENGINE HOOD/DOOR 15. (a) (b) (c) (d) - REAR DOOR REMOVE REAR DOOR LOCK ASSY LH Disconnect the connectors. Disconnect the links from the rear door outside handle. Remove the bolt. Using a torx socket wrench (T30), remove the 4 screws and rear door lock. B52377 16. (a) APPLY BODY GREASE Apply MP grease to the sliding and rotating parts of the door lock. 17. (a) (b) (c) B51386 (d) 18. (a) A B B52377 19. (a) 20. (a) (b) (c) (d) REMOVE REAR DOOR OUTSIDE HANDLE FRAME SUB-ASSY LH Using a torx socket wrench (T30), remove the 2 screws. Using a screwdriver, pry out the rear outside handle cover. Pushing the outside handle in the arrow mark direction as shown in the illustration, remove the outside handle and outside handle frame. Using a torx socket wrench (T30), remove the screw and frame. Torque: 4.0 N⋅m (41 kgf⋅cm, 36 in.⋅lbf) INSTALL REAR DOOR LOCK ASSY LH Using a torx socket wrench (T30), install the rear door lock with the 4 screws. Torque: 5.0 N⋅m (50 kgf⋅cm, 44 in.⋅lbf) for A 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) for B Install the bolts. Connect the links to the rear outside handle. Connect the connectors. INSTALL POWER WINDOW REGULATOR MOTOR ASSY LH Using a torx driver (T25), install the regulator motor with the 3 screws. Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) INSTALL REAR DOOR WINDOW REGULATOR SUB-ASSY LH Install the window regulator with the 4 bolts. Torque: 11.0 N⋅m (112 kgf⋅cm, 8 in.⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3736 75-16 ENGINE HOOD/DOOR B51537 - REAR DOOR 21. INSTALL REAR DOOR SERVICE HOLE COVER LH (a) Install a new service hole cover to the door panel. HINT:
When installing the service hole cover, pull out the links and connectors through the service hole cover.
There should be no wrinkles or folds after attaching the service hole cover.
After attaching the service hole cover, check the sealing condition. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3737 75-23 ENGINE HOOD/DOOR - BACK DOOR STAY ASSY LH 75022-04 DISPOSAL 1. (a) (b) a A b B B65104 DISPOSE OF BACK DOOR STAY ASSY LH Horizontally fix the stay in a vise with the piston-rod pulled out. Wearing safety glasses, gradually cut a part between A and B (shown in the illustration) using a metal saw to gradually release the gas. Specification: Area Measurement a 80 mm (3.15 in.) b 20 mm (0.80 in.) CAUTION: Be careful to cover the area that is being cut as there is a possibility that metal debris could be blown out by the gas (the gas is colorless, odorless and harmless). 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3744 75-22 ENGINE HOOD/DOOR - BACK DOOR STAY ASSY LH BACK DOOR STAY ASSY LH 75021-04 REPLACEMENT HINT:



The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring addition information are included. Use the same procedures for the RH side and LH side. The procedures listed below are for the LH side. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). 1. (a) REMOVE BACK DOOR STAY ASSY LH Remove the 4 bolts and back door stay from the back door panel. HINT: While supporting the back door by hand, remove the back door stay. B51401 2. (a) INSTALL BACK DOOR STAY ASSY LH Install the back door stay with the 4 bolts. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3743 75-18 ENGINE HOOD/DOOR - BACK DOOR 7501Z-04 ADJUSTMENT HINT:

Centering Bolt Standard Bolt Centering bolts are used to mount the door hinge to the vehicle body and door. The door cannot be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (w/ washers) when making adjustments. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). B77635 1. (a) INSPECT BACK DOOR PANEL SUB-ASSY Check that the clearance is within the standard value. A: 5.9 to 8.9 mm (0.232 to 0.350 in.) B: 5.8 to 8.8 mm (0.228 to 0.346 in.) C: 3.8 to 6.8 mm (0.150 to 0.268 in.) D: 2.5 to 0.5 mm (0.039 to 0.059 in.) Standard A C D B B51542 B79656 2. (a) (b) (c) (d) B51377 ADJUST BACK DOOR PANEL SUB-ASSY Adjust the door by loosening the door side hinge bolts. Tighten the door side hinge bolts after the adjustment. Torque: 8.0 N⋅m (82 kgf⋅cm, 71 in.⋅lbf) for door side Adjust the door by loosening the body side hinge nuts. Tighten the body side hinge nuts after the adjustment. Torque: 19.5 N⋅m (199 kgf⋅cm, 14 ft⋅lbf) for body side 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3739 75-19 ENGINE HOOD/DOOR (e) (f) (g) - BACK DOOR Check that the door fit and door linkage are adjusted correctly. Adjust the striker by loosening the striker mounting screws. Torque: 23 N⋅m (235 kgf⋅cm, 17 ft⋅lbf) Using a plastic hammer, tap the striker for adjustment. B51437 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3740 75-17 ENGINE HOOD/DOOR - BACK DOOR BACK DOOR 7508P-04 COMPONENTS Back Window Panel Upper Trim 8.0 (82, 71 in.·lbf) 8.0 (82, 71 in.·lbf) Back Door Trim Cover 19.5 (199, 14) 5.5 (56, 49 in.·lbf) Back Door Key Cylinder 19.5 (199, 14) Back Door Cylindrer to Lock Control Link 5.5 (56, 49 in.·lbf) Back Door Trim Panel Assist Strap Back Door Lock Assist Strap Cover Back Door Outside Handle 12.5 (128, 9) Back Door Outside Garnish N⋅m (kgf⋅cm, in.⋅lbf) : Specified torque B52258 B78828 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3738 75-20 ENGINE HOOD/DOOR - BACK DOOR 75020-04 OVERHAUL HINT:

The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). 1. (a) Clip REMOVE BACK WINDOW PANEL TRIM UPPER Using a screwdriver, disengage the 4 clips and remove the trim. HINT: Tape the screwdriver tip before use. B51398 2. (a) Clip REMOVE BACK DOOR TRIM COVER RH Using a screwdriver, disengage the 3 clips and remove the trim. HINT: Tape the screwdriver tip before use. B51399 3. REMOVE BACK DOOR TRIM COVER LH HINT: Use the same procedures described for the RH side. 4. (a) (b) (c) Clip REMOVE BACK DOOR TRIM PANEL ASSY Remove the assist strap cover. Remove the bolt and assist strap. Using a screwdriver, disengage the 16 clips and remove the back door trim panel. HINT: Tape the screwdriver tip before use. B51400 5. w/ Rear spoiler: REMOVE REAR SPOILER (See page 76-8 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3741 75-21 ENGINE HOOD/DOOR 6. (a) (b) (c) 7. (a) 8. (a) 9. 10. (a) 11. (a) 12. - BACK DOOR REMOVE BACK DOOR LOCK ASSY Disconnect the control cable from the outside handle. Disconnect the back door cylinder to lock control link from the key cylinder. Remove the 3 bolts and the lock control. REMOVE BACK DOOR LOCK CYLINDER ASSY Remove the 2 bolts and cylinder. REMOVE BACK DOOR HANDLE ASSY OUTSIDE Remove the 2 nuts and outside handle. REMOVE LUGGAGE COMPARTMENT DOOR GARNISH SUB-ASSY OUTSIDE (See page 76-13 ) INSTALL BACK DOOR HANDLE ASSY OUTSIDE Install the outside handle with the 2 nuts. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) for B INSTALL BACK DOOR LOCK CYLINDER ASSY Install the cylinder with the 2 bolts. Torque: 5.5 N⋅m (56 kgf⋅cm, 49 in.⋅lbf) for B INSTALL BACK DOOR LOCK ASSY Torque: 12.5 N⋅m (128 kgf⋅cm, 9 ft⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3742 76-8 EXTERIOR/INTERIOR TRIM - REAR SPOILER REAR SPOILER 7602Y-03 REPLACEMENT 1. REMOVE BACK WINDOW PANEL TRIM UPPER (See page 75-20 ) 2. (a) (b) Clip Adhesive Tape B51573 REMOVE REAR SPOILER Remove the 2 bolts and nut. Using a heat light, heat the body and rear spoiler to 40 to 60C (104 to 140F). NOTICE: Do not heat the rear spoiler excessively. (c) Tie both piano wire ends to a wooden block or a similar object. (d) Scrape the adhesive tape off by pulling the piano wire. NOTICE:
If reusing the rear spoiler, take care not to damage the rear spoiler.
Do not damage the body. (e) Remove the rear spoiler. 3. INSTALL REAR SPOILER (a) Using a heat light, heat the body and rear spoiler surface to 40 to 60C (104 to 140F). NOTICE: Do not heat the body and rear spoiler excessively. (b) Remove the adhesive tape from the body. (c) Wipe off the stains with cleaner. (d) If reusing the rear spoiler: Clean the rear spoiler . (1) Using a heat light, heat the body and rear spoiler to 20 to 30C (68 to 86F). NOTICE: Do not heat the body and rear spoiler excessively. (2) Remove the adhesive tape from the rear spoiler. (3) Wipe off the stains with cleaner. (4) (e) Apply new adhesive tape to the rear spoiler as shown in the illustration. Using a heat light, heat the body and rear spoiler. Heating temperature: Body 40 to 60C (104 to 140F) Moulding 20 to 30C (68 to 86F) NOTICE: Do not heat the body and rear spoiler excessively. Adhesive Tape B51574 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3752 76-9 EXTERIOR/INTERIOR TRIM - REAR SPOILER (f) Lift the rear spoiler and release the release sheet from the surface of the rear spoiler. NOTICE:
When the rear spoiler release sheet is removed, take care that no dirt or no dust can get onto the uncoated area.
Do not apply excessive force onto the rear spoiler but steady pressure with your thumbs. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3753 76-1 1 EXTERIOR/INTERIOR TRIM - FRONT DOOR BELT MOULDING ASSY LH FRONT DOOR BELT MOULDING ASSY LH 76026-07 REPLACEMENT HINT:

1. 2. 3. 4. The installation procedures are the removal procedures in reverse order. Use the same procedures for the RH side and LH side. REMOVE POWER WINDOW REGULATOR SWITCH ASSY (See page 75-6 ) REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH (See page 75-6 ) REMOVE DOOR PULL HANDLE (See page 75-6 ) REMOVE FRONT DOOR TRIM BOARD SUB-ASSY LH (See page 75-6 ) 5. (a) (b) (c) Protective Tape REMOVE FRONT DOOR BELT MOULDING ASSY LH Remove the screw. Put protective tape under the moulding. Using a moulding remover or scraper, remove the moulding. B51648 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3755 76-12 EXTERIOR/INTERIOR TRIM - REAR DOOR BELT MOULDING ASSY LH REAR DOOR BELT MOULDING ASSY LH 7602A-06 REPLACEMENT HINT:

1. 2. The installation procedures are the removal procedures in reverse order. Use the same procedures for the RH side and LH side. REMOVE DOOR PULL HANDLE (See page 75-13 ) REMOVE REAR DOOR TRIM BOARD SUB-ASSY LH (See page 75-13 ) 3. (a) (b) (c) Protective Tape REMOVE REAR DOOR BELT MOULDING ASSY LH Remove the screw. Put protective tape under the moulding. Using a moulding remover or scraper, remove the moulding. B51644 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3756 76-10 EXTERIOR/INTERIOR TRIM - NAME PLATE NAME PLATE 76025-07 REPLACEMENT (LH) (RH) 68.5 (2.701) 66 (2.60) 66 (2.60) 40.5 (1.594) 68.5 (2.697) 40.5 (1.594) (3MZ-FE 4WD) 107.4 (4.228) 43.5 (1.713) 33.9(1.335) 28.8 (1.134) 118.1 (4.650) 74.4 (2.960) 75.2 (2.960) 269 (10.59) (4WD) 71.5 (2.815) 74.4(2.929) 67(2.64) (3MZ-FE) 251.8 (9.913) 88 (3.46) 268.3 (10.563) 74.3 (2.925) mm (in.) B51620 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3754 76-16 EXTERIOR/INTERIOR TRIM - ROOF DRIP SIDE FINISH MOULDING CENTER LH ROOF DRIP SIDE FINISH MOULDING CENTER LH 7602B-07 REPLACEMENT HINT:

The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated. On the RH side, use the same procedures as on the LH side. 1. REMOVE ROOF DRIP SIDE FINISH MOULDING CENTER LH (a) Cover the circumference of the moulding with protective tape for protection. (b) Using a remover for the roof moulding, release the engagements of the clips in both front and rear ends of the moulding, and then remove the moulding. NOTICE:
Do not remove the clips. B51649
In case that the clips are damaged or removed accidentally, exchange them for supplied ones. 2. INSTALL ROOF DRIP SIDE FINISH MOULDING CLIP NO.2 NOTICE: Only when exchanging the clips. (a) Remove the adhesive tape that remains on the mounting surface of the body, and then clean the surface with white gasoline. (b) Using a heat light, heat up the clip installation surfaces of the body and moulding. Heating temperature: Protective Tape Body 40 to 60C (104 to 140F) Moulding 20 to 30C (68 to 86F) NOTICE: Do not heat the body and moulding excessively. (c) Set the supplied clips into the positions as shown in the illustration, and press-fit those clips by hand to install them. (d) Install the moulding when 30 minutes or more have passed after press-fitting the clips. HINT:
Initial hardening time: 30 minutes
Prefect hardening time: 24 hours 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3760 76-17 EXTERIOR/INTERIOR TRIM - ROOF DRIP SIDE FINISH MOULDING CENTER LH Rear Side Front Side 2093 (82.4) 1836 (72.28) 1496 (58.9) 1185 (46.65) 874 (34.41) 558 (21.97) 293 (11.54) 63 (2.48) Roof Drip Side Finish Moulding Clip No.2 mm (in.) B51650 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3761 EXTERIOR/INTERIOR TRIM - LUGGAGE COMPARTMENT DOOR GARNISH SUB-ASSY OUTSIDE 76-13 LUGGAGE COMPARTMENT DOOR GARNISH SUB-ASSY OUTSIDE 76027-07 REPLACEMENT 1. REMOVE BACK WINDOW PANEL TRIM UPPER (See page 75-20 ) 2. REMOVE BACK DOOR TRIM COVER RH (See page 75-20 ) 3. REMOVE BACK DOOR TRIM COVER LH (See page 75-20 ) 4. REMOVE BACK DOOR TRIM PANEL ASSY (See page 75-20 ) 5. REMOVE REAR SPOILER (W/ REAR SPOILER) (See page 75-20 ) 6. REMOVE BACK DOOR LOCK ASSY (See page 75-20 ) 7. REMOVE BACK DOOR HANDLE ASSY OUTSIDE (See page 75-20 ) 8. REMOVE LUGGAGE COMPARTMENT DOOR GARNISH SUB-ASSY OUTSIDE (a) Remove the screws and the 2 licence plate lights. (b) Remove the nut and garnish. 9. INSTALL LUGGAGE COMPARTMENT DOOR NAME PLATE NO.1 (a) Using white gasoline, clean the garnish installation surface. (b) Using a heat light, heat the garnish and name plate to 20 to 30
C (68 to 86
F). (c) Install the name plate. NOTICE: Do not heat the garnish and name plate excessively. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3757 76-14 EXTERIOR/INTERIOR TRIM - OUTSIDE MOULDING OUTSIDE MOULDING 7615W-01 REPLACEMENT HINT:

The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. Use the same procedures for the RH side and LH side. 1. (a) Protective Tape B51665 REMOVE OUTSIDE MOULDING Using a heat light, heat the body and moulding to 40 to 60C (104 to 140F). NOTICE: Do not heat the body and moulding excessively. (b) Tie both piano wire ends to a wooden block or a similar object. (c) Scrape the adhesive tape off by pulling the piano wire as shown in the illustration. NOTICE:
If reusing the moulding, take care not to damage the moulding.
Do not damage the body. 2. INSTALL OUTSIDE MOULDING (a) Using a heat light, heat the body mounting surface to 40 to 60C (104 to 140F). NOTICE: Do not heat the body excessively. (b) Remove the protective tape from the body. (c) Wipe off the stains with cleaner. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3758 76-15 EXTERIOR/INTERIOR TRIM - OUTSIDE MOULDING (d) Clean the moulding (if reusing the moulding). (1) Using a heat light, heat the body and moulding to 20 to 30C (68 to 86F). NOTICE: Do not heat the body and moulding excessively. (2) Remove the double-sided tape from the moulding. (3) Wipe off the stains with cleaner. (4) Apply new double-sided tape to the moulding as shown in the illustration. Double-sided Tape Boss B51667 (e) Using a heat light, heat the body and moulding. Heating temperature: Body 40 to 60C (104 to 140F) Moulding 20 to 30C (68 to 86F) NOTICE: Do not heat the body and moulding excessively. (f) Remove the peeling paper from the moulding face. NOTICE: When the peeling paper is removed, take care that dirt or dust do not stick to the adhesive area. (g) Attach the moulding securely to the body, as shown in the illustration. NOTICE: Do not apply excessive force onto the moulding, but steady pressure with your thumbs. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3759 76-1 EXTERIOR/INTERIOR TRIM - FRONT BUMPER FRONT BUMPER 7616V-02 COMPONENTS Front Fender Splash Shield Sub-assy RH 77 (780, 57) Front Bumper Reinforcement Front Fender Splash Shield Sub-assy LH Front Bumper Energy Absorber Radiator Grille Front Bumper Cover w/o Fog Lamp: Front Bumper Hole Cover RH 5.5 (55, 49 in.⋅lbf) w/o Fog Lamp: Front Bumper Hole Cover LH w/ Fog Lamp w/ Fog Lamp Fog Lamp Assy RH Fog Lamp Assy LH N⋅m (kgf⋅cm, ft⋅lbf) : Specified torque B74709 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3745 76-2 EXTERIOR/INTERIOR TRIM - FRONT BUMPER 7616W-01 REPLACEMENT HINT:

The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). 1. (a) Clip A Clip B Clip B Clip Claw REMOVE RADIATOR GRILLE Using a screwdriver, disengage the 4 claws and remove the 4 clips labeled A, 2 clips labeled B and grille. HINT: Tape the screwdriver tip before use. Claw B74702 2. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSY LH Remove the screw and 3 clips. Partially remove the fender liner. (a) (b) HINT: It is not necessary to fully remove the fender liner completely. Partially remove it so that the bumper cover can be removed in step (4). B74703 3. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSY RH HINT: Use the same procedure described for the LH side. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3746 76-3 EXTERIOR/INTERIOR TRIM Claw Claw 4. (a) (b) (c) - FRONT BUMPER REMOVE FRONT BUMPER COVER Put protective tape under the front fender. Remove the 6 screws. Using a screwdriver, disengage the 2 claws and remove the bumper cover. HINT: Tape the screwdriver tip before use. (d) w/ Fog lamp: Disconnect the 2 connectors. Protective Tape B74704 5. REMOVE FRONT BUMPER ENERGY ABSORBER 6. (a) REMOVE FRONT BUMPER REINFORCEMENT Remove the 6 bolts and reinforcement. B74705 7. 8. 9. REMOVE FOG LAMP ASSY LH (W/ FOG LAMP) REMOVE FOG LAMP ASSY RH (W/ FOG LAMP) REMOVE FRONT BUMPER HOLE COVER (W/O FOG LAMP) 10. (a) INSTALL FRONT BUMPER REINFORCEMENT Install the reinforcement with the 6 bolts. Torque: 77 N⋅m (780 kgf⋅cm, 57 ft⋅lbf) B74705 11. (a) INSTALL FRONT BUMPER COVER Install the bumper cover with the 6 screws. Torque: 5.5 N⋅m (55 kgf⋅cm, 49 in.⋅lbf) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3747 76-4 EXTERIOR/INTERIOR TRIM - REAR BUMPER REAR BUMPER 7616X-01 COMPONENTS Rear Bumper Side Retainer RH 3.0 (31, 27 in.⋅lbf) Rear Floor Finish Plate Rear Bumper Side Retainer LH 3.0 (31, 27 in.⋅lbf) Rear Bumper Support No. 1 Rear Bumper Side Mounting Bracket RH Rear Bumper Reinforcement No. 1 Rear Bumper Support No. 1 27 (275, 20) Rear Bumper Side Mounting Bracket LH w/ Quarter Panel Mudguard Sub-assy RH Rear Bumper Bar Rear Bumper Bar RH Rear Bumper Side Support RH Rear Bumper Rear Bumper Bar LH Energy Absorber 8.0 (85, 71 in.⋅lbf) Rear Bumper Side Support LH 3.0 (31, 27 in.⋅lbf) w/ Quarter Panel Mudguard Sub-assy LH 3.0 (31, 27 in.⋅lbf) N⋅m (kgf⋅cm, ft⋅lbf) Rear Bumper Cover : Specified torque B74710 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
: Date
: 3748 76-5 EXTERIOR/INTERIOR TRIM - REAR BUMPER 7616Y-01 REPLACEMENT HINT:

1. 2. The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). REMOVE DECK FLOOR BOX FRONT REMOVE DECK FLOOR BOX REAR Clip C 3. (a) Clip A HINT: Tape the screwdriver tip before use. Clip B Clip A REMOVE REAR FLOOR FINISH PLATE Using a screwdriver, remove the 2 clips labeled A and 2 clips labeled B, 4 clips labeled C and finish plate. Clip B Clip C B74706 4. (a) REMOVE QUARTER PANEL MUDGUARD SUB-ASSY REAR LH (W/ MUDGUARD) Remove the 3 clips, screw and mudguard. B52221 5. REMOVE QUARTER PANEL MUDGUARD SUB-ASSY REAR RH (W/ MUDGUARD) HINT: Use the same procedure described for the LH side. 6. (a) REMOVE REAR BUMPER COVER Put protective tape under the quarter panel. Protective Tape B78873 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3749 76-6 EXTERIOR/INTERIOR TRIM (b) (c) - REAR BUMPER Remove the 6 screws, 4 nuts and 2 clips. Using a screwdriver, disengage the claw labeled A, 4 claws labeled B and bumper cover. HINT: Tape the screwdriver tip before use. Claw B Claw A B74707 7. REMOVE REAR BUMPER ENERGY ABSORBER 8. (a) REMOVE REAR BUMPER REINFORCEMENT NO.1 Remove the 6 nuts and reinforcement. B74708 9. 10. 11. 12. (a) 13. (a) 14. 15. (a) 16. (a) 17. 18. 19. (a) REMOVE REAR BUMPER BAR REMOVE REAR BUMPER BAR LH REMOVE REAR BUMPER BAR RH REMOVE REAR BUMPER SIDE RETAINER LH Remove the 3 screws and side retainer. REMOVE REAR BUMPER SIDE RETAINER RH Remove the 3 screws and side retainer. REMOVE REAR BUMPER SUPPORT NO.1 REMOVE REAR BUMPER SIDE MOUNTING BRACKET LH Remove the screw and bracket. REMOVE REAR BUMPER SIDE MOUNTING BRACKET RH Remove the screw and bracket. REMOVE REAR BUMPER SIDE SUPPORT LH REMOVE REAR BUMPER SIDE SUPPORT RH INSTALL REAR BUMPER SIDE MOUNTING BRACKET LH Install the bracket with the screw. Torque: 3.0 N⋅m (31 kgf⋅cm, 27 in.⋅lbf) INSTALL REAR BUMPER SIDE MOUNTING BRACKET RH 20. HINT: Use the same procedure described for the LH side. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3750 76-7 EXTERIOR/INTERIOR TRIM 21. (a) 22. (a) (b) 23. (a) - REAR BUMPER INSTALL REAR BUMPER REINFORCEMENT NO.1 Install the reinforcement with the 6 nuts. Torque: 27 N⋅m (275 kgf⋅cm, 20 ft⋅lbf) INSTALL REAR BUMPER COVER Engage the 10 claws. Install the bumper cover with the 2 clips, 6 screws and 4 nuts. Torque: 3.0 N⋅m (31 kgf⋅cm, 27 in.⋅lbf) for bolt Torque: 8.0 N⋅m (85 kgf⋅cm, 71 in.⋅lbf) for nut INSTALL QUARTER PANEL MUDGUARD SUB-ASSY REAR LH (W/ MUDGUARD) Install the mudguard with the 3 clips and bolt. Torque: 3.0 N⋅m (31 kgf⋅cm, 27 in.⋅lbf) INSTALL QUARTER PANEL MUDGUARD SUB-ASSY REAR RH (W/ MUDGUARD) 24. HINT: Use the same procedure described for the LH side. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3751 76-18 EXTERIOR/INTERIOR TRIM - ROOF HEADLINING ASSY ROOF HEADLINING ASSY 7616Z-01 COMPONENTS w/ Sliding Roof Roof Silencer Pad No. 1 Sun Roof Opening Trim Moulding Roof Silencer Pad No. 4 Roof Silencer Pad No. 5 Roof Headlining Assy Roof Silencer Pad No. 4 Roof Silencer Pad No. 5 Roof Silencer Pad No. 1 w/o Sliding Roof only: Roof Silencer Pad No. 2 Assist Grip Sub-assembly Room Lamp Assy No.2 Roof Headlining Assy RH Visor Assy Assist Grip Sub-assy Room Lamp Assy No. 1 Visor Holder Roof Console Box Assy Visor Holder LH Visor Assy B77744 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3762 76-19 EXTERIOR/INTERIOR TRIM - ROOF HEADLINING ASSY Rear Floor Finish Plate Tonneau Cover Assy Back Door Weatherstrip Deck Board Sub-assy No. 2 Rear Door Opening Trim Weatherstrip RH Quarter Pillar Garnish RH Front Door Opening Trim Weatherstrip RH Roof Side Rail Garnish Assy RH Deck Board Sub-assy No. 3 Deck Board Sub-assy Center Pillar Garnish RH Front Pillar Garnish RH Roof Side Garnish Assy Inner RH Deck Side Trim Box RH Deck Floor Box Rear Deck Trim Side Panel Assy RH Rear No. 1 Seat Outer Belt Assy RH 42 (420, 31) Front Door Scuff Plate RH Rear Door Scuff Plate RH Center Pillar Garnish Lower RH Front Seat Outer Belt Assy RH Deck Side Trim Box LH Roof Side Rail Garnish Assy LH Roof Side Garnish Assy Inner LH Rear No. 1 Seat Outer Belt Assy LH 42 (420, 31) Front Pillar Garnish LH Quarter Pillar Garnish LH Deck Floor Box Front Center Pillar Garnish LH Front Seat Outer Belt Assy LH Deck Trim Side Panel Assy LH Front Door Opening Trim Weatherstrip LH Rear Door Scuff Plate LH Front Door Scuff Plate LH Center Pillar Garnish Lower LH N⋅m (kgf⋅cm, ft⋅lbf) Rear Door Opening Trim Weatherstrip LH : Specified torque B77611 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3763 76-20 EXTERIOR/INTERIOR TRIM - ROOF HEADLINING ASSY w/ Rear No. 2 Seat Rear Floor Finish Plate Deck Board Sub-assy No.2 Roof Side Rail Garnish Sub-assy RH Roof Side Garnish Assy Inner RH Rear No. 2 Seat Outer Belt Assy RH Deck Board Sub-assy Deck Side Trim Box RH Quarter Pillar Garnish RH Deck Board Sub-assy No.3 Deck Floor Box Rear 42 (420, 31) Roof Side Rail Garnish Sub-assy LH Rear No. 2 Seat Outer Belt Assy LH Deck Side Trim Box LH Deck Trim Side Panel Assy RH Roof Side Garnish Assy Inner LH Quarter Pillar Garnish LH Rear Door Scuff Plate RH Rear Door Scuff Plate LH N⋅m (kgf⋅cm, ft⋅lbf) Deck Trim Side Panel Assy LH : Specified torque B77612 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3764 76-21 EXTERIOR/INTERIOR TRIM - ROOF HEADLINING ASSY 76170-01 REPLACEMENT HINT:

1. The installation procedures are the removal procedures in reverse order. However, only installation procedures requiring additional information are included. A bolt without a torque specification is shown in the standard bolt chart (see page 03-2 ). REMOVE TONNEAU COVER ASSY 2. (a) w/o Rear No. 2 Seat REMOVE DECK BOARD SUB-ASSY Using a screwdriver, disengage the 5 clips, 2 bolts and deck board. HINT: Tape the screwdriver tip before use. w/ Rear No. 2 Seat Clip B51632 B77333 3. 4. B78481 REMOVE DECK BOARD SUB-ASSY NO.2 REMOVE DECK BOARD SUB-ASSY NO.3 5. Clip Clip (a) REMOVE REAR SEAT RECLINING COVER NO.2 RH (w/ REAR NO. 2 SEAT) Using a screwdriver, disengage the 2 clips and remove the bolt and cover. HINT: Tape the screwdriver tip before use. B78269 6. REMOVE REAR SEAT RECLINING COVER NO.2 LH (w/ REAR NO. 2 SEAT) HINT: Use the same procedures described for the LH side. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3765 76-22 EXTERIOR/INTERIOR TRIM - ROOF HEADLINING ASSY 7. REMOVE DECK FLOOR BOX REAR (a) Using a screwdriver, remove the 2 clips and box rear. HINT: Tape the screwdriver tip before use. Clip Clip B77336 8. REMOVE DECK FLOOR BOX FRONT (w/o REAR NO. 2 SEAT) Clip A 9. (a) Clip B Clip A REMOVE REAR FLOOR FINISH PLATE Using a screwdriver, remove the 2 clips labeled A, 4 clips labeled B and finish plate. HINT: Tape the screwdriver tip before use. B77334 10. 11. 12. 13. 14. REMOVE DECK SIDE TRIM BOX LH REMOVE DECK SIDE TRIM BOX RH REMOVE REAR NO.1 SEAT ASSY LH (See page 72-28 , 72-44 ) REMOVE REAR NO.1 SEAT ASSY RH (See page 72-35 , 72-54 ) REMOVE REAR NO.2 SEAT ASSEMBLY (w/ REAR NO. 2 SEAT) (See page 72-61 ) 15. (a) Claw C REMOVE FRONT DOOR SCUFF PLATE LH Using a screwdriver, disengage the 4 claws labeled A, 2 claws labeled B, claw labeled C and remove the scuff plate. HINT: Tape the screwdriver tip before use. Claw B Claw A Claw A Claw A B78482 16. REMOVE FRONT DOOR SCUFF PLATE RH HINT: Use the same procedures described for the LH side. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3766 76-23 EXTERIOR/INTERIOR TRIM 17. (a) Claw Claw - ROOF HEADLINING ASSY REMOVE REAR DOOR SCUFF PLATE LH Using a screwdriver, disengage the 2 claws and remove the scuff plate. HINT: Tape the screwdriver tip before use. B51628 18. REMOVE REAR DOOR SCUFF PLATE RH HINT: Use the same procedures described for the LH side. 19. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH 20. REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH 21. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 22. REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH 23. REMOVE BACK DOOR WEATHERSTRIP 24. (a) Claw Clip REMOVE CENTER PILLAR GARNISH LOWER LH Using a screwdriver, disengage the 2 claws and remove the 5 clips and garnish. HINT: Tape the screwdriver tip before use. B78282 25. REMOVE CENTER PILLAR GARNISH LOWER RH HINT: Use the same procedures described for the LH side. Claw B 26. (a) REMOVE CENTER PILLAR GARNISH LH Using a screwdriver, disengage the 2 claws labeled A and 2 claws labeled B, Remove the cover. HINT: Tape the screwdriver tip before use. (b) Remove the shoulder anchor bolt. Claw A B77325 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3767 76-24 EXTERIOR/INTERIOR TRIM (c) (d) - ROOF HEADLINING ASSY Remove the 2 screws. Using a screwdriver, disengage the clip and remove the garnish. HINT: Tape the screwdriver tip before use. Clip B77326 27. REMOVE CENTER PILLAR GARNISH RH HINT: Use the same procedures described for the LH side. 28. REMOVE ROPE HOOK 29. REMOVE DECK SIDE TRIM COVER LH (a) Using a screwdriver, remove the cover and screw. HINT: Tape the screwdriver tip before use. (b) Using a screwdriver, disengage the 2 claws and remove the trim box. HINT: Tape the screwdriver tip before use. Claw B75576 30. REMOVE DECK SIDE TRIM COVER RH HINT: Use the same procedures described for the LH side. 31. (a) REMOVE DECK TRIM SIDE PANEL ASSY LH w/o Rear No. 2 seat: (1) Remove the 5 bolts and rear seat outer belt floor anchor bolt. (2) Using a clip remover, remove the 6 clips and side panel. (b) w/ Rear No. 2 seat: (1) Remove the 5 bolts and rear seat outer belt floor anchor bolt. (2) Using a clip remover, remove the 6 clips and side panel. Clip B78270 Clip B78271 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3768 76-25 EXTERIOR/INTERIOR TRIM - ROOF HEADLINING ASSY 32. REMOVE DECK TRIM SIDE PANEL ASSY RH HINT: Use the same procedures described for the LH side. 33. (a) Clip B REMOVE QUARTER PILLAR GARNISH LH Using a screwdriver, remove the clip labeled A and clip labeled B and garnish. HINT: Tape the screwdriver tip before use. Clip A B51636 34. REMOVE QUARTER PILLAR GARNISH RH HINT: Use the same procedures described for the LH side. 35. (a) Claw Claw REMOVE ROOF SIDE RAIL GARNISH SUB-ASSY LH Using a screwdriver, disengage the 3 clips and remove the 3 claws and rail garnish. HINT: Tape the screwdriver tip before use. Clip Clip B51637 36. REMOVE ROOF SIDE RAIL GARNISH SUB-ASSY RH HINT: Use the same procedures described for the LH side. 37. (a) REMOVE ROOF SIDE GARNISH ASSY INNER LH w/o Rear No. 2 seat: (1) Using a screwdriver, remove the 4 clips and side garnish. HINT: Tape the screwdriver tip before use. B78283 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3769 76-26 EXTERIOR/INTERIOR TRIM Clip A (b) - ROOF HEADLINING ASSY w/ Rear No. 2 seat: (1) Using a screwdriver, remove the 4 clips labeled A, clip labeled B, remove the side garnish. HINT: Tape the screwdriver tip before use. Clip B B75577 38. REMOVE ROOF SIDE GARNISH ASSY INNER RH HINT: Use the same procedures described for the LH side. 39. REMOVE FRONT PILLAR GARNISH LH (a) Using a screwdriver, remove the front pillar garnish. HINT: Tape the screwdriver tip before use. (b) Pull the garnish upward and remove it from the instrument panel. Clip B51639 (c) Pillar Garnish Clip A Clip A 90 Clip B w/ Curtain shield airbag: (1) Using a screwdriver, disengage the clips clip labeled A and clip labeled B. HINT: Tape the screwdriver tip before use. (d) Remove the pillar garnish. (1) Pull the pillar garnish until the clip marked A in the illustration stretches. (2) Turn the clip marked A in the illustration 90 degrees and remove the pillar garnish. HINT: Use the same procedures described for the LH side. B78340 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3770 76-27 EXTERIOR/INTERIOR TRIM - ROOF HEADLINING ASSY (e) 120 mm (4.72 in.) 700 mm (27.56 in.) Protect the curtain shield airbag LH. (1) Cover the airbag with cloth or a piece of nylon approximately 700 mm (27.56 in.) x 120 mm (4.72 in.) in size. Fix the ends of the cover with tape as shown in the illustration. NOTICE: Cover the curtain shield airbag with the protective cover as soon as the front pillar garnish is removed. Adhesive Tape Protective Cover B78285 40. REMOVE FRONT PILLAR GARNISH RH HINT: Use the same procedures described for the LH side. 41. REMOVE LH VISOR ASSY (a) Remove the 2 screws and visor. 42. REMOVE RH VISOR ASSY (a) Remove the 2 screws and visor. 43. REMOVE ROOF CONSOLE BOX ASSY (a) Remove the 2 screws. (b) Using a screwdriver, remove the 2 clips. HINT: Tape the screwdriver tip before use. B77329 44. (a) REMOVE ROOM LAMP ASSY NO.1 Using a screwdriver, disengage the 2 claws and remove the 2 clips and lamp. HINT: Tape the screwdriver tip before use. 45. REMOVE ROOM LAMP ASSY NO.2 B77331 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3771 76-28 EXTERIOR/INTERIOR TRIM - ROOF HEADLINING ASSY 46. REMOVE ASSIST GRIP SUB-ASSY (a) Using a screwdriver, remove the assist grip plug. HINT: Tape the screwdriver tip before use. (b) Remove the 2 screws and assist grip. Protective Tape B80187 47. (a) REMOVE VISOR HOLDER Remove the holder of the sun visor by turning it to the left. B50596 48. REMOVE SUN ROOF OPENING TRIM MOULDING 49. (a) w/o Sliding Roof (b) w/ Sliding Roof REMOVE ROOF HEADLINING ASSY Using a clip remover, remove the 4 clips and roof headlining. Remove the headlining from the back door. Clip B51643 50. 51. 52. 53. REMOVE REMOVE REMOVE REMOVE ROOF ROOF ROOF ROOF SILENCER SILENCER SILENCER SILENCER PAD NO.4 PAD NO.1 PAD NO.5 PAD NO.2 (W/O SLIDING ROOF) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3772 76-29 EXTERIOR/INTERIOR TRIM - ROOF HEADLINING ASSY 54. (a) INSTALL ROOF HEADLINING ASSY Align the markings, and then install the wire harness with tape. NOTICE: Attach the roof wire harness securely. (b) Install the roof headlining with the 4 clips. w/o Sliding Roof w/ Sliding Roof B77330 55. (a) INSTALL QUARTER PILLAR GARNISH LH Install the rear No. 2 seat outer belt shoulder anchor with the bolt. Torque: 42.0 N⋅m (420 kgf⋅cm, 31 ft⋅lbf) INSTALL QUARTER PILLAR GARNISH RH 56. HINT: Use the same procedures described for the LH side. 57. INSTALL DECK TRIM SIDE PANEL ASSY LH (a) Install the rear seat outer belt floor anchor with the bolt. Torque: 42.0 N⋅m (420 kgf⋅cm, 31 ft⋅lbf) 58. INSTALL DECK TRIM SIDE PANEL ASSY RH HINT: Use the same procedures described for the LH side. 59. INSTALL CENTER PILLAR GARNISH LH (a) Install the front seat outer belt shoulder anchor with the bolt. Torque: 42.0 N⋅m (420 kgf⋅cm, 31 ft⋅lbf) 60. INSTALL CENTER PILLAR GARNISH RH HINT: Use the same procedures described for the LH side. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3773 78-4 GARAGE DOOR OPENER - GARAGE DOOR OPENER SYSTEM 78002-02 INSPECTION These Switches 1. (a) INSPECT GARAGE DOOR OPENER Press the switch and check that each red LED turns on. If one or more of the switches does not turn on the LED, confirm normal operation of the fuse and wire harness, then replace the garage door opener. 2. INSPECT GARAGE DOOR OPENER REGISTRATION AND TRANSMITTING LED B78298 Press Original Transmitter B78299 HINT: Use the KENTMORE home link tester and a tester transmitter for this test. First erase the customer’s transmitter code, and the register the tester transmitter code. (a) Check if the tester transmitter code was successfully registered. HINT: If the code cannot be registered, replace the garage door opener. (b) Press Home Link Tester Press the garage door opener switch that was registered to the tester transmitter. Check if the home link tester’s green LED illuminates. HINT: If the green LED does not illuminate, replace the garage door opener. (c) When the inspection is complete, re-register the customer’s transmitter code(s) again. B78304 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3777 78-1 GARAGE DOOR OPENER - GARAGE DOOR OPENER SYSTEM GARAGE DOOR OPENER SYSTEM 78003-02 REGISTRATION 1. REGISTER TRANSMITTER CODE HINT: The vehicle’s garage door opener records transmitter codes for systems such as garage doors, gates, entry gates, door locks, home lighting systems, security systems or other transmitter-code based systems. The garage door opener is built into the dome lamp No. 1. If replacing the dome lamp No. 1, transmitter codes for any systems previously registered in the garage door opener must be re-registered. (a) Re-register systems in the garage door opener registration mode. NOTICE:
Do not perform transmitter code registration for a system if people or objects are near the system. When registering transmitter codes for a system, injury or damage can occur because the system may open, close, unlock or otherwise operate.
Before transmitter code registration, stop the engine and remove the key from the ignition switch.
The garage door opener cannot be used with systems that: 1) were manufactured before April 1, 1982; or 2) systems that do not meet Federal Safety Standards (for example, garage doors without a jam protection function). HINT:
3 transmitter codes can be registered with the garage door opener, one transmitter code for each of the 3 garage door opener switches.
Disconnecting the battery will not erase the transmitter codes registered with the garage door opener.
An attempt to overwrite a previously registered transmitter code with a new system’s transmitter code may fail. In these situations, the previously registered transmitter code will not be erased. These Switches (1) (2) LED B78298 Select a garage door opener switch for transmitter code registration. Press and hold the selected switch for 20 seconds. The garage door opener will enter registration mode. HINT: Before entering registration mode, the LED is ON. After entering registration mode, the LED flashes at a cycle of 1 Hz. For a ”rolling code” type system, after entering registration mode, the LED flashes at a cycle of 8.8 Hz for 1.6 seconds, and then the LED flashes at a cycle of 1 Hz. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3774 78-2 GARAGE DOOR OPENER (3) Press (4) Original Transmitter B78299 - GARAGE DOOR OPENER SYSTEM After the garage door opener has entered registration mode, bring the original transmitter of the system to be registered within 1 to 3 inches of the garage door opener and press and hold one of the garage door opener switches. Then press the original transmitter switch. If the transmitter code registration was successful, the LED of the garage door opener flashes at a cycle of 5.6 Hz. If no malfunction occurs, release both the garage door opener switch and the original transmitter switch. HINT:


If transmitter code registration fails: 1) the original transmitter’s battery may be low or need to be replaced, or 2) the system to be registered may not be compatible with the garage door opener. Some transmitter’s signals stop after 1 to 2 seconds. For these types of transmitters: 1) press and hold one of the garage door opener switches, and 2) press and release (cycle) the transmitter switch every 2 seconds. Check if the transmitter code was successfully registered. After entering the garage door opener registration mode, transmitter code registration must be completed within 90 seconds. If 90 seconds elapses, the garage door opener will enter low power mode (see step (c)). Timing Chart of Registration Mode: PRESSED Garage Door Opener Switch RELEASED Registrat ion ENTER Mode EXIT LED Operation Original Transmitter 20 sec. ON OFF LED flashes at a cycle of 1 Hz ON LED flashes at a cycle of 5.6 Hz OFF I03487 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3775 78-3 GARAGE DOOR OPENER These Switches (b) - GARAGE DOOR OPENER SYSTEM Erase transmitter codes in the garage door opener clear mode. HINT:

LED B78298
All 3 registered transmitter codes will be erased. No option exists for only erasing one transmitter code. If the switches are released within 10 seconds after the transmitter codes have been erased, the garage door opener will enter registration mode. If the switches are held for 10 seconds or more after the transmitter codes have been erased, default codes will be set to the 3 switches of the garage door opener. Using these default codes, operation of the garage door opener can be checked using a tester. (1) Press and hold the left and right switch of the garage door opener for 20 seconds. The LED will begin to flash at a cycle of 5.6 Hz. Releasing the switches will end clear mode. Timing Chart of Clear Mode: Garage Door Opener Switches (at both ends) PRESSED RELEASED Enter clear mode to erase all 3 codes Load Default Code ON 20 sec. Clear Mode/Default Mode 10 sec. OFF ON LED Operation OFF LED flashes at a cycle of 5.6 Hz A53171 (c) Low power mode: (1) If a garage door opener switch is held for 75 seconds or more, the garage door opener will enter low power mode to economize on power consumption. When the garage door opener has entered low power mode, the LED turns off. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3776 80-2 VEHICLE CONTROL SYSTEM - IGNITION SWITCH 8000H-05 INSPECTION 1. (a) B51200 INSPECT IGNITION OR STARTER SWITCH ASSY Inspect the ignition switch continuity. Switch position Tester connection Specified condition LOCK - No continuity ACC 1-3 Continuity ON 1-2-3 5-6 Continuity START 1-2 4-5-6 Continuity If the continuity is not as specified, replace the ignition switch. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3779 80-1 VEHICLE CONTROL SYSTEM - IGNITION SWITCH IGNITION SWITCH 8000G-04 PROBLEM SYMPTOMS TABLE Symptom Ignition switch is not set in each position Suspected Area See Page 1. Ignition switch 2. Power source circuit 80 2 80-2 - 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3778 82-1 CRUISE CONTROL - CRUISE CONTROL MAIN SWITCH CRUISE CONTROL MAIN SWITCH 8204Q-01 REPLACEMENT HINT: Installation is in the reverse order of removal. 1. PRECAUTION (SEE PAGE 60-1 ) 2. DISCONNECT BATTERY NEGATIVE TERMINAL (SEE PAGE 60-1 ) 3. REMOVE STEERING WHEEL COVER LOWER NO.2 4. REMOVE STEERING WHEEL COVER LOWER NO.3 5. REMOVE HORN BUTTON ASSY (SEE PAGE 60-17 ) 6. (a) (b) REMOVE CRUISE CONTROL MAIN SWITCH Disconnect the connectors. Remove the 2 screws and cruise control main switch. B78426 7. 8. 9. 10. INSTALL HORN BUTTON ASSY (SEE PAGE 60-17 ) CONNECT BATTERY NEGATIVE TERMINAL INSPECT HORN BUTTON ASSY (SEE PAGE 60-1 1) INSPECT SRS WARNING LIGHT (SEE PAGE 05-1207 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3780 99-1 MAINTENANCE - OUTSIDE VEHICLE OUTSIDE VEHICLE 9900V-22 GENERAL MAINTENANCE HINT: These are maintenance and inspection items which are considered to be the owner’s responsibility. They can be done by the owner or they can have them done at a service shop. These items include those which should be checked on a daily basis, those which, in most cases, do not require special tools and those which are considered to be reasonable for the owner to do. Items and procedures for general maintenance are as follows. 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 maintenance 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 increase the exhaust emissions. 2. TIRES (a) Check the pressure with a gauge. If necessary, make adjustment. (b) Check for cuts, damage or excessive wear. 3. WHEEL NUTS (a) When checking the tires, check the nuts for looseness or for missing nuts. If necessary, tighten them. 4. TIRE ROTATION (a) Check the owner’s manual supplement in which the maintenance schedule is shown. 5. WINDSHIELD WIPER BLADES (a) Check for wear or cracks whenever they do not wipe clean. If necessary, replace them. 6. FLUID LEAKS (a) Check the underneath of the vehicle for leaks of fuel, oil, water or other fluid. (b) If you smell gasoline fumes or notice any leak, find and correct the cause. 7. DOORS AND ENGINE HOOD (a) Check that all the doors and the tailgate operate smoothly, and that all the latches lock securely. (b) Check that the engine hood secondary latch prevents the hood from opening when the primary latch is released. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3781 99-2 MAINTENANCE - INSIDE VEHICLE INSIDE VEHICLE 9900W-23 GENERAL MAINTENANCE HINT: These are maintenance and inspection items which are considered to be the owner’s responsibility. They can be done by the owner or they can have them done at a service shop. These items include those which should be checked on a daily basis, those which, in most cases, do not require special tools and those which are considered to be reasonable for the owner to do. Items and procedures for general maintenance are as follows. 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 maintenance 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 increase the exhaust emissions. 2. LIGHTS (a) Check that the headlights, stop lights, taillights, turn signal lights, and other lights are all working. (b) Check the headlight aiming. 3. WARNING LIGHTS AND BUZZERS (a) Check that all the warning lights and buzzers function properly. 4. HORN (a) Check that the horn works normally. 5. WINDSHIELD GLASS (a) Check for scratches, pits or abrasions. 6. WINDSHIELD WIPER AND WASHER (a) Check operation of the wipers and washer. (b) Check that the wipers do not streak. 7. WINDSHIELD DEFROSTER (a) Check that air comes out from the defroster outlet when operating the heater or air conditioner in the defroster mode. 8. REAR VIEW MIRROR (a) Check that the rear view mirror is mounted securely. 9. SUN VISORS (a) Check that the sun visors move freely and are mounted securely. 10. STEERING WHEEL (a) Check that the steering wheel has the specified free play. Be alert for changes in steering condition, such as hard steering, excessive free play or strange noises. 11. SEATS (a) Check that all the front seat controls such as seat adjusters, seatback recliner, etc. operate smoothly. (b) Check that all the latches lock securely in any position. (c) Check that the locks hold securely in any latched position. (d) Check that the head restraints move up and down smoothly and that the locks hold securely in any latched position. (e) For folding-down of the rear seatbacks, check that the latches lock securely. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3782 99-3 MAINTENANCE 12. (a) (b) 13. (a) 14. (a) (b) (c) 15. (a) 16. (a) (b) 17. (a) - INSIDE VEHICLE SEAT BELTS Check that the seat belt system such as the buckles, retractors and anchors operate properly and smoothly. Check that the belt webbing is not cut, frayed, worn or dameged. ACCELERATOR PEDAL Check the pedal for smooth operation, uneven pedal effort or catching. BRAKE PEDAL (See page 32-8 ) Check the pedal for smooth operation. Check that the pedal has the proper reserve distance and freeplay. Check the brake booster function. BRAKES At a safe place, check that the brakes do not pull to one side when applied. PARKING BRAKE (See page 33-2 ) Check that the lever has the proper travel. On a safe incline, check that the vehicle is held securely with only the parking brake applied. AUTOMATIC TRANSMISSION ”PARK” MECHANISM On a safe incline, check that the vehicle is held securely with the selector lever in the ”P” position and all the brakes released. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3783 99-4 MAINTENANCE - UNDER HOOD UNDER HOOD 9900X-21 GENERAL MAINTENANCE 1.




2. (a) 3. (a) 4. (a) (b) 5. (a) (b) 6. (a) 7. (a) 8. (a) 9. (a) (b) 10. (a) (b) (c) 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 maintenance 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. WINDSHIELD WASHER FLUID Check that there is sufficient fluid in the tank. ENGINE COOLANT LEVEL Check that the coolant level is between the LEVEL lines on the see-through reservoir at normal temperature (20°C (68°F)). RADIATOR AND HOSES Check that the front of the radiator is clean and not blocked by leaves, dirt or bugs. Check the hoses for cracks, kinks, rot or loose connections. BATTERY ELECTROLYTE LEVEL Check the indicator. Check that the electrolyte level of all the battery cells is between the upper and lower level lines on the case. BRAKE FLUID LEVEL Check that the brake fluid levels are near the upper level line on the see-through reservoirs. ENGINE DRIVE BELT Check the drive belt for fraying, cracks, wear or oiliness. ENGINE OIL LEVEL Check the level on the dipstick with the engine turned off. POWER STEERING FLUID LEVEL Check the level on the dipstick. The level should be in the ”HOT” or ”COLD” range depending on the fluid temperature. AUTOMATIC TRANSMISSION FLUID LEVEL Park the vehicle on a level surface. With the engine idling and the parking brake applied, shift the selector into all the positions from ”P” to ”L”, and then shift into the ”P” position. 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 ”HOT” range. Perform this check with the fluid at the normal driving temperature (70 to 80°C, 158 to 176°F). (d) 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. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3784 99-5 MAINTENANCE - ENGINE ENGINE 9900Y-20 ON-VEHICLE INSPECTION HINT: Inspect these items when the engine is cold. 1. REPLACE TIMING BELT (See page 2AZ-FE: 14-68 , 3MZ-FE: 14-206 ) 2. INSPECT DRIVE BELT (See page 2AZ-FE: 14-5 , 3MZ-FE: 14-125 ) 3. REPLACE SPARK PLUGS (See page 2AZ-FE: 18-1 , 3MZ-FE: 18-7 ) 4. Outside (a) (b) Inside A66289 5. (a) 6. 7. (a) 8. 9. (a) 10. (a) 11. Canada: INSPECT AIR FILTER Remove the air filter. Visually check that the air filter is not excessively damaged or oily. HINT: Oiliness may indicate that the PCV valve is stuck. If necessary, replace the air filter. (c) Clean the filter with compressed air. First blow from the inside thoroughly, and then blow from the outside of the filter. (d) Reinstall the air filter. REPLACE AIR FILTER Replace the air filter with a new one. REPLACE ENGINE OIL AND OIL FILTER (See page 2AZ-FE: 17-3 , 3MZ-FE: 17-21 ) REPLACE ENGINE COOLANT (See page 2AZ-FE: 16-6 , 3MZ-FE: 16-26 ) AND INSPECT RADIATOR FIN Check that the radiator and condenser are not blocked with leaves, dirt, or insets, and clean the hose connection. INSPECT GASKET IN FUEL TANK CAP (See page 2AZ-FE: 12-6 , 3MZ-FE 12-23 ) INSPECT FUEL LINES AND CONNECTIONS, FUEL TANK VAPOR VENT SYSTEM HOSES AND FUEL TANK BANDS (See page 2AZ-FE: 11-1 , 3MZ-FE: 11-35 ) Visually check the fuel lines for cracks, leakage, loose connections, deformation or tank band looseness. INSPECT EXHAUST PIPES AND MOUNTINGS Visually check the pipes, hangers and connections for severe corrosion, leaks or damage. INSPECT VALVE CLEARANCE (See page 2AZ-FE: 14-6 , 3MZ-FE: 14-127 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3785 99-6 MAINTENANCE - BRAKE BRAKE 9901M-07 ON-VEHICLE INSPECTION P09958 1. INSPECT BRAKE LINE PIPES AND HOSES HINT: Check in a well-lighted area. Check the entire circumference and length of the brake hoses using a mirror as required. Turn the front wheels fully right or left before checking the front brake. (a) Check all the brake lines and hoses for:
Damage
Wear
Deformation
Cracks
Corrosion
Leaks
Bends
Twists (b) Check all the clamps for tightness and connections for leakage. (c) Check that the hoses and lines are clear of sharp edges, moving parts and the exhaust system. (d) Check that the lines install in grommets pass through the center of the grommets. 2. INSPECT FRONT BRAKE PADS AND DISCS (See page 32-23 ) HINT: If a squealing or scraping noise is heard from the brake while driving, check the pad wear indicator. If there are traces of the indicator contacting the disc rotor, the disc pad should be replaced. S02432 3. 4. INSPECT REAR BRAKE PADS AND DISCS (See page 32-29 ) INSPECT OR CHANGE BRAKE FLUID (See page 32-4 ) Fluid: SAE J1703 or FMVSS No.116 DOT3 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3786 99-7 MAINTENANCE - CHASSIS CHASSIS 9902V-01 ON-VEHICLE INSPECTION 1. (a) INSPECT STEERING LINKAGE Check the steering linkage for looseness or damage. Check that:
Tie rod ends do not have excessive play.
Dust seals and boots are not damaged.
Boot clamps are not loose. (b) Inspect the dust cover for damage. 2. INSPECT STEERING GEAR HOUSING OIL (a) Check the steering gear housing for oil leakage. If leakage is found, check for cause and repair it. 3. (a) (b) INSPECT BALL JOINTS AND DUST COVERS Inspect the ball joints for excessive looseness. Maximum ball joint vertical play: 0 mm (0 in.) Check the dust cover for damage. Dust Cover D25091 4. (a) INSPECT DRIVE SHAFT BOOTS Inspect the drive shaft boots for clamp looseness, grease leakage or damage. D25092 5. 6. 7. 8. 9. INSPECT TRANSAXLE FLUID (See page 40-2 ) Canada: REPLACE TRANSAXLE FLUID (See page 40-2 ) INSPECT TRANSFER OIL (See page 31-4 ) Canada: REPLACE TRANSFER OIL (See page 31-4 ) INSPECT AND REPLACE LSD OIL (w/ LSD) (See page 29-5 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3787 99-8 MAINTENANCE 10. (a) - CHASSIS INSPECT DIFFERENTIAL OIL (4WD only) Remove the filler plug and touch inside the hole with your finger. Check that the oil comes to within 5 mm (0.20 in.) of the bottom edge of the hole. If the level is low, add oil until it begins to flows out of the filler hole. Grade: See page 29-5 Drain Plug D25093 11. 12. Canada: REPLACE DIFFERENTIAL OIL (4WD only) (See page 29-5 ) ROTATE TIRES (See page 28-1 ) 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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: 3788 99-9 MAINTENANCE - BODY BODY 9901B-15 ON-VEHICLE INSPECTION 1. (a) (b) 2. (a) (b) (c) (d) (e) Canada: TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY Where necessary, tighten all the parts of the chassis.
Front axle and suspension
Drive train
Rear axle and suspension
Brake system
Engine mounting, etc. Where necessary, tighten all the parts of the body.
Seat belt system
Seats
Doors and hood
Body mountings
Fuel tank
Exhaust pipe system, etc. REPLACE AIR CONDITIONING FILTER Remove the glove compartment assembly. Remove the filter case by holding both sides. Remove the filter from the filter case. Replace the filter with a new one. The installation is in the reverse order of the removal. 2005 HIGHLANDER REPAIR MANUAL (RM1144U) Author
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