Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSTOYOTA2002HIGHLANDER 4WD L4-2.4L (2AZ-FE)REPAIR AND DIAGNOSISHEATING AND AIR CONDITIONINGTESTING AND INSPECTIONCOMPONENT TESTS AND GENERAL DIAGNOSTICSON-VEHICLE INSPECTION
2002 Toyota Highlander 4WD L4-2.4L (2AZ-FE)
On-Vehicle Inspection
2002 Toyota Highlander 4WD L4-2.4L (2AZ-FE)SECTION On-Vehicle Inspection
ON-VEHICLE INSPECTION
1. INSPECT PRESSURE SWITCH NO.1.
a. 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.
b. 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.
2. INSPECT AIR CONDITIONER AMPLIFIER ASSEMBLY CIRCUIT
a. Disconnect the connectors from the A/C amplifier assembly and inspect the connector on the wire harness side, as shown the chart.
If the circuit is as specified, try to replace the A/C amplifier assembly with a new one. If the circuit is as specified, inspect the circuits connected to other parts.
b. Connect the connector to A/C amplifier assembly and inspect the wire harness side connector from the back side, as shown in the chart.
If the circuit is as specified, try to replace the A/C amplifier assembly with a new one. If the circuit is as specified, inspect the circuits connected to other parts.
1. INSPECT PRESSURE SWITCH NO.1.
a. 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.
b. 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.
2. INSPECT AIR CONDITIONER AMPLIFIER ASSEMBLY CIRCUIT
a. Disconnect the connectors from the A/C amplifier assembly and inspect the connector on the wire harness side, as shown the chart.
If the circuit is as specified, try to replace the A/C amplifier assembly with a new one. If the circuit is as specified, inspect the circuits connected to other parts.
b. Connect the connector to A/C amplifier assembly and inspect the wire harness side connector from the back side, as shown in the chart.
If the circuit is as specified, try to replace the A/C amplifier assembly with a new one. If the circuit is as specified, inspect the circuits connected to other parts.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.